Fabric for use in composite materials and method for producing said fabric and a composite material body

Patent metadata

Field	Value
Publication number	US-10161067-B2
Application number	US-201214381166-A
Country	US
Kind code	B2
Filing date	Mar 1, 2012
Priority date	Mar 1, 2012
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

A fabric (10) for use in composite materials having a reinforcing system (11) made of reinforcing warp threads (13) and reinforcing weft threads (14), which are placed on top of one other in two different reinforcing layers (16), (17). A binding system (12) of binding warp threads (20) and binding weft threads (21) is formed from a binding yarn (30) with a lower yarn count than the reinforcing yarn (15). The reinforcing system (11) is enclosed between the binding warp threads (20) on the one side and the binding weft threads (21) on the other side, and thus, held in place at binding points (22). At each binding point (22), a binding warp thread (20) is guided and held between a stationary warp thread (25) and a regular warp thread (24) of a warp thread pair (23) of binding warp threads (20). Between two adjacent binding points of a warp thread pair (23), the stationary warp thread (25) and the regular warp thread (24) have intersecting points (26).

First claim

The invention claimed is:

1. A fabric ( 10 ) for use in composite materials, comprising
a reinforcing system ( 11 ) of reinforcing warp threads ( 13 ) and reinforcing weft threads ( 14 ), said reinforcing warp threads ( 13 ) forming a first reinforcing layer ( 16 ), said reinforcing weft threads ( 14 ) being placed on said first reinforcing layer ( 16 ) of said reinforcing warp threads ( 13 ) without binding with the reinforcing warp threads ( 13 ) for forming a second reinforcing layer ( 17 );
a binding system ( 12 ) of binding warp threads ( 20 ) and binding weft threads ( 21 ), said reinforcing system ( 11 ) being located between the binding weft threads ( 21 ) and the binding warp threads ( 20 ), pairs of said binding warp threads ( 20 ) each comprising a stationary warp thread ( 25 ) and a directly adjacent regular warp thread ( 24 ) which cross each other multiple times with said binding warp threads ( 20 ) being woven to a binding weft thread ( 21 ) by a leno weave at binding points ( 22 ) between the stationary warp thread ( 25 ) and a regular warp ( 24 ) of each pair for securing together the first and second reinforcing layers ( 16 , 17 ) without a weaving connection between the threads of the reinforcing system ( 11 ) and binding system ( 12 ).

2. The fabric ( 10 ) of claim 1 in which intersecting points ( 26 ) between crossing stationary warp threads ( 25 ) and regular warp threads ( 24 ) are located at the binding points ( 22 ) with the weft thread ( 21 ).

3. The fabric ( 10 ) of claim 1 in which reinforcing warp threads ( 13 ) cross the reinforcing weft threads ( 14 ) at intersecting points ( 18 ), and the number of intersecting points of the reinforcing warp threads ( 13 ) with the reinforcing weft threads ( 14 ) of the reinforcing system ( 11 ) is equal to or greater than the number of binding points ( 22 ) of the binding system ( 12 ).

4. The fabric ( 10 ) of claim 1 in which said reinforcing system ( 11 ) is made of a reinforcing yarn ( 15 ) comprising said reinforcing warp and weft threads ( 13 , 14 ) and said binding system is made of a binding yarn ( 30 ) different from said reinforcing yarn ( 15 ) comprising said binding warp and weft threads ( 20 , 21 ), said binding yarn ( 30 ) having a smaller cross-section than the reinforcing yarn ( 15 ).

5. The fabric ( 10 ) of claim 1 in which said reinforcing system ( 11 ) is made up of reinforcing yarn ( 15 ) comprising said reinforcing warp and weft threads ( 13 , 14 ) and said binding system is made up of binding yarn ( 30 ) different from said reinforcing yarns ( 15 ) comprising said binding warp and weft threads ( 20 , 21 ), and said binding yarn ( 30 ) has a lower titer than the reinforcing yarn ( 15 ).

6. The fabric ( 10 ) of claim 4 in which said reinforcing yarn ( 15 ) comprises at least one of carbon, aramid, or glass fibers.

7. The fabric ( 10 ) of claim 4 in which said reinforcing yarn ( 15 ) has a flat cross-section with a dimension in one direction (B) greater than the dimension at a right angle thereto.

8. The fabric ( 10 ) of claim 4 in which said binding yarn ( 30 ) is made of a material that will bind with a plastic material of a composite material during the production of a composite material.

9. The fabric ( 10 ) of claim 4 in which the material and titer of the binding yarn ( 30 ) are such that an interlaminary shearing strength of a composite material produced therefrom deviates from a nominal value prespecified by the reinforcing system ( 11 ) by a maximum of one prespecified tolerance value.

10. The fabric ( 10 ) of claim 4 in which the binding yarn ( 30 ) contains plastic material.

11. The fabric ( 10 ) of claim 4 in which the binding yarn ( 30 ) contains a phenoxy plastic material.

12. The fabric ( 10 ) of claim 4 in which the binding yarn ( 30 ) comprises a core ( 31 ) and a coat ( 32 ) enclosing the core ( 31 ), said core ( 31 ) having a higher melting temperature than said coat ( 32 ).

13. A method for producing the fabric ( 10 ) of claim 1 , comprising the steps of:
loading a weaving machine ( 35 ) with reinforcing warp threads ( 13 ), binding warp threads ( 20 ), reinforcing weft threads ( 14 ), and binding weft threads ( 21 ),
inserting the reinforcing weft threads ( 14 ) and the binding weft threads ( 21 ) in a prespecified sequence,
during insertion of the reinforcing weft threads ( 14 ) maintaining the reinforcing warp threads ( 13 ) in a same upper shed or lower shed, and
during insertion of binding weft threads ( 21 ), for each pair binding warp threads ( 20 ), a binding warp thread ( 20 ) acting as a regular warp thread ( 24 ) is maintained in the same upper or lower shed while a binding warp thread ( 20 ) acting as a stationary warp thread ( 25 ) of each pair, as well as the reinforcing warp threads ( 13 ), are maintained in the other shed, and
intersecting the regular warp thread ( 24 ) with the stationary warp thread ( 25 ) of each pair between the weft insertions with the binding weft thread ( 21 ) for forming ( 1 ) a reinforcing system ( 11 ) of reinforcing weft threads ( 14 ) and reinforcing warp threads ( 13 ) wherein the reinforcing warp threads ( 13 ) form a first reinforcing layer ( 16 ), the reinforcing weft threads ( 14 ) being placed on said reinforcing layer without binding with the reinforcing warp threads ( 13 ) for forming a second reinforcing layer ( 17 ), and ( 2 ) a binding system ( 12 ) of binding weft threads ( 21 ) and binding warp threads ( 20 ) woven together by a leno weave at binding points ( 22 ) for securing together the first and second reinforcing layers ( 16 , 17 ) without a weaving connection between the threads of the reinforcing system ( 11 ) and binding system ( 12 ).

14. The method of claim 13 including guiding the reinforcing warp threads ( 13 ) in a single shared weaving shaft ( 41 ) of the weaving machine ( 35 ), and guiding the stationary warp threads ( 25 ) and the regular warp threads ( 24 ) in different weaving shafts ( 39 , 40 ) of the waving machine ( 35 ).

15. The method of claim 14 including adapting the fabric ( 10 ) to the desired shape of a composite material body to be produced by melting the threads ( 20 , 21 ) of the binding system ( 12 ) by thermal action in at least one melting region ( 46 ).

Assignees

• Bischoff Thomas
• Afsar Melike
• Groz Beckert Kg

Inventors

• Bischoff Thomas
• Afsar Melike

Classifications

• D03D1/00 Primary

  Woven fabrics designed to make specified articles · CPC title

• D03D19/00

  Gauze or leno-woven fabrics · CPC title

• D04H3/04 Primary

  in rectilinear paths, e.g. crossing at right angles · CPC title

• D10B2403/02412

  including several arrays of unbent yarn, e.g. multiaxial fabrics · CPC title

• D03D13/00

  Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft · CPC title