DE102015112896B3 - Multi-layer fabric and corresponding manufacturing process - Google Patents

Abstract

The invention relates to a fabric of warp and weft threads with a construction in the warp direction of at least first, second and third warp threads (11, 13, 12), wherein: - the third warp threads (12) always between the first and second warp threads ( 11, 13) run, - the weft threads (16) by alternating sheds (35, 36, 37, 38) between and below and above these at least three warp threads (11, 13, 12) are passed, and - the third warp threads (12) are made of a different material than the first and the second warp threads (11, 13). Likewise, the invention relates to a method for producing a multi-ply fabric of warp and weft threads by means of a loom.

Description

The invention relates to a multi-layered fabric of warp and weft threads and a method for producing such a multi-layered fabric.

Multi-ply fabrics are diverse in a variety of designs and known for a variety of purposes.

The US 1,802,907 A discloses a weaving loom weaving method comprising pairs of vertically elongated and aligned lax eyes for loose ground warp yarns, wherein between each pair of such pairs in the middle of the strand a litz wire of small height is provided for a pile warp. With such trained strands can be significantly reduce their necessary number for shedding, since less juxtaposed strands are necessary. Also disturbing friction between warp threads can be avoided. The in the US 1,802,907 A disclosed strands can be used in particular for double-plush weaving.

It is an object of the present invention to provide a multi-purpose and robust fabric of several layers, in particular for the production of a molded component, and a corresponding manufacturing method available.

• – die dritten Kettfäden stets zwischen den ersten und zweiten Kettfäden verlaufen,
• – die Schussfäden durch wechselnde Fächer zwischen sowie unter- und oberhalb von diesen mindestens drei Kettfäden hindurchgeführt sind, und
• – die dritten Kettfäden aus einem anderen Material bestehen als die ersten und die zweiten Kettfäden.

This object is achieved by a fabric of warp and weft threads with a construction in the warp direction of at least first, second and third warp threads running one above the other, wherein:

• The third warp threads always run between the first and second warp threads,
• - The weft threads are guided by changing subjects between and below and above these at least three warp threads, and
• - The third warp threads made of a different material than the first and the second warp threads.

Due to the multilayer construction with different materials, in particular with lying between the first and second warp third warp threads a variety of fabric structures with correspondingly different properties and applications can be realized. For example, the first and second warp yarns of the third warp yarns can have very different physical properties, such as different mechanical properties with respect to e.g. B. tear or breaking strength, different thermal behavior, different chemical resistance, etc. have. By selecting the appropriate materials, the multi-layer fabric can be used for a wide variety of applications.

Particularly preferably, the third warp threads contain a high-performance material, for example carbon (carbon) or glass. Carbon and glass fibers are usually embedded in a plastic matrix, so that the third warp threads in this case consist of a composite material. Carbon fibers are characterized by their extreme strength and rigidity and low weight. In particular, the fabric according to the invention can be given a very high tensile strength by the use of carbon. In the present case, the warp threads containing a high-performance material or consisting of a high-performance material are also referred to as reinforcing threads.

It is of particular advantage if the third warp threads are designed as tapes or rovings. Tapes are spread thread collections of substantially parallel running threads that are glued together, the tapes have a greater width than height. Tapes are thus robust and inexpensive surface patterns for especially technical applications. Roving is a bundle, strand or multifilament yarn made of parallel filaments (continuous fibers), which is mainly used in the production of fiber reinforced plastics (FRP) or fiber-reinforced plastics. The cross-section of a roving is usually elliptical or rectangular. Most commonly filaments of glass, aramid or carbon are grouped into rovings. By using the aforementioned thread geometries can in particular produce tissue that in many ways z. B. in lightweight construction, for example in the automotive sector or in aircraft, can be used.

The first and / or the second warp threads preferably contain at least one thermoplastic material. In a particularly advantageous embodiment, the first and / or the second warp threads are made entirely of at least one thermoplastic material. By thermal action, in particular by heating the fabric according to the invention, the thermoplastic material can be melted, wherein the melt then preferably penetrates between the fibers of the high-performance material.

In particular, in combination with in-fabric third warp threads made of a high-performance material, a fabric can be realized by means of the invention, which on the one hand can be excellently shaped, on the other hand has a very high tensile strength due to the internal third warp threads.

The fabric according to the invention can be used, for example, where up to now scrims made from unidirectionally oriented (UD) Reinforcement fibers find use. Compared to the UD-layers, which are used in the prior art, arises when using the fabric according to the invention an advantage in the adaptation of this fabric with unidirectionally oriented reinforcing fibers to the shape of a finished end component. The reinforcing fibers, taken alone, form a UD scrim. The fabric structure in which the reinforcing fibers are embedded as third warp yarns prevents these reinforcing fibers from being undesirably displaced when draped to predetermined shapes. The reinforcing fibers are held in position by the surrounding warp and weft threads. If desired, after draping or conforming to a final shape, the entire fabric structure may be thermally fixed. In this option, the surrounding first and second warp and weft yarns are made of a thermoplastic material.

Accordingly, the invention also makes it possible to produce a formable or deformable fabric, since the plastic matrix of the first and / or second warp threads becomes soft again when the heat input is greater. Thus, inventive fabrics can be formed by hot dies to new, arbitrary geometries. Also, fabrics of the invention are readily recyclable because the carbon or glass fibers can be easily separated from the plastic matrix by heating. Thus, a further development of composite materials such as CFRP (carbon fiber reinforced plastic) is achieved by the invention, which consists of cast in a liquid plastic matrix (usually thermosetting plastics) carbon fibers.

Easy handling is beneficial if the materials of the first and second warp yarns are the same. If the fabric according to the invention is heated, for example, from both sides of the fabric, identical heating temperatures can be used. In a symmetrical layer structure of the fabric, for example outer first and second warp threads of the same material, the same geometry and the same thickness and internal third warp threads, can be realized in a relatively simple manner tissue with well predictable shape and mechanical properties.

It is particularly preferred if the first and second warp threads are designed as tapes. This is especially true in the event that the third warp threads are also designed as tapes. The multi-layer fabric consists according to a preferred embodiment exclusively of tapes. Binding threads for holding the tissue together are particularly preferably not used.

Preferably, at least some, particularly preferably all, weft threads contain at least one thermoplastic material. Furthermore, it is preferred if the weft threads consist entirely of at least one thermoplastic material. Thus, the weft threads may also be part of the thermoplastic matrix covering the third warp threads. In this way, the third warp threads can be completely covered completely by thermoplastic material, namely if the first and second warp threads as well as the weft threads all consist of one or more thermoplastic materials, at least from above and from below.

The at least one thermoplastic material is preferably selected from the group which u. a. The following materials include: olefin homopolymer or copolymer, for example polyethylenes (PE) or polypropylenes (PP), polyamides (PA), polyurethanes (PU), or other thermoplastic materials. These include z. Acrylonitrile-butadiene-styrene (ABS), polylactate (PLA), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK) and polyvinyl chloride (PVC).

Particularly preferably, the first, second and third warp threads and preferably also the weft threads have such a width and are woven into the fabric such that the third warp threads are completely covered by the first and second warp threads and the weft threads from below and above. In this case, all areas of the third warp threads are covered. In the case of thermoplastic first and second warp yarns as well as weft yarns on the one hand and third warp yarns made of a high performance material on the other hand (by heating the fabric, reshaping and allowing to cool), a closed molded article enclosing all high performance fibers can be realized. Only thermoplastic material is visible from both sides of the fabric.

According to a correspondingly advantageous embodiment, the first and second warp threads are at least as wide as the third warp threads. In this case, the first and the second warp threads preferably conceal the third warp threads completely in a plan view and in a bottom view. Thus, the aforementioned encapsulation of the third warp threads can be realized in a simple manner.

According to an advantageous embodiment, in addition to the first, second and third warp threads at least fourth - ie possibly also fifth and possibly also sixth, etc. - warp threads present, always between the first and second warp threads and always in a constant position with respect to the third warp threads, ie always either above or below these third warp threads are arranged in the fabric.

As previously indicated, the first and / or the second warp yarns preferably form the outermost fabric structures, and the third warp yarns form the internal fabric structure of a three-layered fabric. However, it is also possible without further tissue with more than three layers. If, for example, the first warp threads form a layer A, the second warp threads form a layer B and the third warp threads form a layer C or third, fourth and fifth warp threads layers C, C ', C ", etc., the following layer structures are possible, for example: AC-C'-B, AC-C'-C "-B. Here, the layers A and B of warp threads of the same nature with respect to the material, in particular a thermoplastic material, and geometry exist. It is also possible that the third, fourth, etc. warp threads C, C ', etc. consist of the same or different high-performance materials or contain such. In further embodiments, for example, the third and fifth warp threads C contain a high-performance material and fourth warp threads a thermoplastic material.

The invention thus provides, in particular, a fabric with third warp yarns of a composite material (for example, plastic-impregnated or plastic-coated carbon fibers or glass fibers, etc.) in the form of rovings or tapes and furthermore first and second warp threads made of thermoplastic tapes (PET, PP, PA, etc.). The composite material here is preferably completely covered by thermoplastic material in the form of at least the first and second warp threads and the weft threads from below and above. The mass or volume ratio of the first and second warp threads and the weft threads to the third warp threads here is preferably the same over the entire surface and can be precisely defined by the choice of the thickness of the thermoplastic tapes used. The incorporated third warp threads are mechanically stable integrated into the surrounding fabric structures and thus - as far as it allows the binding of the fabric - drapes, d. H. be applied to curved surfaces. To adapt to the contour of the semi-finished products are stretched and warped, which changes depending on the binding and suturing the tissues their drapability. In this way, fiber composites and so-called. Prepreg can be produced. In a thermal consolidation, the fabric can be converted into a dimensionally stable sheet by melting the outer thermoplastic tapes.

• – Es werden eine Vielzahl von in Schussfadenrichtung nebeneinander laufende Kettfadenbündel mindestens bestehend aus jeweils übereinander laufenden ersten, zweiten und dritten Kettfäden einer Fachbildeeinrichtung zugeführt,
• – die Fachbildeeinrichtung öffnet in ihren Webzyklen wechselnde Fächer zwischen den jeweiligen mindestens drei Arten von Kettfäden sowie unter- und oberhalb von diesen, um durch diese Fächer Schussfäden zu führen,
• – wobei die dritten Kettfäden aus einem anderen Material bestehen als die ersten und die zweiten Kettfäden,
• – wobei die ersten und zweiten Kettfäden vorzugsweise einen thermoplastischen Werkstoff enthalten, während die dritten Kettfäden vorzugsweise aus einem Hochleistungswerkstoff, beispielsweise Carbon oder Glas, enthalten.

The invention likewise comprises a method for producing a multi-ply fabric from warp and weft threads, in particular a fabric as described above. The method according to the invention comprises the following steps:

• A plurality of warp thread bundles running side by side in the weft direction are fed to a shedding device at least in each case comprising first, second and third warp threads running one above the other,
• The shedding device opens in its web cycles changing compartments between the respective at least three types of warp threads and below and above them in order to guide weft threads through these compartments,
• The third warp threads being made of a different material than the first and the second warp threads,
• Wherein the first and second warp threads preferably contain a thermoplastic material, while the third warp threads preferably comprise a high-performance material, for example carbon or glass.

This procedure, which also in the post-published DE 10 2014 112 468 A1 and to which reference is hereby made, according to a preferred embodiment, the following is carried out: In a weaving machine, a plurality of strands are arranged next to one another in the weft direction, which is widely known from the prior art. Furthermore, in each case one or more strands are arranged one after the other behind at least some of these strands in the warp direction. At least one warp thread is guided through each of the strands thus arranged in succession, whereby a plurality of warp threads are guided one above the other in the warp direction and in each case form a warp thread stack (a "warp thread stack" is defined here as an arrangement of a plurality of warp threads one above the other). During weaving, the strands arranged one behind the other in a row are then moved non-synchronously, ie alternately, repeatedly upwards and downwards, and thus individually positioned in the z-direction. This results in successively different openings or sheds between superimposed warp threads are entered through which weft threads.

The advantages of this embodiment are to be seen in particular in that, in addition to the strands conventionally positioned side by side, further strands are provided, which in the warp direction, d. H. in the direction of the warp threads, behind the aforementioned (known from the prior art) strands are arranged. This makes it possible that several warp threads can be guided one above the other. Thus, in addition to the - from the prior art well-known - side by side guided warp threads can introduce more warp threads in the tissue, which are superimposed.

In this case, it is preferred if the warp threads overlap one another in a covering or aligned manner. The term "opaque" is understood in the present case that - viewed from above - all superimposed warp threads of a series of behind or successively arranged strands within the width of the widest warp, usually a tape lie. In principle, however, an offset with only partial coverage of two or more superimposed warp threads is possible.

By an alternating upward and downward movement of three strands arranged one behind the other, these strands can be positioned individually and thus also the warp threads guided by these strands. As a result, different openings or sheds between the superimposed warp threads can be realized, through which then the weft threads can be entered. Such openings are functionally comparable to the known from the prior art sheds, since in both cases warp threads (in the present case superimposed warp threads, in the known case adjacent warp threads) are moved away from each other in the z direction to pass a weft.

For producing the fabric according to the invention so at least three strands are arranged one behind the other for each warp pile through which at least a total of three warp threads are performed one above the other in the warp direction, the strands together by alternating up and down movement the warp threads and lead apart to make appropriate weft entries can. In the weft direction in this case a plurality of such rows of three (or more) arranged one behind the other in the warp direction strands is provided.

In order to produce a complex weave pattern, the warp yarn stacks next to one another in the weft direction are moved relative to one another according to the weaving pattern to be achieved, so that the sheds achieved between the warp threads of the warp yarns obtained by repeated upward and downward movement of the warp yarns in a row behind or in succession respective warp thread stack and the thus generated in the weft direction subjects between the weft successively arranged warp thread stacks are coordinated with each other, particularly preferably by means of an electronic machine control.

Each of the strands, which are guided one behind the other in the warp direction, preferably leads in each case to one warp thread, i. H. is designed and arranged for the deflection. In other words, each of these strands is responsible for the up and down movement of a single warp. In an embodiment which is advantageous in this regard, in each of the strands arranged one behind the other in a row in the warp direction, only one stranded eye is provided for deflecting an associated warp thread. By this configuration, a precise control of all warp threads is possible.

The height of the Litzenauges a strand compared to the height of the Litzenauges another, behind arranged strand is preferred, substantially identical, or only slightly different to realize the several, described below preferred layers of the superimposed warp threads. Furthermore, it is advantageous if the width of the Litzenaugen of consecutively arranged strands is substantially equal, which width is preferably adapted to the maximum width of the tapes to be woven.

According to a particularly preferred embodiment, in each case arranged stranded wires, the respective front strand, d. H. the respectively closer to the machine outlet located, at least one and - according to the above - preferably exactly one Litzenauge through which a first warp thread is guided and deflected. This Litzenauge has - for the purpose of said leadership and deflection in the z direction - a lower height than one below or above said Litzenauges arranged extending in the z-direction slot with greater height for positionally fixed or deflection-free passage of at least one second warp thread , The term "fixed position" here means that the second warp thread is not significantly moved when moving up or down the front strand, but remains in position and the slot laterally limiting rods of the strand are guided along it. For guiding the second warp thread, a rear strand arranged closer to the machine entrance is provided, which has at least one and, according to the above, preferably exactly one stranded eye of lesser height for threading and deflecting said second warp thread in the z direction. This rear strand also has a slot extending in the z-direction and having a greater height than the said strand eye of the rear strand, wherein this slot is then arranged above or below said strand eye. The slot of the rear strand serves for positionally fixed or deflection-free passage of at least said first warp thread.

In this case, preferably that strand whose strand eye leads to the uppermost warp thread of a warp thread pile, a slot below this Litzenauges, while that strand whose Litzenauge the lowest warp thread of a warp thread stack leads, has a slot above this Litzenauges.

To produce a fabric according to the invention are in addition to the front and rear strands (for the first and second warp threads) at least third middle strands (for the third warp threads) are arranged in the warp direction between the respective said front and back strands. In this case, the middle strands preferably each guide a third warp thread, for which purpose each middle strand preferably has in each case a corresponding stranded eye for guiding and deflecting such a third warp thread. When in the weft advantageously juxtaposed several central strands of these strands each lead a third warp thread which always runs in the z-direction between the respective first and second warp thread of the same warp thread stack. Thus, the fabrics of the invention are possible with at least three superimposed warp threads.

In the case of further middle strands (ie fourth, fifth,...), The strands lying farther back (ie in the direction of the machine entrance) guide the respectively assigned (fourth, fifth,...) Warp threads in the z-direction between those warp threads which originate from the further ahead (ie in the direction of machine exit) and further back arranged strands are guided. Accordingly, the middle strands preferably each have a slot above their Litzenauges and a slot below her Litzenauges.

• – alle drei Kettfäden oberhalb der Schusseintragsebene (unter „Schusseintragsebene” wird vorliegend diejenige Ebene verstanden, welche von den Schussfäden beim Eintrag in die von den nebeneinander in Schussrichtung angeordneten Kettfäden gebildeten Fächer durchlaufen wird),
• – alle drei Kettfäden unterhalb der Schusseintragsebene,
• – einer oberhalb und zwei unterhalb der Schusseintragsebene,
• – zwei oberhalb und einer unterhalb der Schusseintragsebene.

Since the sequence of the warp threads always remains the same in each case in one warp thread stack, four different positions can be realized with three warp threads of a warp thread stack running one above the other:

• - all three warp threads above the weft insertion level ("weft insertion level" in the present case is understood to mean the plane which is run through by the weft threads when entering the compartments formed by the warp yarns arranged next to one another in the weft direction),
• All three warp threads below the weft insertion level,
• One above and two below the weft insertion level,
• Two above and one below the weft insertion plane.

In general, n + 1 allowable positions result for n superimposed warp threads. In contrast, only binary positions (warp thread above or below the weft insertion plane) are possible in the prior art.

In contrast to the prior art run - as stated above - at least three warp threads on top of each other and form a warp pile. While in the prior art, each warp thread can take only an upper and a lower position, four positions can be realized with three warp yarns running one above the other.

The respective rows or only sections of these rows of front, middle and rear strands are preferably arranged in each case in heddle shafts, so that in this embodiment, a plurality of heddles are provided one behind the other. Manufacturing and operation are thereby simpler and less expensive.

According to an alternative, the weaving machine according to the invention is designed as a jacquard loom, wherein the strands are individually movable using a control.

The invention further relates to a method for processing a fabric of the type described above and / or prepared according to the method described above.

The fabric structure, in which special third warp threads are embedded, prevents these special warp threads, the z. B. are formed as reinforcing threads with or made of a high performance material, in a draping or when adjusting to predetermined curved or otherwise formed three-dimensional structures are moved in an undesirable manner.

In a further method according to the invention for fabric processing, the fabric preferably contains first and second warp threads with at least one thermoplastic material and also weft threads preferably with at least one thermoplastic material, wherein the fabric can be fixed in a three-dimensional form by heating above the melting point of the at least one thermoplastic material , The penetration of the molten thermoplastic material between the fibers of the at least third warp threads results in a stable structure. For this purpose, for example, a suitably designed for the expert not to be explained in detail form tool use.

Finally, the invention also encompasses a molding component produced by the above-described method. Such a molded component can be used, for example, in driveways and aircraft for outer skins.

The invention will be explained in more detail below with reference to figures. The same reference numerals stand for identical or comparable elements. Show it:

1 a perspective view of three consecutively arranged strands and schematically illustrated loom elements;

2 the three consecutively arranged strands of 1 (schematic representation);

3a -D the three strands of the 2 with threaded warp threads in four different positions;

4a D shows the schematic binding principle of a first fabric according to the invention with six exemplary weft threads S1-S6 ( 4a ) as well as a plan view ( 4b ) and a view from the back ( 4c ) of this fabric and a representation of the integration of the third warp threads in this tissue ( 4d );

4e a section of a cross-sectional view through the tissue of 4a - 4d ;

4f a section of a cross-sectional view through another fabric, and

5a D shows the schematic binding principle of a second fabric according to the invention with six exemplary weft threads S1-S6 ( 5a ) as well as a plan view ( 5b ) and a view from the back ( 5c ) of this fabric and a representation of the integration of the third warp threads in this tissue ( 5d ).

In the 1 are shown very schematically essential elements of a weaving machine according to the invention for weaving tapes. At the machine entrance is a creel 40 with a variety of coils 41 from which warp threads are withdrawn in the warp direction K (indicated by the exemplary reference numeral 13 in terms of unwinding from a spool 40 ). At the machine exit the registered weft thread becomes 16 in the present example of a pendulum reed 44 to the finished fabric 18 transported, which subsequently onto a take-up roll 45 is wound up. However, arrangements are also known in which the tissue 18 to the registered shot 16 is transported.

In the web section are three strands 1 . 2 . 3 (hereinafter also with strands 1 - 3 abbreviated) according to the invention behind or shown sequentially arranged in the warp K, wherein the front strand 1 to the machine exit and the rear strand 3 is placed towards the machine entrance. For clarity, the strands 1 - 3 in the present case reproduced in perspective; in reality, they are oriented perpendicular to the warp K direction. In this case, a plurality of rows of strands are preferably arranged next to one another (not shown), these rows being in the image plane (ie in the weft direction S, which in FIG 1 the clarity is also shown obliquely) extend. In this case, the most varied arrangements of rows of strands can be selected, as desired and as a weaving task.

For illustration, it is sufficient in the present case when in the 1 only such a series of three in the warp K consecutively arranged strands 1 - 3 is shown.

Each of the strands 1 - 3 each has a Litzenauge 21 . 22 . 23 (hereinafter also with Litzenaugen 21 - 23 abbreviated) with a lower height than two each arranged above and below these Litzenaugen slots 31a . 31b . 32a . 32b . 33a . 33b (in the following also with oblong holes 31a - 33b abbreviated), which have a longitudinal extent, which is a multiple of the height of the individual Litzenaugen 21 - 23 equivalent. Through each of the Litzenaugen 21 - 23 each is a warp thread 11 . 12 . 13 (hereinafter also with warp threads 11 - 13 abbreviated) threaded in the form of a tap. The arrangement of the strands 1 - 3 as well as the design of the Litzenaugen 21 - 23 as well as the oblong holes 31a - 33b consecutively conditional that the warp threads 11 - 13 seen in plan view one above the other. The long holes 31a - 33b Here are all the same width and adapted to the width of the tapewet warp threads 11 - 13 so that these plan in the Litzenaugen 21 - 23 can run without waving in particular.

In the present case is the through the Litzenauge 21 the front strand 1 threaded first warp thread 11 the lowest warp thread (whereby the opposite order is readily possible, ie, the front strand can also be designed and arranged so that the guided by her warp is the uppermost). From bottom to top, follow the third warp thread 12 and the second warp thread 13 , wherein the uppermost (second) warp thread 13 through the Litzenauge 23 the rearmost strand 3 threaded. Corresponding to the direction of warp K consecutive arrangement of the strands 1 - 3 the warp threads are lost 11 - 13 from the bottom up. The location of the Litzenaugen 21 - 23 is chosen such that the warp threads 11 - 13 not in the same horizontal plane (and thus in the way), but that - with the same amount of deflection of the strands 1 - 3 - There is a small vertical distance between them.

In the 2 are the three consecutively arranged strands in the warp direction 1 - 3 shown again, but rotated in this illustration by 90 ° and reproduced at a distance from each other (in reality, in this view would be only the narrow sides of the strands 1 - 3 to see). It can be seen from this that the three Litzenaugen 21 - 23 are offset in height, hence the three warp threads 11 - 13 keep said vertical distance from each other, so that there is no mechanical tension or too much friction between them. In the 2 In addition, the warp direction K and the weft direction S are shown, which together define the weft insertion plane SE. The weft direction S is perpendicular to the warp direction K, wherein the three strands 1 - 3 are arranged in the warp direction K behind or in succession and usually several rows of consecutively arranged strands in the weft direction S (ie perpendicular to the image plane) are present.

Again 1 can be seen, are through the upper slot 31a the foremost strand 1 the warp threads 12 . 13 threaded, while the lower slot 31b is empty. Through the upper slot 32a the middle strand 2 runs the second warp thread 13 while the first warp thread 11 through the lower slot 32b is guided. Through the lower slot 33b the rear strand 3 are the first and second warp threads 11 . 12 guided while the upper slot 33a is empty.

In the 1 is shown that the two front strands 1 . 2 moved to a lower position while the rear strand 3 are in an upper position. When moving one of the strands - in the 1 For example, the strand can 2 up or the stranded wire 3 be moved down - is in the Litzenauge 22 (or 23 ) of this strand 2 (or 3 ) moving warp thread 12 (or 13 ), while the other two warp threads 11 . 13 (or 11 . 12 ) through the slots 32a . 32b (or 33a . 33b ) of the corresponding strand 2 (or 3 ) are guided without being deflected. This not through the Litzenauge 22 (or 23 ) of the up or down moving strand 2 (or 3 ) guided warp threads 11 . 13 (or 11 . 12 ) so stay due to the design of the slots 32a . 32b (or 33a . 33b ) of this strand 2 (or 3 ) fixed in position, ie these warp threads are not deflected. For example, if the stranded wire 2 of the 1 is moved upward, only the warp thread 12 with moved up.

In the 3a - 3d (again - as in 2 - shown with twisted by 90 ° strands) is in accordance with the predicted clarified, as by alternating up and down movements of the strands 1 - 3 Openings or looms 35 . 36 . 37 . 38 arise in a warp pile through which then weft threads S can be entered (perpendicular to the leaf level). In the 3a are all three strands 1 - 3 shown in a lower position, leaving all three warp threads 11 - 13 due to the threading in the individual Litzenaugen 21 - 23 run through their lowest vertex. In the 3b is the back strand 3 deflected upward, leaving a shed 36 between the uppermost, through the Litzenauge 23 the strand 3 threaded warp thread 13 and the other warp threads 11 . 12 opens up, through which a weft thread 16 (not shown) can be entered. In the case of many adjacent warp thread stacks in the weft direction (comprising, for example, three warp threads in each case 11 - 13 , each of three consecutively arranged in the warp K strands 1 - 3 are guided) and by appropriate control of the up and down movement of all arranged in the warp and weft strands 1 - 3 For example, the shed thread level and the shed formation according to the invention can be matched to one another in order to obtain a complex fabric. In this context is also the upwardly open shed 35 in 3a to understand, because the weft threads through behind it (ie perpendicular to the sheet plane) existing warp thread stack (not shown) are also performed by sheds to obtain the weave.

In the 3c is also the strand 2 lifted up, causing the through her Litzenauge 22 threaded warp thread 12 is taken up, so that another shed 37 between the warp threads 11 and the warp threads 12 . 13 for a weft entry opens. According to the 3d are all three strands 1 - 3 and thus all warp threads 11 - 13 shown in the upper position, which - for the illustrated warp pile - a downwardly open shed 38 results. In total there are four different positions by means of the three strands 1 - 3 possible. In general, n + 1 positions can be realized if n is the number of strands arranged one behind the other.

The next cycle will be the warp threads 11 - 13 preferably in the reverse order - first lowering the strand 1 , then the strand 2 , then the strand 3 - moved downwards. A mutual "overtaking" of the warp threads 11 - 13 is therefore not possible; their order from top to bottom always stays the same.

Of course it is also possible to use more than one of the strands 1 - 3 raise or lower simultaneously. For example, in the in 3a illustrated situation, the two rear strands 2 . 3 be raised at the same time. By such a group-wise lifting and lowering of multiple strands, the variability of the desired weaving patterns can be further increased.

In the 4a the schematic binding principle of a fabric with six exemplary weft threads S1-S6 is shown, while side by side running warp rows are marked with the letters A-F. This representation gives - seen from top to bottom - the successively in the warp direction (in the image plane inside) located weft threads S1-S6. The weft S1 is thus first passed through the tray, then the weft S2, etc. In the 4a are also exemplary two different warp thread stack with the reference numeral 15 characterized. The 4a each represents the location and position of the individual warp threads 11 . 12 . 13 , all of which are designed here as tapes, in relation to the respective weft 16 , also formed throughout as a tape, dar.

The 4b -D show the binding picture of the 4a appropriate tissue 18 , and that 4b a plan view, the 4c a view from the back as well as the 4d the integration of the third warp threads 12 into the tissue 18 , In the representations of 4b -D run all warp threads 11 - 13 and the weft threads 16 in the picture plane.

In the plan view of 4b are always only the lower, first warp threads 11 as well as the weft threads 16 to see. This is consistent with the above statement that the order of the warp threads 11 . 12 . 13 from top to bottom is always the same. Accordingly, in the rear view of 4c only the upper, second warp threads 13 and the weft threads 16 to recognize. The in the 4b and 4c invisible third warp threads 12 lie either directly below or above the weft threads 16 or between the first and second warp threads 11 . 13 (S. 4a ). This is in the 4e illustrated once again, in this illustration, the warp threads 11 . 12 . 13 and the weft 16 (here S1 the 4a ) are not densely woven, but are shown stylized for a better illustration.

In the 4d is in plan view the integration of the third warp threads 12 into the tissue 18 in relation to the weft threads 16 shown (the first and second warp threads 11 . 13 are not reproduced).

It should also be noted that with the three or more superimposed warp threads 11 . 12 . 13 the up and down movement of the strands 1 . 2 . 3 can be controlled so that the weft 16 in the finished fabric 18 can be seen in at least one weft row neither from the front nor from the back. There may in this case be several such weft thread rows which do not fix the tissue, which are separated from one another by conventional weft thread rows binding the tissue. In the cross-sectional representation of 4f is schematically shown in this respect (for only a pattern repetition in the weft direction), such as three superimposed warp threads 11 . 12 . 13 the weft 16 in a warp pile between the warp threads 11 and 12 and in the adjacent warp thread stack between the warp threads 12 and 13 running.

In the 5a D is a second possible binding principle for a fabric according to the invention 18 shown, wherein the same reference numerals have been used as in the other figures. By a different pattern for the formation of the openings or the sheds (see the sheds 35 - 38 in the 3 ), a different bond is obtained, and also in the tissue 18 of the 5 the third warp threads 12 always between the first and second warp threads 11 . 13 run (s. 5b . 5c ). The 5d again shows in plan view the integration of the third warp threads 12 into the tissue 18 in relation to the weft threads 16 shown, wherein the first and second warp threads 11 . 13 are not reproduced here.

The first, second and third warp threads 11 . 13 . 12 as well as the weft threads are particularly preferably formed in the embodiments shown in the figures as tapes or rovings. Here are the third warp threads 12 in particular a high-performance material, for example carbon or glass.

The first and the second warp threads 11 . 13 as well as advantageously the weft threads 16 contain particularly preferably in the embodiments shown in the figures at least one thermoplastic material. Preferably, they consist entirely of at least one thermoplastic material, for example of an olefin homopolymer or copolymer, for example polyethylene (PE) or polypropylene (PP), of polyamide (PA), polyurethane (PU), acrylonitrile-butadiene-styrene (ABS) , Polylactate (PLA), polymethyl methacrylate (PMMA), polycarbonates (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK) and / or polyvinyl chloride (PVC).

As can be seen from the figures, the present invention comprises the first, second and third warp threads 11 . 13 . 12 as well as the weft threads 16 such a tape width that the third warp threads 12 completely from the first and second warp threads 11 . 13 as well as the weft threads 16 are covered. Here are the first and second warp threads 11 . 13 as well as the weft threads 16 at least as wide as the third warp threads 12 and completely obscure these in top view and bottom view.

According to the above, therefore, a fabric can be realized in which thermoplastic tapes in the form of first and second warp threads (or other further warp threads then running inside the fabric) at least third warp threads in the form of tapes or rovings with a high performance material (preferably a Cover composite material with carbon or glass in a plastic matrix, eg a carbon tape) from above and below. Preferably, by means of the method described above, the individual layers of the first, second and third warp threads forming tapes are controlled via the strands and form the respective shed (also referred to as general opening above), in which the also preferably made of thermoplastic material weft thread is entered. Via the selected binding, the composite tape or the roving (ie the carbon or carbon fibers) consisting of the third warp threads can be incorporated into the thermoplastic fabric with more or less flotation. By choosing the thickness of the thermoplastic tapes (first and second warp threads, weft threads), an exact fiber-matrix ratio can be selected. The resulting unconsolidated sheet is flexible, the composite components being fixed in position by the weave of the fabric. The fabric is, as far as the binding allows, drapeable. By applying pressure with simultaneous heating above the melting point of the selected thermoplastic matrix system, the tissue is fixed in the desired shape. During this process, the thermoplastic constituents melt and the melt penetrates the composite fibers, i. H. for example, carbon or glass fibers. The result is a homogeneous composite component that can be installed after drying and cooling.

The invention has been explained in more detail with reference to embodiments. Combinations, as far as they are technically possible, are also encompassed by the invention, as are modifications within the claims. Also, there are generally no restrictions with regard to the number of strands arranged one behind the other in the warp direction and the arrangement of the rows arranged in the weft direction, the rows at least partially consisting of strands arranged one behind the other. Here too, warp yarns that do not form the top and bottom warp yarns (the first and second warp yarns) of a warp pile may contain a thermoplastic material or other material than a high-performance material.

LIST OF REFERENCE NUMBERS

1

front strand

2

middle strand

3

rear strand

11

first warp thread

12

third warp thread

13

second warp thread

15

Kettfadenstapel

16

weft

18

tissue

21

heald

22

heald

23

heald

31a

Long hole

31b

Long hole

32a

Long hole

32b

Long hole

33a

Long hole

33b

Long hole

35

shed

36

shed

37

shed

38

shed

40

gate

41

Do the washing up

44

reed

45

up roll

K

warp

S

weft direction

SE

Weft insertion level

Claims (19)

Tissue of warp and weft threads having a construction in the warp direction of at least first, second and third warp threads ( 11 . 13 . 12 ), where: - the third warp threads ( 12 ) always between the first and second warp threads ( 11 . 13 ), - the weft threads ( 16 ) by changing sheds ( 35 . 36 . 37 . 38 ) between and below and above these at least three warp threads ( 11 . 13 . 12 ), and - the third warp threads ( 12 ) consist of a different material than the first and the second warp threads ( 11 . 13 ). Fabric according to the preceding claim, characterized in that the third warp threads ( 12 ) contain a high performance material, such as carbon or glass, and preferably consist entirely of such a high performance material. Fabric according to one or more of the preceding claims, characterized in that the third warp threads ( 12 ) are designed as tapes or rovings. Fabric according to one or more of the preceding claims, characterized in that the first and / or the second warp threads ( 11 . 13 ) contain at least one thermoplastic material and preferably consist entirely of at least one thermoplastic material. Fabric according to one or more of the preceding claims, characterized in that the first and second warp threads ( 11 . 13 ) are designed as tapes. Fabric according to one or more of the preceding claims, characterized in that at least some, preferably all, weft threads ( 16 ) contain at least one thermoplastic material and preferably consist entirely of at least one thermoplastic material. Fabric according to one or more of claims 4-6, characterized in that the at least one thermoplastic material is selected from one or more representatives of the following group: olefin homo- or copolymer, for example polyethylenes (PE) or polypropylenes (PP), polyamides (PA), polyurethanes (PU), acrylonitrile-butadiene-styrene (ABS), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK), polyvinylchloride ( PVC). Fabric according to one or more of the preceding claims, characterized in that the first, second and third warp threads ( 11 . 13 . 12 ) and preferably also the weft threads ( 16 ) have such a width and are woven into the fabric such that the third warp threads ( 12 ) completely from the first and second warp threads ( 11 . 13 ) as well as the weft threads ( 16 ) are enclosed. Fabric according to one or more of the preceding claims, characterized in that the first and second warp threads ( 11 . 13 ) are at least as wide as the third warp threads ( 12 ) and that the first and the second warp threads ( 11 . 13 ) in top view and in bottom view, the third warp threads ( 12 ) completely obscure. Fabric according to one or more of the preceding claims, characterized in that in addition to the first, second and third warp threads ( 11 . 13 . 12 ) at least fourth warp threads are always present between the first and second warp threads ( 11 . 13 ) and always in a constant position, ie either above or below, with respect to the third warp threads ( 12 ) are arranged in the tissue. A method for producing a multi-ply fabric from warp and weft threads by means of a weaving machine, in particular a fabric according to one of the preceding claims, wherein the method comprises the following steps: a plurality of warp thread bundles running side by side in the weft direction at least consisting of first running one above the other, second and third warp threads ( 11 . 13 . 12 fed to a shedding device, the shedding device opens in its web cycles changing compartments between the respective at least three warp threads and below and above them in order to pass through these subjects weft threads ( 16 ), the third warp threads ( 12 ) consist of a different material than the first and the second warp threads ( 11 . 13 ), and wherein the first and second warp threads ( 11 . 13 ) preferably contain a thermoplastic material while the third warp threads ( 12 ) preferably contain a high performance material, for example carbon or glass. Method according to the preceding claim, characterized in that as material for the first and / or the second warp threads ( 11 . 13 ) and / or the weft threads ( 16 ) at least one thermoplastic material is used which is selected from one or more representatives of the following group: olefin homo- or copolymer, for example polyethylenes (PE) or polypropylenes (PP), polyamides (PA), polyurethanes (PU), acrylonitrile Butadiene-styrene (ABS), polylactate (PLA), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK), polyvinylchloride (PVC). Method according to one or more of the preceding method claims, characterized in that in addition to a plurality of strands (S) arranged next to one another in the weft direction (S) ( 1 ) of the loom behind at least some of the aforementioned strands ( 1 ) in the warp direction (K) arranged strands ( 2 . 3 ) are provided, and that by each of such in each case successively arranged strands ( 1 . 2 . 3 ) at least one warp thread ( 11 . 12 . 13 ), whereby several warp threads ( 11 . 12 . 13 ) are guided one above the other in the warp direction (K), wherein the strands arranged one behind the other in a row (FIG. 1 . 2 . 3 ) alternately repeatedly moved up and down and thus individually positioned in the z-direction, whereby successively different sheds ( 35 . 36 . 37 . 38 ) between superimposed warp threads ( 11 . 12 . 13 ) are realized by which weft threads ( 16 ). Method according to the preceding claim, characterized in that it comprises the following steps: - at least one in the running direction of the warp threads ( 11 . 12 . 13 ) closer to the machine outlet arranged front strand ( 1 ) with at least one, preferably exactly one, stranded eye ( 21 ) of lesser height for threading a first warp thread ( 11 ) and deflecting this first warp thread ( 11 ) by a repeated upward and downward movement in the z-direction and with at least one below or above said at least one Litzenauges ( 21 ) arranged in the z-direction extending slot ( 31a ) with greater height for the positionally fixed or deflection-free passage of at least one second warp thread ( 13 ), it is at least one in the direction of the warp threads ( 11 . 12 . 13 ) behind the front wire ( 1 ) and arranged closer to the machine input rear strand ( 3 ) with at least one, preferably exactly one, stranded eye ( 23 ) with lesser height to Threading said second warp thread ( 13 ) and deflecting this second warp thread ( 13 ) in the z-direction and with at least one above or below said at least one Litzenauges ( 23 ) arranged in the z-direction extending slot ( 33b ) of greater height for the positionally fixed or deflection-free passage of at least said first warp thread ( 11 ), - at least one middle stranded wire ( 2 ) in said rows of strands ( 1 . 2 . 3 ) between said front and rear strands ( 1 . 3 ) provided for guiding in the z-direction of then a total of at least three superimposed warp threads ( 11 . 12 . 13 ), this at least one middle strand ( 2 ) at least one, preferably exactly one, Litzenauge ( 22 ) for guiding and deflecting an associated third warp thread ( 12 ) and a slot ( 32a ) above and a slot ( 32b ) below their respective said at least one Litzenauges ( 22 ) for deflection-free passage of at least the first and second warp threads ( 11 . 13 ), wherein the first and second warp threads ( 11 . 13 ) in the direction of the warp threads through the respective at least one Litzenauge ( 21 . 23 ) of the front or rear strand ( 1 . 3 ) or the rear or front strand ( 3 . 1 ), and the others, between the first and second warp yarns ( 11 . 13 ) warp threads ( 12 ), in the case of only one middle strand ( 2 ) the third warp thread ( 12 ), in ascending or descending order by the respective at least one Litzenauge ( 22 ) of the middle strands ( 2 ), it is by repeated mutual relative movements of the front, the at least one middle and the rear strand ( 1 . 2 . 3 ) in the z-direction alternately defined sheds ( 35 . 36 . 37 38 ) between the at least three superimposed first, second and third warp threads ( 11 . 13 . 12 ) formed for the purpose of weft insertion. Method according to one or more of the preceding method claims, characterized in that the third warp threads ( 12 ) completely from the first and second warp threads ( 11 . 13 ) as well as the weft threads ( 16 ) are covered from above and below. Method according to one or more of the preceding method claims, characterized in that the mass or volume ratio of third ( 12 ) to first and second warp threads ( 11 . 13 ) is set constant over the entire fabric surface, this ratio being determined in particular by the choice of the thickness of the first and second warp threads (FIG. 11 . 13 ) is adjustable. A method of processing a tissue according to one or more of claims 1-10 and / or produced according to one or more of the preceding method claims, wherein the tissue ( 18 ) is applied by draping to a curved or otherwise shaped three-dimensional structure. A method of processing a tissue according to one or more of claims 1-10 and / or produced according to one or more of the preceding method claims, wherein the tissue ( 18 ) first and second warp threads ( 11 . 13 ) and preferably weft threads ( 16 ) Contains at least one thermoplastic material, wherein the fabric is converted into a three-dimensional structure by heating above the melting point of the at least one thermoplastic material. Molded part produced according to the preceding method claim.

Images