JP2010509516A - Inorganic fabric - Google Patents

Abstract

The fabric is formed from yarn containing inorganic filaments coated with rayon. Specifically, the inorganic filaments are spun from a volcanic black rock melt and include calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide and boron. Because of its composition, this fabric is heat resistant and is light even though it is light. Fabric, melting point of 1500 ° C. to 1650 ° C., the practical range, density of 1.6 g / ^cc, a surface density of 160g / ^{m 2} ~350g / m 2 of -130 ° C. to 700 ° C., and 500lbf ^/ in 2 ~1800lbf ^/ In ² shows the tensile strength.

Description

  The present invention relates generally to fabrics formed from yarn. More specifically, the present invention relates to high performance fabrics formed from yarns containing inorganic filaments. The invention is particularly useful for making fabrics from yarns obtained from inorganic raw materials including but not limited to black rock.

  Conventional fabrics are generally made from organic or synthetic polymer fibers. Because of their composition, these fabrics have very limited use at high temperatures and under conditions that require resistance to forces. Specifically, such fabrics degrade rapidly when subjected to high temperatures, and under most conditions they are usually of limited strength.

  Increasingly, fabrics are formed with higher performance yarns than conventional yarns. High performance yarns have both high strength and high elastic modulus compared to conventional yarns. In general, high performance yarns are formed from inorganic filaments. The use of these filaments has led to a new group of yarns and fabrics with high tensile strength and tensile modulus and the ability to maintain the above properties at high temperatures. Nevertheless, the strength and heat resistance of fabrics formed from known inorganic filaments may be further improved.

  In order to further improve the strength and heat resistance of known fabrics, the present invention uses inorganic raw materials such as volcanic rocks to produce inorganic filaments that can be woven into fabrics. Inorganic filaments produced from volcanic rocks have been found to exhibit excellent strength and heat resistance characteristics. Similarly, fabrics woven or formed from these inorganic filaments exhibit similar excellent strength and heat resistance characteristics.

  In view of the above, an object of the present invention is to provide a fabric formed from inorganic yarn. Another object of the present invention is to provide a fabric formed from organic yarn obtained from volcanic rock. Yet another object of the present invention is to provide a fabric formed from yarns containing inorganic filaments coated with rayon. Yet another object of the present invention is to provide a high strength heat resistant fabric that is relatively easy to manufacture, simple to use, and relatively cost effective.

  The present invention is directed to fabrics formed from yarns comprising inorganic filaments formed from volcanic rocks and coated with rayon. Specifically, the inorganic filaments are spun from a volcanic rock melt. The volcanic rock is preferably black rock containing aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, magnesium oxide, calcium oxide, sodium oxide and potassium oxide. In addition to black rock, the melt preferably includes additives including iron oxide, whitestone and boron.

  After spinning the filaments from the melt, they are sized or coated with a rayon sizing agent. The sized filaments are then twisted together to form a yarn by methods well known in the art. The resulting yarn has a diameter in the range of 10-15 mm, preferably about 98% by weight inorganic filaments and 2% by weight rayon.

  Volcanic black rock is formed with a range of components, but in its manufacturing process, the yarn is about 35-45 wt% calcium oxide, 30-40 wt% magnesium oxide, 5-10 wt% oxidation. Potassium, less than 2% aluminum oxide, 5-10% iron oxide, less than 2% silicon dioxide, less than 2% titanium dioxide, less than 2% sodium oxide, less than 2% boron and It is preferable to control to contain 1 to 5% by weight of rayon. The yarn is about 40% calcium oxide, 36.6% magnesium oxide, 8.4% potassium oxide, 0.8% aluminum oxide, 8.85% iron oxide, 0.85% More preferably, it comprises wt% silicon dioxide, 0.8 wt% titanium dioxide, 0.8 wt% sodium oxide, 0.6 wt% boron and 2 wt% rayon.

  Because of its composition, the fabric of the present invention has a melting point of about 1500 degrees Celsius (1500 ° C.) to about 1650 degrees Celsius (1650 ° C.). In addition, the fabric has a working range of about -130 degrees Celsius (-130 degrees Celsius) to about 700 degrees Celsius (700 degrees Celsius).

In addition to its excellent thermal properties, the fabrics of the present invention exhibit very good strength and have good ballistic properties. Specifically, it has a tensile strength of from about 500 pounds per square inch (500 lbf / in ² ) to about 1800 pounds per square inch (1800 lbf / in ² ). Further, the fabric has a surface density of about 160 grams / square meter (160 g / m ² ) to about 350 grams / square meter (350 g / m ² ). The fabric is also relatively light and has a density of about 1.6 grams / cubic centimeter (1.6 g / cc).

  The novel features of the invention, as well as the invention itself, both in terms of its structure and operation, will be best understood from the accompanying drawings when taken in conjunction with the accompanying description. In the drawings, like reference characters refer to like parts.

1 is an enlarged schematic side view of a fabric according to an embodiment of the present invention. It is the schematic which illustrates the manufacturing method of the inorganic thread | yarn by this invention. FIG. 2 is a schematic diagram of several exemplary weave styles that can be used in fabrics according to the present invention.

  Referring to FIG. 1, a high strength heat resistant fabric according to the present invention is shown and designated as 10 as a whole. As shown in the figure, the fabric 10 includes a plurality of filling yarns 12 arranged so as to be substantially parallel to each other. Further, the plurality of warp yarns 14 are woven with the filling yarns 12 in a meandering shape (that is, a shape above and below the adjacent filling yarns 12). For the purposes of the present invention, both the fill yarn 12 and the warp yarn 14 include a yarn 16 formed from inorganic volcanic rocks, additives and rayon. As a result, the fabric 10 consists solely of inorganic yarns 16 and will exhibit certain desired characteristics as discussed below.

  Referring now to FIG. 2, an apparatus 18 for producing the inorganic yarn 16 is shown. As shown in the figure, the apparatus 18 includes a heating furnace 20. The furnace 20 is preferably a cupola furnace, which includes a chamber 22 surrounded by a side wall 24. The chamber 22 is dimensioned to accept the raw material 26 required to produce the inorganic yarn. Specifically, the raw material 26 includes black rock 28 and an additive 30. As shown, black rock 28 and additive 30 are fed into chamber 22 in the form of crushed solids. When it has been put into the chamber 22, it is liquefied therein to form a melt 32.

  Downstream of the heating furnace 20, the device 18 includes a spinning device 34. The spinning device 34 may be integrated with the heating furnace 20 or may be directly connected to the heating furnace 20 for receiving the melt 32. Alternatively, the melt 32 can be supplied to the spinning device 34 via a delivery tool such as ladle or the like. In any event, the spinning device 34 includes a pump or other means for pushing the melt 32 through one or more openings to form a plurality of filaments 36. The opening of the spinning device 34 is preferably formed by a fixed platinum nozzle that can withstand the high temperature of the melt 32.

  As shown in FIG. 2, the device 18 further includes a cooling device 38 located downstream of the spinning device 34. Similar to the spinning device 34, the cooling device 38 may be integrated with or connected to the heating furnace 20. As shown, the cooling device 38 is arranged to receive a plurality of filaments 36 from the spinning device 34. In addition, a sizing station 40 is disposed downstream of the cooling device 38 to receive a plurality of filaments 36 therefrom. The sizing station 40 includes a sizing agent 42 that can be applied to a plurality of filaments 36 to form a plurality of fibers 44. As further shown in FIG. 2, a twisting device 46 is disposed immediately downstream of the sizing station 40. The twisting device 46 receives a plurality of fibers 44 and forms the inorganic yarn 16 from the fibers.

  More particularly, the black rock 28 of the present invention is preferably made of a type of volcanic rock commonly found in Oregon, Washington, and elsewhere. Such black rock 28 is typically about 44% by weight calcium oxide, 41% by weight magnesium oxide, 10% by weight potassium oxide, 1% by weight aluminum oxide, 1% by weight iron oxide, 1% by weight silicon dioxide, Contains 1 wt% titanium dioxide and 1 wt% sodium oxide. Unless otherwise treated with or mixed with other materials, black rock 28 generally has a melting point in excess of 1200 degrees Celsius (1200 ° C.). Prior to introducing the black rock 28 into the chamber 22 of the furnace 20, the black rock 28 is sorted into discrete pieces having a diameter “d” of about 4-8 inches. All of the individual pieces of black rock 28 preferably have approximately the same diameter “d”.

  As further shown in FIG. 2, additive 30 is provided in the form of a ground solid. Additive 30 has a melting point of about 900 ° C. and contains about 26-33% by weight potassium permanganate, 39-45% by weight iron oxide, 22-31% by weight white stone and 3% by weight boron. Is preferred. For the present invention, potassium permanganate is provided as a fuel source for melting raw material 26 and iron oxide is provided to modify black rock 28. In addition, boron and about 58 wt% calcium oxide, 41 wt% magnesium oxide, less than 1 wt% silicon oxide and less than 1 wt% to reduce the melting point and facilitate processing of the raw material 26 mixture. Provide Shiroishi containing iron oxide.

  In the batch process, a desired amount of black rock 28 and additive 30 are fed to the furnace 20. The raw material 26 supplied to the chamber 22 is preferably basically composed of 60 to 90% by weight of black rock 28 and 40 to 10% by weight of additive 30. In certain preferred embodiments, the raw material 26 consists essentially of 87-88% black rock 28 and 13-12% additive 30. In such an embodiment, the mixture of raw materials 26 comprises about 5-6% by weight potassium permanganate, 4-6% by weight white stone, 8% by weight iron oxide and 0.6% by weight boron. The raw material 26 is preferably about 100 parts black rock 28 and about 14 parts additive 30 by volume.

  Once in the chamber 22 of the furnace 20, the mixture of raw materials 26 is heated to a temperature in the range of about 955 ° C to 1270 ° C, preferably 1200 ° C to 1270 ° C. Regardless of the specific temperature obtained, the mixture of raw materials 26 is heated enough to liquefy the raw materials 26 into a melt 32 having a viscosity suitable for processing. During heating, potassium permanganate is burned as fuel, facilitating liquefaction of other raw materials 26.

  After the melt 32 is properly formed, it is sent to the spinning device 34. The spinning device 34 pushes the melt 32 into the nozzle and extrudes the melt 32 into a plurality of filaments 36. The resulting filament 36 has a diameter in the range of approximately 1-10 microns. In order to prevent the filament 36 from being deformed, it is sent to a cooling device 38 where it is cooled and hardened into a soft solid. During the cooling step, the cooling device 30 first cools the plurality of filaments 36 to 800 ° C. and holds the temperature for 30 minutes. The filaments 36 are then cooled to 355 ° C. and held at that temperature for 30 minutes. As a result, the plurality of filaments 36 become a substantially soft solid. This facilitates later processing.

  After cooling to 355 ° C., the filament 36 is sent to the sizing station 40. In the sizing station 40, the rayon sizing agent 42 is applied to the plurality of filaments 36. Specifically, a plurality of filaments 36 are coated with a rayon sizing agent 42 to form a plurality of fibers 44. The rayon sizing agent 42 is preferably in the form of a yarn and is provided in an amount such that the rayon results in the formation of 2% by weight fibers 44. As a result of the rayon coating, the fibers 44 are protected from mechanical damage and yarn formation from the fibers 44 is facilitated. When sizing is performed, the fibers 44 are collected and processed by the twisting device 46. Specifically, the twisting device 46 pulls out the plurality of fibers 44 and twists them to form the inorganic yarn 16. The obtained inorganic yarn 16 preferably has a diameter in the range of 10 to 15 mm.

  For the purposes of the present invention, the yarn 16 produced by the above process comprises approximately 40% by weight calcium oxide, 36.6% by weight magnesium oxide, 8.4% by weight potassium oxide, 0.8% by weight oxidation. Aluminum, 0.85 wt% iron oxide, 0.85 wt% silicon dioxide, 0.8 wt% titanium dioxide, 0.8 wt% sodium oxide, 0.6 wt% boron, 8 wt% Preferably it contains iron oxide and 2% by weight of rayon. Such yarn 16 has a melting point in the range of about 1500 ° C to about 1650 ° C and a practical range of about -130 ° C to 700 ° C. In addition, the yarn is relatively light and has a density of about 1.6 grams / cubic centimeter (1.6 g / cc).

  Although a representative weave comprising inorganic yarn 16 is shown in FIG. 1, it will be appreciated that any number of weaves can be used to form the fabric 10 of the present invention. Some examples of weaving are shown in FIG. These are all well known in the art. Specifically, FIG. 3 shows a plain weave, a clawfoot satin weave, a 2 × 2 basket weave, a 2/2 twill weave, a 2/1 twill weave, and a tangle weave. For the purposes of the present invention, such weaves can be selected, designed or utilized to control the weight, thickness, density and strength of the fabric 10. In addition, a specific weave may be desired for a specific application of the fabric 10.

  Although the specific fabrics shown and disclosed in detail herein can fully achieve the objectives and provide the advantages described hereinabove, they are merely examples of this preferred embodiment of the present invention and are not attached. It is to be understood that no limitation of the construction or design details shown herein is intended to be limited except as set forth in the appended claims.

Claims (20)

  A fabric formed from yarn comprising inorganic filaments coated with rayon, wherein the inorganic filaments are formed from volcanic black rock.   The fabric of claim 1, wherein the inorganic filaments are spun from a melt of volcanic black rock.   The fabric according to claim 1, wherein the inorganic filament comprises calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide and boron. The yarn is about 35-45% by weight calcium oxide;
30-40% by weight magnesium oxide,
5-10% by weight potassium oxide,
Less than 2% by weight of aluminum oxide,
5-10 wt% iron oxide,
Less than 2% by weight of silicon dioxide,
Less than 2% by weight of titanium dioxide,
Less than 2% by weight of sodium oxide,
4. The fabric of claim 3, comprising less than 2% by weight boron and 1-5% by weight rayon.   The fabric of claim 1 wherein the yarn is about 98 wt% filaments and 2 wt% rayon. About 40% by weight of calcium oxide,
36.6% by weight of magnesium oxide,
8.4% by weight potassium oxide,
0.8% by weight aluminum oxide,
8.85 wt% iron oxide,
0.85 wt% silicon dioxide,
0.8 wt% titanium dioxide,
0.8% by weight sodium oxide,
6. The fabric of claim 5, comprising 0.6 wt% boron and 2 wt% rayon.   The fabric of claim 1, having a melting point of about 1500 degrees Celsius (1500 ° C.) to about 1650 degrees Celsius (1650 ° C.).   The fabric of claim 1, having a practical range of about -130 degrees Celsius (-130 degrees Celsius) to about 700 degrees Celsius (700 degrees Celsius). The fabric of claim 1, having a surface density of from about 160 grams / square meter (160 g / m ² ) to about 350 grams / square meter (350 g / m ² ). The fabric of claim 1 having a tensile strength of from about 500 pounds per square inch (500 lbf / in ² ) to about 1800 pounds per square inch (1800 lbf / in ² ). Mixing an additive containing potassium permanganate with a volcanic rock to produce a raw material;
Melting the raw material to produce a melt;
Spinning the melt to produce a plurality of filaments having a diameter substantially in the range of 1 to 10 microns;
Cooling the plurality of filaments;
Sizing the plurality of filaments with a rayon agent to produce fibers;
Producing a yarn by twisting the plurality of fibers;
A fabric comprising a woven yarn produced by weaving the yarn into a fabric.   12. The fabric of claim 11, wherein the volcanic rock is black rock and the raw material comprises about 100 parts black rock and about 14 parts additive.   The fabric according to claim 11, wherein the additive further comprises iron oxide, crushed white stone and boron.   12. The fabric of claim 11, wherein the potassium permanganate provides fuel in the melting step.   The fabric of claim 11 having a melting point of from about 1500C to about 1650C.   12. The fabric of claim 11, having a practical range of about -130 degrees Celsius (-130 degrees Celsius) to about 700 degrees Celsius (700 degrees Celsius). The fabric of claim 11, having a surface density of about 160 grams / square meter (160 g / m ² ) to about 350 grams / square meter (350 g / m ² ). The fabric of claim 11, having a tensile strength of from about 500 pounds per square inch (500 lbf / in ² ) to about 1800 pounds per square inch (1800 lbf / in ² ).   A fabric comprising a yarn weave composed of inorganic filaments coated with rayon, wherein the inorganic filaments are formed from volcanic black rock.   20. The fabric of claim 19, wherein the inorganic filament is spun from a melt of volcanic black rock and comprises calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide and boron. .

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