KR101319361B1 - Method and apparatus of forming integrated multilayer fabrics - Google Patents

Abstract

The present invention relates to a method and apparatus for producing a multilayer fabric having a predetermined integrated pattern. In one embodiment, the method comprises a plurality of winding yarn carriers disposed in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction. A step of providing, a step of forming a plurality of intersection points of the winding yarn by moving the at least one winding yarn carrier in the second direction according to the integration pattern, a plurality of winding yarn layer at a predetermined position along the first direction Conveying the binder yarns through, fixing the binder yarns in place, and pressing the binder yarns toward the pel of the multilayer fabric; And winding up the formed multilayer fabric.

Description

METHOD AND APPARATUS OF FORMING INTEGRATED MULTILAYER FABRICS}

FIELD OF THE INVENTION The present invention generally relates to multilayer fabrics, in particular a predetermined integrated pattern formed of winding yarns disposed in a plurality of layers bound together at an angle by a set of through-the-layers binder yarns. An integrated multi-layer fabric having

Integrated multilayer fabrics find wide application, especially in advanced composite materials, power transmission and conveyor belts, and fabrics in paper molding machines.

Advanced composite materials include high performance fibers in the matrix. Depending on the fiber and matrix materials and the manufacturing parameters, advanced composites, in particular, weight to strength ratio and modulus to weight ratio, fatigue strength, damage tolerance, customizable coefficient of thermal expansion, chemical resistance, weatherability, temperature resistance This is excellent.

Fiber is a basic load-bearing component in fiber reinforced composites. Fibers are often preconfigured in various forms to facilitate the fabrication of composite component parts. Advanced composite materials often consist of fabrics and sheets, or prepreg tapes, which are monolayer fabrics or parallel continuous fibers held by matrix forming materials. They are used to fabricate parts by laminate layup and tape or filament winding. Conventional laminated composite materials are vulnerable to exfoliation because the layers of strong fibers are often connected only by matrix materials which are much weaker than the fibers. Introduction of the fiber reinforcement in the thickness passing direction of the three-dimensional composite material can effectively control the peeling failure and increase the damage tolerance of the composite material. In addition to improving performance, composite materials reinforced with integrated fiber structures may also provide other benefits, such as the possibility of automatic and net shape processing and low manufacturing costs.

The entire interlock and adjacent layer interlocked three-dimensional fabric can be formed by weaving or braiding. In such fabrics, the yarns are crimped due to interlacing or interwining, and the yarn crimps in the fabric cause a decrease in the stiffness and strength of the composite material reinforced with this fabric. The fabric layer is integrated by interlocks, but there is no reinforcing yarn positioned directly in the thickness passing direction.

In addition, multilayer fabrics having layers of parallel fibers of a predetermined angle bound by the knitting process, known as non-crimped fabrics, are also commonly used in reinforcing composite materials. Methods of making such multilayer fabrics are disclosed in US Pat. No. 4,518,640 to Wilkens. This method is suitable for making flat yarns with a fixed yarn orientation. The cotton oriented layer generally comprises high performance fibers such as glass and / or graphite fibers, but the knitted yarn is generally a poly (ethylene terephthalate) (PET) or aramid, etc. rather than using the same kind of high performance fibers as the cotton oriented layer. Made of flexible fibers.

Fabrics having three-dimensional rectangles or other cross-sectional shapes of I and T cross sections can be formed by three-dimensional weaving and braiding processes, for example, as disclosed in US Pat. No. 4,312,261 (Florentine) and US Pat. No. 5,085,252 (Mohamed et al.). It may be composed of reinforcing fibers in both directions in the plane direction and the thickness passing direction. In general, these processes are not limited to the dimensions of the fabric that can be produced.

The tubular fabric may be composed of reinforcing fibers in both directions in the circumferential layer and the thickness passing direction, as disclosed, for example, in US Pat. No. 4,001,478 (King) and US Pat. No. 4,346,741 (Banos et al.). This process does not provide the flexibility to change yarn orientation and fabric geometry at other locations within the fabric as needed.

Conventional methods of forming integrated fabrics lack the flexibility to change fiber orientation and / or cross-sectional shape and / or dimensions when forming the fabric. Conventional methods are often associated with disadvantages such as low yield, low degree of automation, the need for frequent replenishment of yarn packages, and low fiber incorporation.

Therefore, there is a conventional problem that has not been solved so far to deal with the above-mentioned shortage and insufficiency.

The method disclosed in the present invention overcomes the aforementioned limitations and shortcomings of existing methods of forming integrated fabrics, thereby making it possible to produce complex parts as well as simple parts without yarn interweaving or interweaving. This method provides, among other advantages, in particular the use of large yarn packages, simple tension control, the ability to scale up to produce large cross-sectional fabrics, and high process automation.

In one aspect, the present invention relates to a method of making a multilayer fabric having a predetermined integrated pattern with winding yarns and binder yarns. In one embodiment, the method includes a plurality of wound yarn carriers disposed in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction. Includes steps to provide. Each winding yarn carrier has a set of spatially separated supply yarn packages suitable for feeding the winding yarns to form a winding yarn layer, whereby the winding yarns supplied from the plurality of winding yarn carriers Form a yarn layer. In one embodiment, the plurality of winding yarn carriers comprises a plurality of winding yarn layers at predetermined angles ranging from about 0 ° to about ± 90 ° with respect to the first direction coincident with the longitudinal direction of the formed multilayer fabric. It is arranged to form.

The method comprises the steps of: (a) forming a plurality of intersections of the winding yarns by moving the at least one winding yarn carrier along the second direction according to the integration pattern; (b) conveying the binder yarns through the plurality of winding yarn layers at a predetermined position along the first direction, and fixing the binder yarns in position; (c) pressing the binder yarn towards the fell of the multilayer fabric; (d) winding up the formed multilayer fabric; And (e) repeating steps (a) to (d) until a multilayer fabric having the desired dimensions is produced.

The method also includes the step of removing sagging of the binder yarn before the winding step is performed.

In one embodiment, the binder yarns are carried by a plurality of binder yarn insertion needles positioned relative to the plurality of winding yarn carriers. The conveying step is performed by passing a plurality of binder yarn insertion needles through a plurality of winding yarn layers at a predetermined position along the first direction, and fastening the plurality of winding yarn layers together through the layers.

In one embodiment, the predetermined integration pattern is formed by controlling the number of layers of winding yarns, the relative distance of movement of the winding yarn carriers, and the implementation or omission of binder yarns during operation.

In another aspect, the present invention relates to an apparatus for producing a multilayer fabric having a predetermined integrated pattern. In one embodiment, the apparatus comprises a plurality of winding yarn carriers arranged in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction. Have Each winding yarn carrier has a set of spatially separated supply yarn packages suitable for supplying the winding yarns to form a winding yarn layer, such that the winding yarns supplied from the plurality of winding yarn carriers A drinking yarn layer is formed. Movement of the one or more winding yarn carriers in opposite directions creates a plurality of intersections by corresponding winding yarns. Each winding yarn carrier may be moved at an angle or in a straight line along the second direction.

In addition, the apparatus conveys the binder yarns through the plurality of winding yarn layers at a predetermined position along the first direction, and passes through the layers to fasten the plurality of winding yarn layers together to the plurality of winding yarn carriers. A plurality of binder yarn insertion needles positioned relative to each other, and at least one suitable for insertion through the opening of the laid winding yarn for a beat-up motion of pressing the binder yarn towards the pel of the fabric at a given time Has a body bar of (beating bar).

In one embodiment, the apparatus further comprises a plurality of shaping rings suitable for gathering the plurality of winding yarn layers and supporting the winding yarn layers during the binder needle insertion and body needle movement. The position of the plurality of shaping rings is changeable during each cycle of fabric formation.

In addition, the apparatus moves a retaining yarn through the open loop of the binder yarn to bind the fabric when the plurality of binder yarn inserting needles form the open loop by inserting the binder yarn through the plurality of winding yarn layers and bending the binder yarn. To secure the yarn, it may further have a retaining yarn feed needle and a retaining yarn insertion needle positioned relative to the plurality of binder yarn insertion needles.

In addition, each binder yarn insertion needle is held in order to keep the binder yarn loops open during insertion of the holding yarns and to tighten the binder yarns while limiting the bending curvature of the binder yarns when the binder yarns are taut after insertion of the holding yarns. It may further have an auxiliary bar accompanying.

In one embodiment, the apparatus may comprise a knitting mechanism having a needle and a yarn feeder to form a loop of retaining yarn through an open loop of folded binder yarns, the retaining yarn being a binder The yarn is held in place, and when the binder yarn insertion needle is retracted and the sagging of the binder yarn is removed, the binder yarn is prevented from falling out.

In one embodiment, the apparatus further comprises one or more tension control devices positioned in each winding yarn carrier to adjust the tension of the winding yarns as the winding yarns are pulled out, and that the winding yarns fall out during body needle movement. To prevent this, it has a braking mechanism associated with one or more tension control devices.

In another aspect, the invention is arranged in a multi-layered structure along the first direction, is configured to be operatively movable with respect to each other in a second direction perpendicular to the first direction, by supplying a winding yarn A plurality of winding yarn carriers each having a set of spatially separated feed yarn packages suitable for forming a sleeping yarn layer (the winding yarns supplied from the plurality of winding yarn carriers form a plurality of winding yarn layers and Movement in the opposite direction of the bridging yarn carrier creates a plurality of intersections with corresponding winding yarns); A plurality of binder yarn insertion needles positioned relative to the plurality of winding yarn carriers; A retaining yarn supply needle and a retaining yarn insertion needle having a hook positioned with respect to the plurality of binder yarn insertion needles; And a method for producing a multilayer fabric having a predetermined integrated pattern in connection with an apparatus having at least one body needle bar.

In one embodiment, the method comprises: (a) moving at least one winding yarn carrier along a second direction to form a plurality of intersections of the winding yarns, according to the unifying pattern; (b) conveying the binder yarns through the plurality of winding yarn layers and forming the open loop by bending the binder yarns, the plurality of binder yarn insertion needles through the plurality of winding yarn layers at a predetermined position along the first direction. Inserting step; (c) securing the inserted binder yarn in position to fasten the plurality of winding yarn layers together through the layer; (d) inserting at least one body needle bar through the opening of the laid winding yarn for body needle movement to press the binder yarn towards the pel of the fabric at a predetermined time; (e) winding up the formed multi-layer fabric at a predetermined speed; And (f) repeating steps (a) to (e) until a multilayer fabric having the desired dimensions is produced.

In one embodiment, the step of securing the binder yarn in position comprises: (a) inserting a retaining yarn insertion needle through a binder yarn loop; (b) retracting the binder yarn insertion needle associated with the binder yarn loop from the top surface of the fabric without tensioning the binder yarn; (c) moving the retaining yarn supply needle inward to feed the retaining yarn to the hook of the retaining yarn insertion needle; (d) retracting the holding yarn insertion needle through the binder yarn loop to fix the holding yarn in the previous holding yarn loop; (e) tensioning the binder yarn when further retracting the holding yarn insertion needle; (f) moving the retaining yarn insertion needle around the next binder yarn loop; And (g) repeating steps (a) to (f) until all binder yarns are fixed and taut in position.

In one embodiment, the method further comprises the step of soaking the winding yarn layer before the step of inserting is performed.

The present invention provides a method of forming an integrated multi-layer fabric having a variety of constant or variable cross-sectional shapes, constant or variable fiber orientations and integration patterns. In integrated multilayer fabrics there are two lines of yarn, one of the winding yarns and the other of the binder yarns. The winding yarns are placed in the plurality of layers at a predetermined angle that may vary from about 0 ° to about ± 90 ° relative to the longitudinal direction of the fabric. The binder yarns pass through the layers to fasten the layers of the winding yarns together. Auxiliary systems of holding yarns may be used to hold the binder yarn in place. Since the main function of the holding yarn is not to provide structural strength and rigidity to the structure of the fabric, but to simply hold the binder yarn in place, flexible fibers such as nylon or PET threads can be used as the holding yarn. The feed yarns forming the winding yarns of each layer are located in separate carriers. Forming a plurality of new intersections of the winding yarns by moving each winding yarn carrier according to the unifying pattern; Conveying the plurality of binder yarns through the layer of winding yarn at a desired position and holding the binder yarn in place; Pressing the binder yarn to the position where the fabric is to be formed and repeating the operating cycle comprising the steps of removing all slack in the yarn and winding the newly formed fabric by a controlled distance in the machine direction, i. To form a fabric with fiber orientation and integration pattern. Integrated multi-layer fabrics having varying cross-sectional shapes, varying fiber orientations, and varying unified patterns may, in the course of the forming process, number of interlocking fiber layers, relative distances of winding yarn carrier movement, and implementation of binder yarns or It is formed by controlling omission.

Accordingly, the object of the present invention consists of a multilayer of fibers bound together by binder yarns passing through the layers, each layer following a desired fiber orientation, and the fibers of the layer not interlaced or interwinding, the desired cross-sectional shape. To provide a method for forming an integrated multi-layer fabric.

Another object of the present invention is to provide a method of forming an integrated multi-layer fabric of the desired cross-sectional shape. Examples of cross sections include, in particular, regular or irregular tubular and I cross sections, T cross sections, U cross sections, and flat cross sections.

It is another object of the present invention to provide a method of forming an integrated multi-layer fabric of variable cross-sectional shape such that the cross-sectional dimension can vary along the length of the fabric.

Another object of the present invention is to provide a method of forming an integrated multi-layer fabric of variable cross-sectional shape so that the shape can change along the length direction of the fabric.

Another object of the present invention is to provide a method of forming an integrated multi-layer fabric of variable cross-sectional shape such that the wall thickness of the hollow-shaped fabric, or the three-dimensional fabric thickness can vary along the length of the fabric.

It is an object of the present invention to provide a method of forming an integrated multi-layer fabric of variable cross-sectional shape such that the thickness for the fabric of the hollow cross section can vary in thickness along the longitudinal direction of the fabric.

Another object of the present invention is to provide a method of forming an integrated multi-layer fabric of variable cross-sectional shape such that the integration pattern can be changed by the method of fixing or omitting selected binder yarns, or fixing binder yarns.

Another object of the present invention is to provide a method of forming an integrated fabric in which the fiber orientation of each layer can vary along the length of the fabric.

Another object of the present invention is to remove the yarn from the yarn supply package without returning to form a fabric layer, thereby eliminating the need for springs or elastic bands for drawing and pulling back the yarns commonly required in two- and three-dimensional braiding processes. It is to provide a method of forming an integrated multi-layer fabric by removing.

Another object of the present invention is to integrate the yarn by controlling the tension of the yarn with a direct tension control device which is readily implemented by the fact that the yarns forming the fabric layer from the package only move in one direction without compensating for the yarn return. It is to provide a method of forming a multilayer fabric.

These and other aspects of the invention are apparent from the following description of the preferred embodiments taken in conjunction with the following drawings, although modifications and changes may be made therein without departing from the spirit and scope of the novel concept of the invention. Will be

1 is a schematic view of an apparatus for producing a multi-layer fabric according to an embodiment of the present invention.
2 is a schematic view of a method of making a multilayer fabric according to one embodiment of the invention.
3 is a schematic representation of a sequential process of the manufacture of a multilayer fabric in connection with an apparatus according to one embodiment of the invention, where (a) is a top view of the apparatus and (b) is a sectional view of the apparatus;
4 is a schematic representation of a sequential process of making multilayer fabrics in connection with an apparatus according to one embodiment of the invention, where (a) is a top view of the apparatus and (b) is a cross-sectional view of the apparatus;
5 is a schematic representation of a sequential process of making multilayer fabrics in connection with an apparatus according to one embodiment of the invention, where (a) is a top view of the apparatus and (b) is a cross-sectional view of the apparatus.
6 is a schematic representation of a sequential process of making a multilayer fabric in connection with an apparatus according to one embodiment of the invention, where (a) is a top view of the apparatus and (b) is a sectional view of the apparatus.
FIG. 7 is a schematic representation of a tubular fabric having a [45 / -45 / 0/90 / -45 / 45] layup in accordance with an embodiment of the present invention, given the degree of layer orientation from the inner surface to the outer surface depending on the degree drawing.
8 schematically illustrates fabrics (a)-(i) of various cross-sectional shapes made in accordance with embodiments of the present invention.

The accompanying drawings illustrate one or more embodiments of the invention and, together with the descriptions set forth, illustrate the principles of the invention. Wherever possible, the same reference numerals are used throughout the drawings to refer to the same or similar components of the embodiments.

Since various changes and modifications are apparent to those skilled in the art within the present invention, the present invention is described for the purpose of illustration only and in particular the following examples. Hereinafter, various embodiments of the present invention will be described in detail. Referring to the drawings, like reference numerals designate like elements throughout the drawings. The meanings of "a", "an" and "the" as used in the following description and the appended claims include plural references unless the context clearly dictates otherwise. . In addition, the meaning of "in" used in the description herein and in the claims that follow, unless the context clearly indicates otherwise, "in" and "phase ( on) ".

The terms used in this specification generally have their conventional general meanings within the context of the present invention and the specific context in which each term is used. Certain terms used to describe the invention are discussed below or elsewhere in this specification to provide additional guidance to the practitioner in connection with the description of the invention. The use of examples in all of this specification, including examples of any term discussed herein, is merely illustrative and does not limit the scope and meaning of the invention or the illustrated term. Likewise, the invention is not limited to the various embodiments given herein.

As used herein, "degree", "about" or "approximately" means within a given value or range, generally within 20 percent, preferably within 10 percent, more preferably within 5 percent. The figures given here are approximate and, although not specified, mean that the terms "degree", "about" or "approximately" can be considered.

Embodiments of the present invention will be described with reference to the accompanying drawings of FIGS. 1 to 8. In accordance with the object of the present invention, the invention practiced and broadly described herein, in one aspect, relates to an integrated multi-layer fabric formed of yarns disposed in a plurality of layers that are bound together at a predetermined angle by a set of layer passing yarns. It relates to a method of forming an integrated multi-layer fabric in which a variety of constant or variable cross-sectional shapes, constant or variable fiber orientations and integration patterns can be customized, depending on the needs of local fiber architecture and fabric geometry.

According to the present invention, an integrated multi-layer fabric is produced from two lines of yarn: winding yarn and binder yarn. The winding yarns are placed in the plurality of layers at a predetermined angle that may vary from about 0 ° to about ± 90 ° relative to the longitudinal direction of the fabric. Binder yarns are used to fasten the winding yarns of the desired layer together. The number of layers of winding yarns may vary as desired but is limited by the number of winding yarn carriers in the apparatus. In one embodiment, by means of an optional geometric mandrel appropriately along the machine direction, the layer of winding yarn may be shaped to form a hollow fabric or a fabric having a core. The orientation of the winding yarns relative to the individual layers can be changed relative to other locations within the fabric when forming the fabric.

Referring to FIG. 1, an apparatus 100 for producing an integrated multi-layer fabric having a predetermined integrated pattern in accordance with one embodiment of the present invention is shown schematically. The device 100 has two winding yarn carriers 110a, 110b arranged in a two-layer structure along the first direction 101, each winding yarn carrier 110a / 110b having a first direction 101. And operatively moveable with respect to each other along a second direction 102a / 102b perpendicular to). The winding yarn 130 is provided by a plurality of yarn supply packages 120. Yarn supply packages 120 that supply the winding yarns 130 to form each layer of fabric are mounted spaced apart into one individual yarn carrier 110a / 110b. In this exemplary embodiment shown in FIG. 1, the fabric 112 manufactured by employing the mandrel 103 is wound, and the end of the winding yarn 130 extending from the supply yarn package 120 has a mandrel 103. It is included in the fabric laid on. Movement of the one or more winding yarn carriers 110a, 110b in opposite directions 102a, 102b creates a plurality of intersections 132 by corresponding winding yarns 130.

In this embodiment, the winding yarn carriers 110a, 110b are configured to be angular rotation individually or in concert, along the directions 102a and / or 102b. Rotation of the winding yarn carriers 110a, 110b takes place about the axis 101 of the mandrel 103. Thus, multilayer fabrics such as tubular or tubular can be produced. In another embodiment, the winding yarn carrier may be configured to be movable linearly, individually or in concert, along the (second) direction perpendicular to the (first) direction in which the winding yarn carrier is aligned / positioned. In operation, the movement of the winding yarn carrier is controlled by the control system. By controlling the number of layers of the winding yarn, the relative distance of the winding yarn carrier movement, the distance of the fabric winding in the first direction, and the implementation or omission of the binder yarn in operation, a predetermined integrated pattern is formed.

In addition, in the exemplary embodiment, since the two winding yarn carriers 110a and 110b are utilized, the winding yarn 130 supplied from the two winding yarn carriers 110a and 110b may have two winding yarn layers. Form. However, there is no limit to the number of winding yarn carriers used in practicing the present invention. According to the invention, the number of yarn carriers for winding determines the maximum number of layers of fabric to be produced.

Each winding yarn carrier positions the yarn in the layer at a desired angle by movement in the circumferential direction such as rotation of a hard ring carrier. The winding yarn carrier may be hard or flexible. The rigid carrier may be circular or have other geometric shapes as shown in the example. Examples of flexible carriers include belts, chains, and coupling mechanisms moving on tracks.

In one embodiment, the winding yarns from some winding yarn carriers can be supplied from stationary creels. These carriers may be stationary during the process of placing the winding yarn in the O ° layer, or may move back and forth to form ribs in the fabric.

The package supplying the winding yarns may supply a number of threads during the winding movement, including one yarn per package or multiple yarns in a single package. The package may be flanged, cross wound, or other configuration. The winding yarn package can be located on the inside, outside, side, or inside of the carrier.

In addition, one or more tension control devices (not shown) may be fitted on each winding yarn carrier to adjust the tension when the winding yarn is pulled out. The braking mechanism can be employed separately or as part of the tension control device to prevent the winding yarn from falling out during the beat-up.

In addition, the apparatus 100 conveys / inserts the binder yarn through the plurality of winding yarn layers at a predetermined position along one direction 101 to fasten the plurality of winding yarn layers through the layers. It has one or more binder yarn insertion needles 140 positioned relative to the plurality of winding yarn carriers 130.

The binder yarn is provided by a suitable package, which may be a plurality of thread packages or individual packages such as beams. The binder yarn is inserted through the layer of winding yarn 130 into the appropriate interior designated by the integration pattern and fixed in place. Much like sawing, the newly laid winding yarns 130 can be gathered together and then the binder yarns can be introduced in the direction through the layer. The sawing layer integration may result in some impalement of the winding yarn. In addition, in order to avoid penetration of the winding yarns as in the example illustrated above, the binder yarns may be inserted through the openings between the newly formed intersections 132 of the winding yarns 130 before gathering the winding yarns together. Can be. In particular, there are several choices for binder yarn placement mechanisms including various types of knitting instruments, rapier yarn transfer mechanisms, shuttles, sewing machines.

In the embodiment shown in FIGS. 1 and 3 to 6, a plurality of binder yarn insertion needles 140 are used to insert a binder yarn through a layer of winding yarns and open loops by the bent binder yarns. ). The apparatus 100 may also have a retained yarn supply needle 172 and a retained yarn insertion needle 174 positioned relative to the plurality of binder yarn insertion needles 140. The plurality of binder yarn insertion needles 140 forms a retaining yarn supply needle 172 and a retaining yarn insertion needle 174 when the binder yarn is inserted through the plurality of winding yarn layers and forms an open loop by bending the binder yarn. Move the retaining yarn through the open loop of the binder yarn to secure the binder yarn to the fabric.

Preferably, the apparatus 100 is provided with a set of needles for binder yarns and retaining yarns in the same number as the number of winding yarn packages for fast operating speed. The movement of each needle set follows the command by the control system. At a minimum, only one holding yarn needle pair is needed. In this case, the pair of needles completes one turn of movement in the circumferential direction with respect to the laid winding yarn layer in each fabric forming cycle.

As shown in FIG. 1, the device 100 also has one or more body needle bars 160 suitable for insertion through the opening of the winding yarn laid at a given time for body needle movement, so that The binder yarn is pressed against the pel 105.

In operation, the one or more body needle bars 160 pass through the openings of the winding yarns 130 placed for body needle movement at appropriate times and toward the binder 105 of the fabric in preparation for insertion of the binder yarns. Pressurize. Body needle movement prior to the insertion of the binder yarn may cause the binder yarn to be positioned as close to the pel 105 of the fabric as possible. The body needle bar is of a suitable geometric shape and can be fitted with a rotatable wheel or have low frictional resistance to minimize wear and damage to the winding yarn. Alternatively or in addition to the pre-insert body needle, post insertion body needle motion may be performed following binder yarn insertion, to press the newly inserted binder yarn to the pel 105 of the fabric. Although multiple bars are desirable for operational effectiveness and efficiency, a single body needle bar can be advanced in the circumferential direction to achieve the same movement.

The apparatus 100 further includes a plurality of shaping rings 151, 153, 155 suitable for gathering the plurality of winding yarn layers and supporting the winding yarn layer during insertion of the binder yarn and body needle movement. The position of the plurality of shaping rings can be changed during each cycle of fabric formation.

In addition, the apparatus 100 maintains the binder yarn loops open while the holding yarns are inserted, and tightens the binder yarns while limiting the bending curvature of the binder yarns when the binder yarns are taut after the holding yarns are inserted. It may further comprise an auxiliary bar (not shown) accompanying each binder yarn insertion needle 140.

The apparatus may comprise a knitting mechanism having a needle and a yarn feeder to form a loop of holding yarn through the open loop of the bent binder yarn, which holds the binder yarn in place and holds the binder When the yarn insertion needle retracts and removes sagging of the binder yarn, it prevents the binder yarn from falling out.

According to the present invention, an integrated multilayer fabric can be produced according to the following steps in connection with the above-described apparatus. First, a plurality of intersection points of the winding yarns are formed by moving the at least one winding yarn carrier along the second direction. This movement is controlled by the control system according to the integration pattern. Subsequently, binder yarns are conveyed or inserted through a plurality of yarn layers for winding at a predetermined position along the first direction, and are fixed in position. The binder yarn is pressed towards a plurality of intersections of the winding yarns to form a multilayer fabric. Subsequently, the formed multilayer fabric is wound up. The above steps are repeated until a multilayer fabric having the desired dimensions is produced.

This process can be operated in continuous or stepwise motion, in synchronism with the movement of the winding yarn carrier, binder yarn insertion, body needle and fabric winding.

Referring to Figures 2 and 3, in particular Figure 2, a flow chart for making a multilayer fabric according to one embodiment of the present invention is shown. In this embodiment, six ring-shaped winding yarn carriers 310a to 310f are employed.

Prior to beginning this process, each winding carrier 310a, 310b, 310c, 310d, 310e or 310f is equipped with a winding yarn package 320, and the inner diameter of the tubular fabric 312 to be produced in diameter and The ends of the yarns are tied to a mandrel 303 located inside the shaping ring 351 along the matching mandrel axis 301. After the initial operation to reach steady state in step 201, the next step completes one cycle. In step 211, the winding yarn carriers 310a-310f move in accordance with the designed / predetermined fabric pattern to allow the winding yarn 330 to enter. In one embodiment, the winding yarn carriers 310a (top), 310f (bottom) move in the forward direction (counterclockwise) during one step, and the winding yarn carriers 310b, 310e during one step. Moving in the reverse direction (clockwise), the winding yarn carrier 310c is in a stationary state, and the winding yarn carrier 310d completes one rotation. Next, in step 213, braking is performed on the winding yarn 330 in order to stop the insertion of the winding yarn 330. In step 220, the body needle bar 360 moves to a pel of fabric for the body needle and then retracts. In step 231, the binder yarn 342 is inserted through the opening between the winding yarn intersections 332. In step 233, binder yarn 342 is inserted and held in place by retaining yarn 371. In step 235, all sagging of the binder yarn and the holding yarn are removed. In step 237, a control system (not shown) determines whether binder yarn insertion is complete. If the binder yarn insertion has not been completed, the process begins at step 231. If the binder yarn insertion is complete, the braking of the winding yarn 330 is released in step 240. Subsequently, in step 250, the fabric 312 is wound up at a predetermined distance or speed by the mandrel. In step 255, the control system determines whether the desired fabric is completed. Once the desired fabric has been completed, the manufacturing process is complete at step 270. If the desired fabric is not completed, the parameters can be adjusted at step 260 if necessary, then the process is repeated from step 211.

The order of processing can be adjusted and the movement can be continuous or stepwise. The combination of the speed of the winding yarn carrier (step size of the carrier movement) and the fabric winding speed of the machine direction (step size of the mandrel movement) determine the local yarn orientation in the fabric. By varying the speed of the yarn carrier relative to the fabric winding speed, the yarn orientation can be changed as desired. Thus, fabrics can be produced by varying the layer angles along the length by adjusting the relative speeds of winding and fabric winding because the fabric is formed. In order to wind the layer near 90 °, the number of yarns pulled out of the package is not limited, or thinner yarns are thus used for the desired layer thickness.

3-6 schematically show an example of a binder yarn insert and a corresponding fastening mechanism according to one embodiment of the present invention. Some movements of the auxiliary parts and parts are well known to those skilled in the art and are omitted here. The plurality of binder yarn insertion needles 340 insert the binder yarns 342 through the layers of the winding yarns 330 to form an open loop defined by the bent binder yarns, so that the retaining yarns 371 form a loop. It can pass through to fix the binder yarn. The auxiliary bar (not shown) is accompanied by binder yarn insertion needles 340, respectively, to insert the retaining yarn 371 while keeping the binder yarn loop open, and to tighten the binder yarn after inserting the retaining yarn 371. This helps to limit the bending curvature of the binder yarn 342 when it is taut. Knitting mechanisms, including needles and yarn feeders, form a loop of holding yarn through the open loop of the bent binder yarn. Retaining yarn 371 holds binder yarn 342 in place of fabric 312, binder yarn 342 when binder yarn insertion needle 340 retracts and sagging of binder yarn 342 is removed. It aims to prevent this from falling out.

The order of forming the holding yarn loops to fix the binder yarn is the steps (a) to (d) shown in Figs. 3 to 6, as follows.

In step (a), as shown in FIG. 3, the friction between the winding yarns 330 is reduced when the predetermined amount of the winding yarns 330 is released by the angular movement of the winding yarn carriers 310a to 310f. The outer shaping ring 355 is lowered. Body needle bar 360 is pressed onto the winding yarn layer for body needle prior to binder yarn insertion, and then the outer shaping ring 355 is raised to collect the winding yarn layer. The body needle bar 360 then retracts.

In step (b), as shown in FIG. 4, through the opening of the winding yarn layer, the holding open loop 345 is exposed on the top surface of the fabric 312. Retaining yarn insertion needle 374 passes through binder yarn loop 345.

In step (c), as shown in FIG. 5, the binder yarn insertion needle 340 retracts from the top surface of the fabric 312 without tensioning the binder yarn 341. The retaining yarn supply needle 372 moves inward to feed the retaining yarn 371 to the hook of the retaining yarn insertion needle 374.

In step (d), as shown in FIG. 6, the retaining yarn insertion needle 374 retracts through the binder yarn loop 345 and secures the retaining yarn 371 within the previous retaining yarn loop. If the binder yarn insertion needle 340 is further retracted, the binder yarn 341 is taut.

The holding yarn insertion mechanism moves to the next binder yarn position in the circumferential direction, and steps (c) and (d) are repeated to fix and tighten all the binder yarns 341. The mandrel to return the fabric proceeds upward for winding the fabric.

The above steps are repeated until the entire fabric is completed.

In this illustrative example, the mandrel carrying the finished fabric moves upwards such that the holding yarn (or binder yarn when not using the holding yarn) loops on the outer surface of the fabric. Alternatively, the mandrel and fabric can be moved downwards through the shaping ring such that loops formed by the holding yarn (or binder yarn when not using the holding yarn) appear on the inner surface of the fabric.

According to the invention, the insertion and fixing of each binder yarn by the holding yarn at any given point can be carried out or omitted by the control system, thus replacing the integration pattern as desired even in the same kind of fabric. have.

Movement in the opposite direction of one or more winding yarn carriers creates a plurality of intersections by corresponding winding yarns, which affects the pattern of the fabric. FIG. 7 shows an example of a tubular fabric having a [45 / -45 / 0/90 / -45 / 45] layup according to one embodiment of the present invention, given the degree of layer orientation from the inner surface to the outer surface.

According to the above-described method, it is possible to form fabrics of various cross-sectional shapes. Some of them are shown in FIG. 8 as an example. In addition to fabrication of the cylindrical tubular structure (a), many modifications are possible to produce fabrics with different cross-sectional shapes or varying cross-sectional shapes along the length. The mandrel may be non-circular in shape, producing a non-circular cross-section of fabric as shown in (b) and (c). In addition, the cross-sectional size or shape of the fabric may vary depending on the length as shown in (d). In other variations, a flat (e) or other shaped cross section (f) may be produced without using a mandrel and instead using a shaping mechanism. In addition, a panel of flat cross section can be produced by open cut of the tubular fabric (a), and the T-section (f) can be formed by folding the tubular fabric (a). Typically, when the carriers move in one direction as a whole, the winding yarns from each carrier form a continuous layer of yarns in the fabric. However, by strategically placing the yarn package at the proper location of the carrier and alternatively moving the carrier back and forth, a discontinuous layer can be placed. Single or plural such discontinuous layers appear as valleys of the fabric (g). Width, height, and valley spacing can vary as desired. The valleys can be on the outer, inner or both sides of the fabric. By open-cutting the tubular fabric g in which the ribs were formed, it is possible to obtain a fabric having a flat cross section having a valley. By varying the amount of axis (0 degree) yarns at different cross-sectional locations, placing the incomplete layer of winding yarns, or using both, fabrics (i) can be made that change the wall thickness in the cross section.

In short, the present invention describes, in particular, an apparatus and method for producing an integrated multilayer fabric in which winding yarns arranged in a plurality of layers at a predetermined angle are bound together by a set of layer passing yarns. Depending on the requirements for local fiber architecture and fabric geometry, integrated multilayer fabrics can be customized to vary constant or variable cross-sectional shapes, constant or variable fiber orientations, and integration patterns.

The foregoing descriptions of exemplary embodiments of the invention have been given for purposes of illustration and description only, and are not intended to be exhaustive or to limit the invention to the precise form disclosed. In view of the above teachings, many modifications and variations are possible.

This embodiment has been selected and described in order to explain the principles of the invention and its practical application, to enable others skilled in the art to utilize the invention and its various embodiments and to consider various modifications suitable for a particular use. Alternative embodiments will be apparent to those skilled in the art without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described herein.

301: mandrel axis
312: Tubular Fabric
303: mandrel
310a ~ 310b: Winding Yarn Carrier
320: Winding Yarn Package
330: Winding Yarn
340: Binder Yarn Insert Needle
342: Binder Yarn
345: holding open loop
351: Shaping Ring
355: Outer Shaping Ring
360: Body Needle Bar
371: Yuji Yarn
372: Retaining Yarn Feed Needle
374: Keeping Yarn Insert Needle

Claims (20)

A method of making a multilayer fabric having a predetermined integrated pattern with winding yarns and binder yarns,
(a) a plurality of winding yarn carriers disposed in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction-the winding yarn carrier Each providing a set of spatially separated winding yarns supplied from one or more feed yarn packages mounted on a corresponding winding yarn carrier or stationary creel to form a winding yarn layer, wherein Providing the plurality of winding yarns supplied from the plurality of winding yarn carriers to form a plurality of winding yarn layers;
(b) forming a plurality of crossing points of said winding yarn by moving at least one said winding yarn carrier along said second direction in accordance with said integration pattern;
(c) conveying said binder yarn through a plurality of said winding yarn layers at a predetermined position along said first direction, and fixing said binder yarn in place;
(d) pressing said binder yarn toward a pellet of said multilayer fabric;
(e) winding up the formed multi-layer fabric; And
(f) repeating steps (b) to (e) until a multilayer fabric having the desired dimensions is produced. The method of claim 1,
The plurality of winding yarn carriers are arranged such that the winding yarns form a plurality of winding yarn layers at a predetermined angle in a range of 0 ° to ± 90 ° with respect to a first direction coinciding with the longitudinal direction of the formed multilayer fabric. And wherein each of the yarn packages supplies one or more of the winding yarns. The method of claim 1,
One or more of the binder yarns are moved by a binder yarn insertion system having at least one binder yarn insertion needle positioned relative to the plurality of winding yarn carriers, and the conveying step is a predetermined position along the first direction. And passing the at least one binder yarn insertion needle through the plurality of winding yarn layers, through the layer to fasten the plurality of winding yarn layers together. The method of claim 1,
And removing the sagging of the binder yarn before the winding step is performed. The method of claim 1,
The predetermined integration pattern is formed by controlling the number of layers of the winding yarn, the relative moving distance of the winding yarn carrier, the distance of fabric winding in the first direction, and the implementation or omission of the binder yarn during operation. How to be. A fabric structure produced according to the method of claim 1,
Hollow circle in a hollow integrated multiaxial form having a predetermined integrated pattern consisting of winding yarns arranged in a multiaxial direction at a predetermined angle, in a plurality of layers bound together by a set of binder yarns passing through the layers. Fabric structure having a cross-sectional shape of a hollow ellipse, hollow square or hollow rectangle, the thickness of which is uniform or varied inside. An apparatus for producing a multilayer fabric having a predetermined integrated pattern,
(a) a plurality of winding yarn carriers disposed in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction-the winding yarn carrier Each provides a set of spatially separated winding yarns supplied from one or more feed yarn packages mounted on corresponding winding yarn carriers or stationary krill to form a winding yarn layer, wherein the plurality of winding yarns The winding yarns supplied from the carrier form a plurality of winding yarn layers, and movement in opposite directions of one or more of the winding yarn carriers creates a plurality of intersections by corresponding winding yarns;
(b) said plurality of winding yarn carriers for conveying a binder yarn through said plurality of winding yarn layers at a predetermined position along said first direction to fasten together said plurality of winding yarn layers through a layer; A plurality of binder yarn insertion needles positioned relative to; And
(c) at least one body needle bar suitable for inserting through an opening of an interposed winding yarn for a beat-up motion of pressing the binder yarn towards the pel of the fabric at a predetermined time (beating bar) device. The method of claim 7, wherein
During the body needle movement with the binder yarn inserted, the shaping ring further comprises a plurality of shaping rings suitable for gathering the plurality of winding yarn layers and supporting the winding yarn layers. The device is changeable in position during each cycle of fabric formation. The method of claim 7, wherein
A holding yarn supplying needle and a holding yarn insertion needle positioned relative to the plurality of binder yarn insertion needles, wherein the plurality of binder yarn insertion needles insert the binder yarns through the plurality of winding yarn layers And forming the open loop by bending the binder yarn, wherein the retaining yarn feed needle and the retaining yarn insertion needle move the retaining yarn through the open loop of the binder yarn to secure the binder yarn to the fabric. The method of claim 9,
In order to keep the binder yarn loops open during insertion of the holding yarns and to tighten the binder yarns while limiting the bending curvature of the binder yarns when the binder yarns are taut after insertion of the holding yarns. And an auxiliary bar carrying said binder yarn insertion needle. The method of claim 9,
And a knitting mechanism having a needle and a yarn feeder to form a loop of the retaining yarn passing through the open loop of the bent binder yarn, wherein the retaining yarn holds the binder yarn in place. Retaining and preventing the binder yarn from falling out when the binder yarn insertion needle is retracted and the sagging of the binder yarn is removed. The method of claim 7, wherein
And at least one tension control device positioned in each of the winding yarn carriers to adjust the tension of the winding yarns when withdrawing the winding yarns. 13. The method of claim 12,
And a braking mechanism associated with the one or more tension control devices to prevent the winding yarn from falling out during the body needle movement. 13. The method of claim 12,
Wherein each winding yarn carrier is movable at an angle or in a straight line along the second direction. (i) a plurality of winding yarn carriers disposed in a multi-layer structure along a first direction and configured to be operatively movable with respect to each other along a second direction perpendicular to the first direction-the winding yarn carrier Each provides a set of spatially separated winding yarns supplied from one or more feed yarn packages mounted on corresponding winding yarn carriers or stationary krill to form a winding yarn layer, wherein the plurality of winding yarns The winding yarns supplied from the yarn carriers form a plurality of winding yarn layers, and movement in opposite directions of one or more of the winding yarn carriers creates a plurality of intersections by corresponding winding yarns;
(ii) a plurality of binder yarn insertion needles positioned relative to the plurality of winding yarn carriers; And
(iii) at least one body needle bar
A method of making a multilayer fabric having a predetermined integrated pattern in connection with an apparatus comprising:
(a) forming a plurality of intersection points of said winding yarn by moving at least one winding yarn carrier along said second direction, in accordance with said integration pattern;
(b) conveying the plurality of binder yarns through the plurality of winding yarn layers and forming the open loop by bending the binder yarns, the plurality of winding yarn layers through the plurality of winding yarn layers in a predetermined position along the first direction. Inserting a binder yarn insertion needle in the chamber;
(c) securing the inserted binder yarn in position to fasten the plurality of winding yarn layers together through a layer;
(d) inserting at least one body needle bar through the opening of the interposed winding yarn for body needle movement to press the binder yarn towards the pel of the fabric at a predetermined time;
(e) winding the formed multi-layer fabric at a predetermined speed; And
(f) repeating steps (a) to (e) until a multilayer fabric having a desired dimension is produced. The method of claim 15,
The apparatus further comprises a retaining yarn feed needle with a hook and a retaining yarn insertion needle positioned relative to the plurality of binder yarn insertion needles. 17. The method of claim 16,
The step of fixing the binder yarn in position,
(a) inserting the retaining yarn insertion needle through a binder yarn loop;
(b) retracting the binder yarn insertion needle associated with the binder yarn loop from the top surface of the fabric without tensioning the binder yarn;
(c) moving the retaining yarn supply needle inward to feed the retaining yarn to the hook of the retaining yarn insertion needle;
(d) retracting the holding yarn insertion needle through the binder yarn loop to secure the holding yarn in a previous holding yarn loop;
(e) tensioning the binder yarn when further retracting the holding yarn insertion needle;
(f) moving said retaining yarn insertion needle around a next binder yarn loop; And
(g) repeating steps (a) to (f) until all binder yarns are fixed and taut in position. The method of claim 15,
The predetermined position at which the binder yarn is inserted corresponds to an opening defined between newly formed intersections of the winding yarn. The method of claim 15,
And soaking the winding yarn layer before the inserting step is performed. The method of claim 15,
Each said winding yarn carrier is movable at an angle or in a straight line along said second direction.

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