KR20100014241A - Inorganic fabric - Google Patents

Abstract

A fabric is formed from yarn comprised of inorganic filaments coated with rayon. Specifically, the inorganic filaments are spun from a melt of volcanic black rock and are comprised of calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide, and boron. As a result of its composition, the fabric is temperature resistant and lightweight, yet strong. Preferably, the fabric exhibits a melting point between 1500°C and 1650°C, a working range of-130°C to 700°C, a density of 1.6 g/cc, a surface density between 160 g/mand 350 g/m, and a tensile strength between 500 lbf/inand 1800 lbf/in.

Description

Inorganic Fabrics {INORGANIC FABRIC}

The present invention relates to a woven fabric formed of yarn. More specifically, the present invention relates to a high performance fabric formed from twisted yarns composed of inorganic filaments. The present invention is particularly useful for, but not limited to, producing fabrics from twisted yarns derived from inorganic raw materials including black rock.

Conventional fabrics are typically produced from organic or synthetic polymer fibers. Due to their composition, the fabric has very limited use under conditions where force resistance is required and at high temperatures. Specifically, such fabrics deteriorate rapidly when applied at high temperatures, and the fabrics typically have limited strength under most conditions.

Fabrics are increasingly formed of high performance yarns rather than conventional yarns. High performance yarns have both increased strength and increased elastic modulus compared to conventional yarns. Typically, high performance twisted yarns are formed of inorganic filaments. The use of the filaments results in a new class of twisted yarns and fabrics with high tensile strength and modulus, the filaments having the ability to retain these properties at elevated temperatures. In addition, the strength and heat resistance of fabrics formed from known inorganic filaments can be correspondingly improved.

In order to correspondingly improve the strength and heat resistance of known fabrics, the present invention produces inorganic filaments that can be woven into fabrics using raw materials such as volcanic rock. Inorganic filaments made of volcanic rock have been found to exhibit good strength and heat resistance qualities. Likewise, fabrics woven or otherwise formed of such inorganic filaments also exhibit equally good strength and heat resistance qualities.

In view of the above, it is an object of the present invention to provide a fabric formed of inorganic yarns. Another object of the present invention is to provide a fabric formed of organic twisted yarn derived from volcanic rock. Another object of the present invention is to provide a fabric formed of twisted yarn comprising inorganic filaments coated with rayon. Another object of the present invention is to provide a high strength heat resistant fabric which is relatively easy to manufacture, simple to use and fairly cost effective.

The present invention relates to a fabric formed from twisted yarns formed of volcanic rock and coated with inorganic filaments coated with rayon. More specifically, the inorganic filaments are spun from the melt of volcanic rock. Preferably, the volcanic rock is a black rock composed of aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, magnesium oxide, calcium oxide, sodium oxide and potassium oxide. In addition to the black rock, the melt preferably comprises an additive comprising iron oxide, white stone and boron.

After the filament is spun from the melt, the filament is sized or coated by a rayon sizing agent. The sized filaments are then twisted together to form twisted yarns in a manner well understood in the art. Preferably, the resulting twisted yarns have a diameter in the range of 10 to 15 millimeters, with approximately 98 weight percent inorganic filament and 2 weight percent rayon.

Black volcanic rocks are formed in a certain component range, but the manufacturing process is 35 to 45% by weight of calcium oxide, 30 to 40% by weight of magnesium oxide, 5 to 10% by weight of potassium oxide, less than 2% by weight of aluminum oxide, iron oxide to 5 to 10 It is preferably adjusted to consist of weight percent, less than 2 weight percent silicon dioxide, less than 2 weight percent titanium dioxide, less than 2 weight percent sodium oxide, less than 2 weight percent boron, and 1 to 5 weight percent rayon. More preferably, the twisted yarn is approximately 40% by weight of calcium oxide, 36.6% by weight of magnesium oxide, 8.4% by weight of potassium oxide, 0.8% by weight of aluminum oxide, 8.85% by weight of iron oxide, 0.85% by weight of silicon dioxide, 0.8% by weight of titanium dioxide, 0.8 wt% sodium oxide, 0.6 wt% boron, and 2 wt% rayon.

As a result of the composition, the fabric of the present invention has a melting point of approximately 1500 ° C to approximately 1650 ° C. In addition, the fabric has an operating range of approximately -130 ° C to approximately 700 ° C.

In addition to its excellent thermal properties, the fabrics of the present invention exhibit good strength and good ballistic properties. Specifically, the fabric has a tensile strength of approximately 500 lbf / in ² to approximately 1800 lbf / in ² . In addition, the fabric has a surface density of approximately 160 g / m ² to approximately 350 g / m ² . In addition, the fabric is relatively very lightweight and has a density of about 1.6 g / cc.

The novel features of the invention, as well as the invention itself, will all be best understood from the accompanying drawings taken in connection with the accompanying description, with respect to their structure and operation, wherein like reference characters indicate similar parts, wherein

1 is an enlarged schematic side view of a fabric according to an embodiment of the present invention.

2 is a schematic diagram illustrating a method of producing an inorganic yarn according to the present invention.

3 is a schematic representation of various exemplary weaving styles that may be used in the fabric according to the present invention.

Referring to FIG. 1, the high strength heat resistant fabric described in the present invention is shown and generally indicated by 10. As shown, the fabric 10 consists of a plurality of fill yarns 12 arranged substantially parallel to one another. Also, a plurality of warp yarns 14 are woven into wefts 12 in the form of serpentine (ie, above and below adjacent wefts 12). For the present invention, both the weft 12 and the warp 14 are comprised of yarn 16 formed of inorganic volcanic rock, additives and rayon. As a result, the fabric 10 consists only of inorganic yarns 16 and exhibits certain desirable properties discussed below.

Referring now to FIG. 2, a system 18 for making inorganic yarn 16 is shown. As shown, the system 18 includes a furnace 20. The furnace 20 is preferably a cupola furnace and comprises a chamber 22 formed of sidewalls 24. The chamber 22 is dimensioned to receive the raw material 26 needed to make inorganic yarns. Specifically, the raw material 26 includes a black rock 28 and an additive 30. As indicated, the black rock 28 and the additive 30 are provided to the chamber 22 in the form of pulverized solids. Once these materials are received in the chamber 22, they are liquefied inside to form a melt 32.

Downstream of the furnace 20, the system 18 includes a spinning device 34. The spinning device 34 may be integrated with the furnace 20 or may be directly connected to the furnace 20 to receive the melt 32. Alternatively, the melt 32 may be delivered to the spinning device 34 via a carrier, such as a ladle. In both cases, the spinning device 34 includes a pump or other means for forcing the melt 32 through one life or several holes to form a plurality of filaments 36. Preferably, the aperture of the spinning device 34 is formed by a stationary platinum nozzle capable of withstanding the high temperatures of the melt 32.

As shown in FIG. 2, the system 18 further includes a cooling device 38 disposed downstream of the spinning device 34. Like the spinning device 34, the cooling device 38 can be integrated with or connected to the 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 located 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 the plurality of filaments 36 to form the plurality of fibers 44. As further shown in FIG. 2, a twisting device 46 is located directly below the sizing station 40. The twisting device 46 receives a plurality of fibers 44 and forms inorganic yarns 16 therefrom.

More specifically, the black rock 28 of the present invention is preferably a type of volcanic rock commonly found in Oregon, Washington and elsewhere. Such black rock 28 is typically 44% by weight of calcium oxide, 41% by weight of magnesium oxide, 10% by weight of potassium oxide, 1% by weight of aluminum oxide, 1% by weight of iron oxide, 1% by weight of silicon dioxide, 1% by weight of titanium dioxide, and It contains 1% by weight of sodium oxide. Black rock 28 typically has a melting point of 1200 ° C. or higher, unless otherwise treated with or mixed with other materials. Before being introduced into the chamber 22 of the furnace 20, the black rock 28 is graded into individual pieces having a diameter “d” of about 4 to 8 inches. Preferably, all of the individual pieces of black rock 28 have substantially the same diameter "d".

As further shown in FIG. 2, the additive 30 is provided in the form of a ground solid. The additive 30 preferably has a melting point of about 900 ° C. or more and includes about 26 to 33 wt% of potassium permanganate, 39 to 45 wt% of iron oxide, 22 to 31 wt% of whitestone, and 3 wt% of boron. For the present invention, potassium permanganate is provided as a fuel source for melting the raw material 26 and iron oxide is provided to deform the black rock 28. In addition, whitestone and boron containing about 58% calcium oxide, 41% magnesium oxide, less than 1% silicon dioxide and less than 1% iron oxide lower the melting point of the mixture of the raw material 26 and promote processing. It is provided to make.

As a batch process, the desired amount of black rock 28 and additives 30 are delivered to the furnace 20. Preferably, the raw material 26 provided in the chamber 22 consists essentially of 60 to 90% by weight of the black rock 28 and 40 to 10% by weight of the additive 30. In a particular preferred embodiment, the raw material 26 consists essentially of 87-88% of the black rock 28 and 13-12% of the additive 30. In one such embodiment, the mixture of raw material 26 comprises about 5-6% potassium permanganate, 4-6% whitestone, 8% iron oxide, and 0.6% boron. By volume analysis, the raw material 26 is preferably about 100 parts of the black rock 28 and about 14 parts of the additive 30.

When located in the chamber 22 of the furnace 20, the mixture of raw materials 26 is heated to a temperature in the range of approximately 955 ° C. to 1270 ° C., preferably to 1200 ° C. to 1270 ° C. Regardless of the specific temperature learned, the mixture of raw materials 26 is sufficiently heated to reduce the raw materials 26 to liquefy into a melt 32 having viscous properties for processing. During heating, potassium permanganate is burned as fuel and promotes the step of liquefying other raw materials 26.

After the melt 32 is properly formed, it is transferred to the spinning device 34. The spinning device 34 extrudes the melt 32 into a plurality of filaments 36 by forcing the melt 32 through its nozzle. The resulting filament 36 has a diameter substantially in the range of 1 to 10 microns. To prevent deformation of the filaments 36, they are delivered to the cooling device 38 to be cooled and cured into a soft solid body. During the cooling process, the cooling device 30 first cools the plurality of filaments 36 to 800 ° C. and maintains the temperature for 30 minutes. Next, it cools the plurality of filaments 36 to 355 ° C. and maintains the temperature for 30 minutes. As a result, the plurality of filaments 36 reach a substantially soft solid state that facilitates further processing.

After cooling to 355 ° C., the filament 36 is passed to a sizing station 40. In the sizing station 40, a rayon sizing agent 42 is applied to the plurality of filaments 36. Specifically, the plurality of filaments 36 are coated by the rayon agent 42 to form the plurality of fibers 44. The rayon agent 42 is preferably in the form of a twisted yarn, provided in an amount that forms 2% by weight of the fibers 44 from which rayon is produced. As a result of the rayon coating, the fibers 44 are protected from mechanical damage and the formation of twisted yarns from the fibers 44 is promoted. Once they are sized, the fibers 44 are collected and processed by the twisting device 46. Specifically, the twisting device 46 drafts and twists the plurality of fibers 44 to form the inorganic twisted yarn 16. Preferably, the resulting inorganic yarn 16 has a diameter in the range of 10 to 15 millimeters.

For the present invention, the twisted yarn 16 prepared according to the above method is preferably about 40 wt% calcium oxide, 36.6 wt% magnesium oxide, 8.4 wt% potassium oxide, 0.8 wt% aluminum oxide, 0.85 wt% iron oxide, and dioxide It consists of 0.85% silicon, 0.8% titanium dioxide, 0.8% sodium oxide, 0.6% boron, 8% iron oxide and 2% rayon. Such yarn 16 has a melting point in the range of approximately 1500 ° C. to approximately 1650 ° C. and has an operating range of about −130 ° C. to 700 ° C. In addition, the twisted yarn is relatively very light and has a density of about 1.6 g / cc.

1 shows a representative weave composed of inorganic yarns 16, it will be understood that any number of weaves may be used to form the fabric 10 of the present invention. Several typical weaves, all of which are well known in the art, are shown in FIG. 3. Specifically, FIG. 3 includes illustrations of plain weave, crowfoot satin weave, 2 × 2 basket weave, 2/2 twill weave, 2/1 twill, and leno weave. For the present invention, these weaves can be selected, designed or used to control the weight, thickness, density and strength of the fabric 10. In addition, specific weaves may be required for the particular use of the fabric 10.

While certain fabrics as shown and described in detail herein may fully achieve the objects described above and provide advantages, they are merely described in the appended claims as illustrating the presently preferred embodiments of the invention. It is to be understood that no limitation is intended to the details of the structure or design of the invention.

As mentioned above, the present invention is used to provide a high performance fabric formed of twisted yarn composed of inorganic filaments.

Claims (20)

A fabric formed of yarns coated with rayon and composed of inorganic filaments formed of volcanic black rock. The fabric of claim 1 wherein the inorganic filament is spun from a melt of black volcanic rock. The woven fabric of claim 1 wherein the inorganic filament consists of calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide, and boron. The method of claim 3, wherein the speaker is approximately Calcium oxide 35-45 wt%; Magnesium oxide 30-40 wt%; Potassium oxide 5-10% by weight; Less than 2% by weight of aluminum oxide; Iron oxide 5-10% by weight; Less than 2% by weight of silicon dioxide; Less than 2% by weight titanium dioxide; Less than 2% by weight sodium oxide; Less than 2% by weight of boron; And Rayon 1 to 5% by weight Included, fabric. The fabric of claim 1, wherein the twisted yarn is approximately 98% by weight filament and 2% by weight rayon. The method of claim 5, wherein the speaker is approximately 40% by weight calcium oxide; Magnesium oxide 36.6 weight%; 8.4 wt% potassium oxide; 0.8 wt% aluminum oxide; Iron oxide 8.85 wt%; 0.85% silicon dioxide; 0.8 wt% titanium dioxide; 0.8 wt% sodium oxide; 0.6 wt% boron; And 2% by weight of rayon Included, fabric. The fabric of claim 1, wherein the fabric has a melting point of approximately 1500 ° C. to approximately 1650 ° C. 7. The fabric of claim 1, wherein the fabric has an operating range of approximately −130 ° C. to approximately 700 ° C. 7. The fabric of claim 1, wherein the fabric has a surface density of approximately 160 g / m ² to approximately 350 g / m ² . The fabric of claim 1, wherein the fabric has a tensile strength of approximately 500 lbf / in ² to 1800 lbf / in ² . As a fabric, Mixing the volcanic rock with an additive comprising potassium permanganate 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 a fiber; Twisting the plurality of fibers to produce a twisted yarn; And In the step of weaving the yarn into a fabric Woven, consisting of woven twisted yarn manufactured by. 12. The fabric of claim 11 wherein the volcanic rock is black rock and the raw material comprises approximately 100 parts of black rock and approximately 14 parts of additives. The fabric of claim 11, wherein the additive further comprises iron oxide, pulverized whitestone, and boron. The fabric of claim 11 wherein the potassium permanganate fuels the fusing step. The fabric of claim 11, wherein the fabric has a melting point of about 1500 ° C. to about 1650 ° C. 13. The fabric of claim 11, wherein the fabric has an operating range of approximately −130 ° C. to approximately 700 ° C. 12. The fabric of claim 11, wherein the fabric has a surface density of approximately 160 g / m ² to approximately 350 g / m ² . The fabric of claim 11, wherein the fabric has a tensile strength of approximately 500 lbf / in ² to 1800 lbf / in ² . A fabric comprising ray weave, coated with rayon, made of inorganic filaments formed of black volcanic rock. 20. The fabric of claim 19 wherein the inorganic filament is spun from a melt of black volcanic rock and consists of calcium oxide, magnesium oxide, potassium oxide, aluminum oxide, iron oxide, silicon dioxide, titanium dioxide, sodium oxide and boron.

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