SE509944C2 - Three dimensional nonwoven fabric for composites - Google Patents

Abstract

Plate (P) with a front surface, used for making an integrated nonwoven three dimensional fabric with three gps. of yarns or other fibres (including brittle ones) incorporated into the textile prod. at right angles to each other using this plate, comprises the following parts : (I) two sets of profiled grooves (C, D) at right angles to each other in the same plane as the front surface of (P); (II) two gps. of binder yarn spool supports (K, L) integrated with (P), that have profiles at one end matching those of (C, D) to enable each support to move along a groove; (III) two pairs of arrangement (I) allowing (K, L) to move from one groove to another and pass through (P) in a closed run without leaving (P), around axial yarns (Z) that extend through rows and columns of holes (B) in (P) and therefore through (I); and (IV) guide tubes (G) around each hole for (Z), both of which are surrounded by (C, D). The fibres or yarns comprise eg. carbon, glass, ceramic, polyester etc..

Description

15 threads can be the result of unfavorable interaction between the fibers (yarns or threads) and elements of the processing machine or machines. Due to such an unfavorable interference, the high-quality fibers can rupture and thus reduce the reliability of the elliptical composite material.

The second point concerns the elongation properties of the high-quality fibrous material. If the yarns or yarns of high-quality fibrous material are subjected to shrinkage or corrugation, the result of the structural properties of the textile (such as crossing due to weaving or looping due to knitting or twisting due to braiding) reduces the tensile properties of the yarn or yarn. This is because during shrinkage in the yarn, the resulting line of tensile stress will deviate from the yarn axis. It is thus important for a textile product which is intended for a composite material application that the constituent yarns are preferably kept as straight as possible, ie preferably without shrinkage.

The conventional methods for forming textile products for the manufacture of integrated 3D textile product systems for composite material applications are weaving, knitting and braiding. These methods inevitably lead to shrinkage in the yarn of the textile product. This is because the yarn is crossed (weaving), placed in loops (knitting) and intertwined (braiding) to achieve an integrated structure of the textile. Apart from these conventional 3D textile forming methods, there are so-called nonwoven, ie non-woven technology in textile production. There are many ways to produce a nonwoven 3D textile product, such as needle punching, warping with liquid jet, thermal bonding, glue bonding, etc.

In addition to these well-known methods, there is a completely different method that can be assumed to have some similarity to the weaving technique. By means of this unique non-woven textile forming process, however, the 3D textile product is produced without any braiding between the yarns used, unlike the weaving process, where crossing by braiding between warp and weft is characteristic of the main process. Furthermore, this non-woven 3D textile forming process differs from the conventional weaving process in that it is mainly intended to process three sets of yarns to form a non-woven 3D textile article as opposed to the weaving process which is mainly intended to process two sets of yarns. namely the warp and the weft. Consequently, these three sets of yarns are composed substantially perpendicular to each other in the manufactured non-woven 3D textile product.

In the absence of any crossing by braiding between the yarns used, the integrated structure of this type of non-woven 3D textile is a result of the unique way of connecting (not tying) the three sets of yarns used. The integrated structure of the nonwoven 3D fabric is achieved, as shown in Fig. 1, by allowing two sets of yarns (X and Y) to extend transversely through the third set of yarns (Z) and between the corresponding opposite outermost yarns. in sets Z of the nonwoven 3D textile. It will be appreciated that such a unique way of allowing the yarns of the two sets X and Y to extend transversely enables a self-bonding of the textile fabric structure. Thus, in such a non-woven 3D textile product, the constituent three sets of yarns are composed substantially perpendicular to each other, i.e. one set of yarns is oriented along the longitudinal direction of the textile, another set of yarns is oriented along the width direction of the textile and the last set of yarns oriented along the thickness direction of the textile product.

Furthermore, due to the absence of breakthrough ect in the yarns used, it is possible to avoid shrinkage of all the constituent yarns in such a woven 3D textile article, 509 944: 10 15 20 25 30 35 509 944 4 as shown in Fig. 1. such a textile product particularly suitable for composite material application. It is thus quite clear that such a process and a textile product is completely different from the weaving process and a woven textile product. To facilitate the understanding of the present invention, which differs from the weaving process, a list of some new equivalent terms used to describe the nonwoven 3D textile forming process, the nonwoven 3D textile forming apparatus and the nonwoven 3D textile is attached. This attached list is for guidance only.

In order for a method to be able to treat brittle continuous fibrous materials, such as ceramics, coal, glass, etc., up to a satisfactory 3D textile product, ie a textile product with a minimum of broken fibers, which is particularly suitable for composite material application, it is very important for the device for the manufacture of the textile product to treat such brittle fibers extremely carefully to avoid unnecessary breakage of the fibers. Damage to the delicate fibers during the textile forming process is mainly a result of the adverse effect of the elements of the textile production device.

For example, with special reference to the weaving device, the damage to brittle fibers can occur due to the frictional effect of the elements which feed the weft (shuttle, sword, etc.) on the warp yarns of brittle fibrous material during work with the weft thread, the silver wire under so-called shedding, or the friction and impact of the loom on the warp and weft yarns of brittle fibrous material during the weaving operation, etc. It is thus obvious that in order to produce a satisfactory textile product consisting of brittle fibrous material, the adverse interaction between the element or elements of the machine the textile product and the brittle fibrous material are kept at a minimum of 509 944 due to the fact that the interaction between the fibrous material and the machine element or elements can not be eliminated as a whole.

In order to meet the requirement for a safe production of brittle fibrous materials or other fibrous materials, fibrous manufacturers naturally offer a suitable finish or protective coating, called adhesive bonding, to enable further treatment without difficulty. However, due to the characteristic of certain processes for the production of textile products, such as weaving and knitting, such a protective coating may not prove to provide sufficient protection, especially in the case of brittle fibrous materials such as ceramics, coal, etc. For example, the conventional weaving process will be too demanding of brittle fibers, such as ceramics and coal, to allow satisfactory production of the textile product. There is, of course, the possibility of braiding such brittle fibrous materials since the features of the braiding process are such that they will cause less damage to the brittle fibers compared to the weaving process. However, a situation may arise for a given final application of the composite material where a woven textile product construction may be preferable to a braided textile product construction or it may be difficult to braid a particular size or shape. From their point of view, it is sufficiently obvious that it will be advantageous to have a device which can safely treat all types of fibers, including brittle fibrous materials, up to a satisfactory textile product which is particularly suitable for use as a composite material.

INVENTION: The main object of the present invention is to provide a safe treatment of all fiber types incl. brittle fibrous material, up to an integrated 3D textile system, which is particularly suitable for composite material application. Thus, other objects of the invention are to preferably eliminate shrinkage of the yarns included in the 3D textile article.

Said object is achieved by means of the device according to the present invention, the characteristics of which appear from the following claim 1. By means of the device according to the invention, all kinds of fibers, incl. brittle fibrous material types, are safely treated to form an integrated nonwoven 3D fabric and further, the device of the present invention ensures that the yarns included in the nonwoven 3D fabric are handled without shrinkage. In this way, such a textile product will be particularly suitable for composite material applications.

BRIEF DESCRIPTION OF THE DRAWINGS: The present invention will now be described in detail with one embodiment with reference to the accompanying drawings.

Fig. 1 shows a perspective view of the integrated non-woven 3D textile product, which can be produced by means of the device according to the present invention. In actual production, all the yarns included in the 3D textile shown will of course be tightly packed to achieve a sufficiently high degree of volume fraction of fiber. Fig. 2 shows a general perspective view of the complete device for producing the non-woven 3D textile product. Figs. 3 and 4 schematically show the transverse sequence of the two sets of twine carriers used in this device and which form an integral part of the actual device shown in Fig. 2. Fig. 5 shows the end view of a tube holder plate sonx former the main part of the device according to the present invention. Fig. 6 shows a cross section through the tube holder plate along the lines VI-VI in Fig. 5. Fig. 7 shows the end view of the tube holder plate together with a twine carrier. 10 15 20 25 30 35 509 944 7 DESCRIPTION OF THE PREFERRED EMBODIMENT: From Fig. 1 it is apparent that this integrated nonwoven 3D textile article consists of three sets of yarns X, Y and Z which are mutually perpendicular to each other. Accordingly, the three sets of yarns used are: (1) the set of reinforcing / main yarns (axial) Z, (2) the set of binding yarns (horizontal) X, and (3) the set of binding yarns (vertical) Y. As shown in FIG. 2 and 6, each yarn end of the set of the axial yarns Z, the feed source of which is located in the spool rack J, can be pulled through a tube G, which is fixed in each of the openings B on the plate P. The binder yarn carriers K position the set of horizontal yarns X and the twine yarn carriers L position the set of vertical yarns Y in the production of the integrated nonwoven 3D textile article shown in Fig. 1.

In order to produce an integrated non-woven textile product with the structure described above, a device according to the embodiment shown in Fig. 2 'is preferably used.

The device consists of a frame A which supports the tube holder plate P and a clamp H for holding the produced textile product F. The clamp H forms part of the receiving system for the textile product and is preferably mounted to facilitate a regular feeding of the produced textile product. The tube holder plate P has a plurality of openings B which are arranged to form rows and columns. Attached to each of these openings is a tube G as shown in Fig. 6. Accordingly, the tube tubes G form rows and columns on the plate P. As already mentioned, each yarn end in the set of axial yarns Z can be pulled out through each of these. tube G, as shown in Fig. 6. However, it is not necessary to occupy all the rows and columns of tubes with yarn ends from set Z. Depending on the number of yarn ends in set Z that can replace a given textile structure, some of the tubes G may be left blank. . All the yarn ends in the set Z which have been pulled out through the tubes G are held together in the clamp H. As can be seen from Fig. 2, the yarns in the set Z converge from the tubes G towards the textile article. Furthermore, the plate P has built-in, horizontal grooves D and C on one side of the tube holder plate P. The grooves D and C run on each side of each row and column of the pipes G. The length of the grooves D and C extends beyond the outermost (upper and lower) ) the rows and (left and right) columns of the pipes G. Thus, each groove in the two sets of grooves D and C runs between two adjacent rows and columns and also along each of the outsides of the outermost rows and columns of the pipes. G as shown in Figs. 2 and 6. In this way, there is a total of one groove more in the horizontal and vertical directions D and C than the total number of rows and columns formed by the tubes G. The grooves D and C which in the example shown are T shaped grooves as shown in Fig. 6, act as guides for the twine carriers K and L. Each twine carrier in the sets K and L has a matching profile to fit with sliding fit in the T-shaped slotted grooves D and C.

The twine carriers are arranged to contain a spool for the twine. An empty spool in a twine carrier can be replaced by a full spool without the corresponding twine carrier having to be removed from the built-in grooves in the plate P. In this way all twine carriers form an integral part of the tube holder plate P. Furthermore, the total number of twine carriers in each one of the sets K and L equal to the corresponding total number of rows and columns formed by the tubes G.

Furthermore, an arrangement for providing an integrated structure of the produced 3D textile product is arranged in the plate P at each end of the horizontal and vertical grooves D and C. Thus, four such arrangements are provided; two for the horizontal groove ends of the grooves D and two for the vertical groove ends of the grooves C. This arrangement involves a single shift of all twine carriers of a given set K or L at the end point of their transverse movement from the tracks in which they have arrived at the corresponding adjacent tracks. By means of such a track arrangement it becomes possible to transversely move the binder yarn carriers in the sets I (and I. in a closed circuit as indicated in Figs. 3 and 4).

Each set of twine carriers K and L is transversely moved alternately over corresponding grooves D or C and preferably at the same time for higher efficiency in textile production. The simultaneous transverse movement of the twine carriers in a given set K or L also depends on the shape of the cross section of the textile product being produced. The drive devices for the twine carriers can consist of rods or bands etc. which are driven from the groove ends at the sides of the tube holder plate P. Although all twine carriers i, a given set I <or .I are transversely moved simultaneously, each of the twine carriers in the given sets K and L in accordance with the sequence schematically indicated in Figs. 3 and 4. The sequence of the transverse movement of the twine carriers is definitive because it is intended to directly implement the integrated structure of the textile article.

To begin the process, a set of twine carriers is moved, for example the horizontal set K, for example from the right end to the left end of the grooves D. It is necessary in this part of the process that the top twine carrier is transversely moved in the groove above the top row of tubes G. As a result, the twine from this top twine carrier will be laid on the outside of the top row of yarns Z. Any other twine in this set X will be laid between the corresponding two adjacent rows of yarns in set Z. 10 15 20 25 30 35 509 944 10 Next, the vertical set of twine carrier L. is transversely displaced. In order to directly achieve the integrated structure of the textile article, it is necessary to start the transverse movement of this set of twine carrier L from the upper end of the groove C and with the the leftmost binding twine carrier transversely in the leftmost bel dedicate the groove C. As a result, the binding yarn from this leftmost binding yarn carrier will be laid out on the outside of the yarn's Z on the leftmost column. Every other binding yarn in this set Y will be laid between the corresponding two adjacent columns of yarns in set Z.

Thereafter, the horizontal set of twine carriers K is moved transversely from the left side to the right side of the groove D. However, this time these twine yarns in set K are not caused to transversely move in the same groove as they arrived. In this transverse return movement, each twine carrier in the set K is caused to move transversely in a groove which is immediately below the corresponding previously traversed groove. This change of twine carrier in the set K to the corresponding adjacent groove D is achieved by means of the groove arrangement located on the current side. As a result, the leftmost yarn in the vertical set Y located on the outside of the leftmost row of yarns in set Z is tied into the set of twine X which is now folded back. In this way, direct bonding is completed on the left side of the produced 3D textile product. In this transverse return movement, the lower binder carrier therefore moves transversely in the lower groove D. As a result, the yarn from this lower binder carrier will be open on the outside of the bottom row of yarns in set Z. Each other 10 15 20 25 30 35 509 944 ll twine in this set X will be laid between the corresponding two adjacent rows of the yarns in set Z.

Thereafter, the vertical set of twine carriers L is transversely moved from the lower end to the upper end of the grooves C. This time, however, these twine carriers in the set L are not transversely moved in the same groove in which they have arrived. In this return transverse movement, each twine carrier in set L is caused to be transversely moved in a groove which is immediately to the right of the corresponding previous groove in which transverse movement has taken place.

This change of twine carrier in the set L to the corresponding adjacent vertical grooves C is achieved by the groove arrangement located on the current side.

In this case, the bottom yarn in the horizontal set of binding yarns Z, which is located on the outside of the bottom row of yarns in set Z, is tied together with the set of binding yarns Y which is now folded back. In this way, complete and direct self-binding of the underside of the produced 3D textile product is achieved. In this return movement, therefore, the rightmost binding twine carrier is moved transversely in the rightmost groove C.

As a result, the yarn from this rightmost binding yarn carrier will be opened on the outside of the rightmost column of the yarns in set Z. Each other binding yarn in set Y will be placed between the corresponding two adjacent columns of yarns in the set. Z.

Upon completion of the described one cycle of operations, the two sets of twine carriers I <and L are back at their original starting positions. The subsequent new cycle of transverse movement of binder yarn starts again from these starting positions just as before and positioning of the fed binder yarn at the blank to 10 15 20 25 30 35 | text ï fl w 509 944 12 the textile product is carried out in the same regular way. In this new cycle of operations, the two sets of twine carriers K and L are alternately moved alternately in exactly the same sequence and in the same groove, in which they have previously been transversely displaced at the beginning of the cycle, since all twine carriers in the two sets K and L are switched to corresponding adjacent grooves. by means of the track arrangement. As a result, the rightmost yarn in the vertical set of binding yarns Y located on the outside of the rightmost column of yarns in set Z is tied together with the set of binding yarns X which is now folded back. In this way, the right side of the produced 3D textile product is completed and directly self-bonded. In the same way, the top yarn in the horizontal set of binding yarns X, which is located on the outside of the top row of yarns in set Z, is tied together with the set of binding yarns Y, which is now folded back. In this way, complete and direct self-binding is achieved on the top of the produced 3D-produced textile product.

In the described sequence of transverse movement of binder yarns, the other operations, such as positioning of the laid binder yarn at the blank for the textile product, are carried out regularly with appropriate steps to facilitate normal production of the textile product. However, in order to prevent damage to the fibrous material, the binding yarns which have been inserted between the rows and the columns are not opened between the yarn ends of the set Z by means of a weaving spoon against the textile product as is the case with a weaving machine. In the present device, a rod is used to jointly position all inserted binder yarns in a given set against the textile article.

Since the outermost rows of the columns of the yarn ends in set Z form four outer sides, a maneuverable rod is placed at each outer side. After a given set of twine carriers has completely left the 10 15 20 25 30 35 “: 'to get 509 §44 13 outermost row or column. of tube 'G and inserted into the groove arrangement, the inserted binder yarns and the outermost row or column of yarn ends in set Z form an angular space on the current side. The rod located at the corresponding outside of the set of yarns Z is operated to be inserted into the formed angular space and move towards the blank for the textile article.

Since the rod moves outside the yarn ends in set Z, no frictional effect occurs between the two. The forwardly moving rod thus positions the newly inserted binding yarns at the blank for the textile fabric. After reaching the position of the textile blank, the rod is held there to hold back the positioned binding yarns, until subsequent binding yarns in the second set have been similarly positioned and held back. The newly positioned binding yarn thus locks the previously inserted binding yarns in the second set at the previous position for the textile blank. The rod that held back the previously inserted binding yarns can now be moved back out of the angular space.

However, it always moves. each rod to the same fixed position at the textile article, which is determined before the process is started depending on the size of the cross-section of the textile article to be produced. As a result, the textile product produced has a uniform cross-sectional size along its entire length.

As will now be seen from the present description of the nonwoven 3D textile forming process, the two sets of twine carriers K and L are alternately moved in a closed circuit as indicated in Figs. 3 and 4. Each twine from the two sets of twine carriers K and L are placed straight between. the corresponding opposite surfaces of the three-dimensional textile article.

Consequently, no shrinkage occurs on any of the three sets of yarns. Since each twine carrier 10 15 20 25 30 35 509 944 * fšï'V n w 1511 - ~ 14 is transversely moved in a closed circuit shape, each of the twine yarns encloses a corresponding row or column of yarn ends in the set Z in the form of a loop. It is obvious that by such a laying of binder yarn in a loop shape and together with the described ordered sequence of transverse movements of the two sets of binder yarn carriers K and L, the integrated structure of the textile product is carried out.

As can further be observed from the description of the method, the yarns in set Z are not subjected to any kind of displacement in the whole cycle of operations, which is the case in the weaving process, where the warp yarns are subjected to peeling to enable the warp and weft yarns to cross. It is obvious that this process of forming a textile product is completely different from the weaving process.

From the features of the non-woven 3D textile forming process described above and from Fig. 2 it can be seen that the yarns in the set Z are kept constantly converging. Thus, the shape of either of the two adjacent passages sonx formed by the rows and columns of the yarn ends in set Z will not be identical. As a result of the non-uniform shapes of the passages, the yarns in set Z will prevent the transverse movement of the binder yarn carriers, which are made of uniform shape and size.

This is because the convergence angle at each yarn end of set Z will tend to be different from that formed by the adjacent yarn end of set Z. Obviously, there is a possibility of causing a constant interference between these yarns of set Z during the transverse movement of the bandage. - the yarn carriers K and L. There is thus a risk that the yarns in set Z are damaged during the transverse movement of the twine yarn carriers K and L. The risk of damaging the yarns in the set 10 15 20 25 30 35 '^ "V". i rt '_. ,, _ m 15 maa-ä -fi Z is further increased when the twine carriers, especially those belonging to the horizontal set K, deflect in the downward direction, depending on the gravity of its fulcrum, which is at one end of the T-shaped groove D.

It is obvious that in order to produce an integrated non-woven 3D textile product successfully and more specifically from a brittle fibrous material, a practical solution to the problems described above is required. More specifically, devices are required for the following: (1) A device for forming a uniform and clear passage between the rows and columns of the yarns in the set Z for unobstructed transverse movement of the twine carriers K and L, (2) a device for ensuring a reliable protection for the yarns in the set Z against the transverse binding yarn carriers K and L and (3) a device for forming support for the downwardly sloping binder yarn carriers, especially in the horizontal set K during transverse movement.

The present invention according to claim 1 overcome in a unique way these and other problems in that the tube holder plate P is included in the present device. According to the present invention, the tube holder plate is characterized by (1) that it comprises tubes G fixed in rows and columns in formation according to Figs. 5 and 6, (2) that it comprises built-in grooves D and C on one side of the plate P according to Figs. 2 and 6, (3) that it comprises two sets of twine carriers K and L, belonging to the grooves D and C, respectively, so that the two sets of twine carriers K and L consist of an integral part of the plate P during their transverse movement according to fig. 2, 6 and 7 and (4) that it comprises a groove arrangement for carrying out the integrated structure of the produced non-woven 3D textile article.

DESCRIPTION OF THE INVENTION: Each of the tubes G extends perpendicularly from the front and back of the plate P as shown in Fig. 6. The length of the extension of each tube G from the front of the plate P is not less than the length of the binder carrier extending out of the grooves D and C, as indicated in Fig. 6. Furthermore, the ends of each of the tubes have smooth edges so as not to cause damage to the yarns passing therethrough. The length of the extension of each tube G from the back of the plate P can be selected according to the requirements which can be further imposed on each tube G for secondary purposes to be described below. It is currently known that each yarn end in the set Z passes through a corresponding tube G from the spool holder J to the fabric of the fabric. Therefore, the secondary purposes are many in number, for which each tube G can be further used. For example, the rear portion of the tube G may be used to inject air under pressure in a direction opposite to the direction in which the yarn end of the set Z is advanced for the purpose of stretching the yarn end in the set Z; alternatively, polymer, glue and other suitable compositions are injected for the purpose of coating the yarn ends in set Z during the textile forming process to produce modified products; alternatively, the yarn end in the set Z can be heated during the textile forming process to improve the process of product modification etc. Returning to the primary utility and function of the tube G according to the present invention, the arrangement of the tubes G in the plate P in the manner described as previously discussed, is overcome in a unique way. Thus, the fixation of the tubes G in the plate P in rows and columns while allowing continuous passage for the yarn ends of the set Z in rows and columns means: (1) that reliable protection of the yarns in the set Z from the transverse binder carriers are provided, (2) uniformly shaped and open passage is obtained in both the horizontal and vertical directions for unobstructed transverse movement of the binder carriers through the yarns in set Z, (3) the downwardly sloping horizontal set of binder carrier K receives support and thereby prevents interference between the twine carriers and the yarns in set Z.

With the arrangement described above, it is obvious that the twine yarn carriers K and L, when moved transversely in the corresponding grooves D and C, can under no circumstances interfere with the yarns in the set Z, since the projecting tubes G contribute to forming a uniformly formed free passage. , as indicated in Fig. 6. Furthermore, the tubes G reliably protect the yarns in the set Z from the transverse twine carriers in the sets K and L. In addition, the tube G especially supports the twine yarn carriers in the horizontal set K so that they do not tilt downwards and thus prevent interference with the yarn ends. in the set Z. The arrangement of the tubes G in the plate P in the manner described thus allows all fiber types, including brittle fiber types, to be safely processed until an integrated non-woven 3D textile product.

Claims (1)

A device for the manufacture of an integrated nonwoven three-dimensional textile article, consisting essentially of three sets of yarns of any type of fiber, including brittle fibers, so as to use the three sets of yarns are included in the produced textile article in a substantially mutually perpendicular orientation by means of the device, comprising a plate (P) with a front surface characterized in that the plate (P) comprises: a) two sets of profiled grooves (D and C ) which are arranged in a mutually perpendicular configuration in the same plane as the front surface of the plate (P), the length of each groove in the two sets of grooves (D and C) extending linearly between their respective pairs of groove arrangements. b) two sets of twine spool carriers (K and L), each set having a matching profile at one end for fitting into the profiled grooves (D and C) so that each of the twine spool carriers can be moved in its groove without possibility to leave the groove, whereby the twine spool carriers are integrated with the plate (P). c) two pairs of said groove arrangements, arranged so that each pair is located at the ends of said groove arrangement and has between them all the other profiled grooves (D and C) and is arranged to allow the twine spool carriers (K and L) is shifted from its just traversed groove to adjacent grooves so that by using a pair of opposite groove arrangements, the twine spool carriers can be caused to traverse the plate j. a closed loop, without leaving the plate (P), around the corresponding row and column of the axial yarns (Z), which are arranged to pass openings in the plate and thus the groove arrangements and d) said openings (B), which extend through the entire thickness of the plate (P) and are arranged in rows and columns, wherein in each opening is provided with a guide tube (G) arranged to allow the axial yarns to pass through the plate (P), and each opening, containing said guide tube (G), which is received by means of a yarn during textile production, is completely surrounded by the profiled grooves in the groove sets.