US20130209725A1 - Reinforced nonwoven fabric - Google Patents
Reinforced nonwoven fabric Download PDFInfo
- Publication number
- US20130209725A1 US20130209725A1 US13/704,104 US201113704104A US2013209725A1 US 20130209725 A1 US20130209725 A1 US 20130209725A1 US 201113704104 A US201113704104 A US 201113704104A US 2013209725 A1 US2013209725 A1 US 2013209725A1
- Authority
- US
- United States
- Prior art keywords
- flat textile
- textile structure
- reinforcing grid
- structure according
- braces
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H11/00—Non-woven pile fabrics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G1/00—Severing continuous filaments or long fibres, e.g. stapling
- D01G1/02—Severing continuous filaments or long fibres, e.g. stapling to form staple fibres not delivered in strand form
- D01G1/04—Severing continuous filaments or long fibres, e.g. stapling to form staple fibres not delivered in strand form by cutting
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G13/00—Mixing, e.g. blending, fibres; Mixing non-fibrous materials with fibres
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G7/00—Breaking or opening fibre bales
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
- D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4274—Rags; Fabric scraps
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
- D04H3/045—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles for net manufacturing
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B32B2262/0276—Polyester fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
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- B32B2605/00—Vehicles
- B32B2605/08—Cars
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23929—Edge feature or configured or discontinuous surface
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/23957—Particular shape or structure of pile
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/23964—U-, V-, or W-shaped or continuous strand, filamentary material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/23993—Composition of pile or adhesive
Definitions
- the present invention relates to a woven material that has been reinforced for improved handling during the manufacturing process, a component incorporating the reinforced nonwoven material, and its use.
- the present invention relates to a carbon fiber nonwoven with a reinforcing grid contained therein.
- DE 92 07 367 U1 Disclosed in DE 92 07 367 U1 is a laminate whose surfaces were formed using spunbonded fabric, and which consists of at least two layers of spunbonded fabric and at least one scrim layer, preferably a scrim layer made out of reinforcing yarns, wherein the scrim layers or scrim layer lie(s) between a respective two spunbonded fabric layers (DE 92 07 367 U1, page 2, 2 nd complete sentence).
- DE 10 2006 060 241 A1 discloses a carrier insert comprised of a flat textile structure and a reinforcement, in which the flat textile structure, which already exhibits the reinforcement, was solidified hydrodynamically. Described in particular are spunbonded fabrics, which are generated by randomly depositing freshly melt-spun filaments, and consist of endless synthetic fibers made up of melt-spinnable polymer materials (DE 10 2006 060 241 A1, paragraph [0036]).
- EP 1 584 737 A1 discloses a strengthened, flat nonwoven, which encompasses at least two layers of endless fiber nonwoven made of polyester and a glass fiber grid secured between the nonwoven layers.
- carbon fibers in terms of manufacturing technique has to do with the composition of the carbon fiber surface.
- carbon fibers in flat textile structures exhibit a very weak adhesion between the fibers, and hence lead to a low cohesion between the flat textile structures.
- This low adhesion or low cohesion finally impacts the manufacturing process for flat textile structures comprised of carbon fibers, thus necessitating a reinforcing grid.
- the reinforcing grid contained in the nonwoven material must be as inconspicuous as possible from outside, and the meshes of the reinforcing grid should not produce any troughs on the surface of the flat textile structure.
- nonwoven layers are responsible for the mechanical stability of the final component that integrates the flat textile structure owing to their percentage of carbon fibers, so that the presence of a reinforcing grid has a detrimental effect on the strength-weight ratio for the component.
- the use of a reinforcing grid influences the draping characteristics of the nonwoven material.
- the draping ability here deteriorates as the strength of the reinforcing grid rises.
- the reinforcing grid must satisfy the purpose for which used, specifically provide adequate reinforcement for the flat textile structure, so as to ensure an improved handling of the latter in the manufacturing process.
- the object of the present invention is to prepare a flat textile structure that exhibits the mentioned desired characteristics, while largely avoiding the mentioned shortcomings.
- the object of the present invention is achieved by an advantageous combination of layer thickness or weight per unit area for the flat textile structure, the proportion of carbon fibers in the weight per unit area, and the proportionate weight per unit area of the reinforcing grid.
- One aspect of the present invention involves a flat textile structure encompassing a reinforcing grid and at least one pile layer flatly situated on at least one surface of the reinforcing grid, characterized in that
- Another aspect of the present invention is an article that encompasses at least two flat textile structures flatly joined together according to the present invention.
- Another aspect of the present invention is a component that encompasses the flat textile structure according to the invention or the article according to the invention impregnated with a polymer matrix.
- Another aspect of the present invention is the use of the component according to the invention for manufacturing parts of an automobile.
- FIG. 1 shows the schematic structural design of a flat textile structure ( 1 ) according to one aspect of the present invention.
- the reinforcing grid ( 3 ) according to the invention as represented by its grid braces ( 30 ), is here secured between two pile layers ( 2 ) according to the invention, as represented by its fibers ( 20 ).
- FIG. 2 shows the schematic structural design of a preferred embodiment of the flat textile structure ( 1 ) according to the invention.
- Two vertically stacked pile layers ( 2 ) here lie on one side of the reinforcing grid ( 3 ), while one pile layer ( 2 ) lies on the other side.
- This embodiment is preferred because the surface of the flat textile structure ( 1 ) exhibits better optical and tactile characteristics on the side with the two vertically stacked pile layers ( 2 ). This becomes advantageous when primarily only one side of the component is visible in the subsequent component that integrates the flat textile structure ( 1 ), for example in the case of vehicle doors.
- FIG. 3 shows the schematic structural design of an embodiment of the flat textile structure ( 1 ) according to the invention.
- Two vertically stacked pile layers ( 2 ) here lie on one side of the reinforcing grid ( 3 ), while the other side of the reinforcing grid ( 3 ) remains clear.
- This embodiment is advantageous in particular when the optical and tactile requirements relate exclusively to one side of the flat textile structure ( 1 ).
- ile layer is known to the expert. It refers to a loose layer of randomly intertwined single fibers that has not been solidified, for example through needling.
- Methods for manufacturing a pile layer ( 2 ) are known to the expert, for example willowing or carding.
- the alignments for the single fibers ( 20 ) in the pile layer ( 2 ) are more or less homogenously distributed.
- the fibers ( 20 ) in the pile layer ( 2 ) exhibit a preferred direction in some methods, for example in the carding method. This means that the alignment of the fibers ( 20 ) in the pile layer ( 2 ) is more often encountered in one specific direction than in other directions. This is because the fibers ( 20 ) are always combed back and forth in the same direction in the carding process.
- the resulting pile layer ( 2 ) frequently exhibits a greater strength longitudinally to the preferred direction of the fibers ( 20 ) than perpendicular thereto.
- the term “preferred direction” of the pile layer ( 2 ) must be understood in the light of the definition provided here.
- a “woven” or “woven material” or a “woven layer” or “woven material layer” refers to a pile layer ( 2 ) that has been solidified, for example through needling.
- Solidification methods can be thermal, mechanical or chemical in nature.
- Thermal solidification typically involves melting open a medium that is already added to the flat textile structure before the pile is manufactured, for example.
- mechanical methods encompass needling and stitching.
- the chemical method typically involves spraying on an adhesive.
- the methods relating to the pile layer ( 2 ) are also applied during the solidification of the flat textile structure ( 1 ) according to the invention. All pile layers ( 2 ) present in the flat textile structure ( 1 ) and the reinforcing grid ( 3 ) are here joined together.
- pile layer ( 2 ) that was further processed into a woven exhibits a preferred direction for the fibers ( 20 ), this can often also be discerned from the surface of the woven material, for example after the pile layer ( 2 ) has been needled.
- the flat textile structure ( 1 ) according to the invention is referred to as “nonwoven plies” in certain contexts.
- the flat textile structure ( 1 ) exhibits a weight per unit area of 80-110 g/m 2 , wherein the carbon fibers in the flat textile structure ( 1 ) have a proportionate weight per unit area of 65 to 84%, and the reinforcing grid ( 3 ) has a proportionate weight per unit area of 3 to 10 g/m 2 .
- This embodiment is especially suited for use in components in the automotive industry to replace thin metal sheets, for example engine hoods, doors, fenders, etc.
- the reinforcing grid ( 3 ) can be located between two consecutive pile layers ( 2 ) inside the flat textile structure ( 1 ).
- the advantage here is that the desired optical and tactile composition can be ensured on both surfaces of the flat textile structure ( 1 ).
- the reinforcing grid ( 3 ) can also be advantageous for the reinforcing grid ( 3 ) to be located on the outside of the flat textile structure ( 1 ).
- Very thin flat textile structures ( 1 ) can here be fabricated, at least one side of which exhibits the desired optical and tactile composition.
- this embodiment is especially suited for use in components according to the invention, which as intended are visible only from one side in the finished product, for example, vehicle doors.
- the pile layers ( 2 ) are comprised predominantly of carbon fibers.
- the portion that does not consist of carbon fibers is referred to as the “foreign fiber portion”.
- the foreign fiber portion can relate both to the entire flat textile structure, as well as only to the pile layer ( 2 ).
- a low foreign fiber portion is basically desired, since the stability of the component according to the invention drops as the foreign fiber portion rises.
- carbon fibers are very cost-intensive.
- foreign fibers can be added to the fibers to be processed in a targeted manner, specifically in such a way that the carbon fibers make up a percentage of the overall weight per unit area of the flat textile structure ( 1 ) according to the subject matter of the present invention, preferably a percentage measuring 65 to 84%.
- the reinforcing grid ( 3 ) preferably consists of threads of endless fibers ( 30 ), which are present as scrims, wovens, knots or knits, wherein scrims are preferred, since they are the easiest to fabricate, and exhibit the smallest layer thickness at the intersecting points by comparison to knits.
- the fibers in the reinforcing grid ( 3 ) can consist of polyester, glass, polyamide, polyethylene, aramide fibers and/or carbon, wherein polyester and glass represent preferred materials for reasons of cost in conjunction with the ratio between strength and fiber thickness.
- the structural constituents of the reinforcing grid ( 3 ) are referred to as “braces” or “grid braces” and “intersecting points” within the framework of this invention, in keeping with the general meaning ascribed to a grid.
- the preferred titers for the braces ( 30 ) in the reinforcing grid ( 3 ) preferably measure 120 to 350 dtex. Also preferred are titers between 150 and 280 dtex, since optimal results are achieved in this range with respect to the strength and scope of the troughs, which are formed by the meshes of the reinforcing grid ( 3 ) on the surface of the flat textile structure ( 1 ) according to the invention, and a sufficient draping ability is ensured.
- the intersecting points of the reinforcing grid ( 3 ) can exhibit a binding agent. If the reinforcing grid ( 3 ) is a scrim layer, it is preferred that a binding agent be used at the intersecting points. No special limitations are placed on the selection of binding agent. However, PVAC-based binding agents are preferred, since they are hot sealable, and make it especially easy and inexpensive to manufacture the reinforcing grid ( 3 ).
- the reinforcing grid ( 3 ) preferably consists of two to three blades of parallel braces ( 30 ). However, more than three blades are also possible.
- the checkerboard structure ( 5 ) is preferred, i.e., the reinforcing grid ( 3 ) exhibits square meshes.
- FIG. 5 provides a schematic view depicting a cutout from this structure. The advantage here has to do with a maximum isotropy for the strength of the flat structure, meaning with a directionally independent strength.
- the distance between the braces ( 5 a ) preferably measures 10 to 50 mm in this embodiment, more preferably 10 to 18 mm, since the troughs described above are less pronounced given smaller meshes.
- FIG. 4 provides a schematic view depicting a cutout from this structure.
- the blades of the diagonal braces ( 4 b ) thus form rhomboid meshes.
- the distance between the longitudinal braces ( 4 a ) preferably measures 5 to 20 mm.
- the distance between the diagonal braces ( 4 b, 4 c ) within a blade preferably measures 7 to 50 mm, since the troughs described above are sparingly pronounced as a result, while a sufficient strength is ensured at the same time.
- a blade of parallel braces ( 30 ) of the reinforcing grid ( 3 ) is preferably aligned longitudinally to the preferred direction of the fibers ( 20 ) in the pile layers ( 2 ), if any, while combining the reinforcing grid ( 3 ) and pile layers ( 2 ). This helps to simplify the manufacturing process.
- a method for manufacturing the flat textile structure ( 1 ) according to the invention in which the reinforcing grid ( 3 ) is situated between two consecutive pile layers ( 2 ) typically encompasses the same steps, preferably within a continuous process:
- a method for manufacturing the flat textile structure ( 1 ) according to the invention in which the reinforcing grid ( 3 ) is secured to the outside of the flat textile structure ( 1 ) typically encompasses the following steps, preferably within a continuous process.
- pile in conjunction with the method described above refers to both a pile layer ( 2 ) and the reinforcing grid ( 3 ).
- nonwoven plies of the flat textile structure ( 1 ) according to the invention, hereinafter referred to as “nonwoven plies”, can be flatly joined together, thereby giving rise to the article according to the invention.
- the preferred directions of the individual nonwoven plies ( 1 ), if any, can be aligned parallel to each other. However, depending on how and where the article is used, it can also be advantageous to flatly join the nonwoven plies ( 1 ) at different angles to each other with respect to their preferred direction.
- One preferred embodiment provides a composite of three nonwoven plies ( 1 ), wherein the preferred direction of the middle and upper nonwoven ply ( 1 ) is aligned at an angle of 45° or ⁇ 45° to the preferred direction of the lower nonwoven ply ( 1 ). This yields an increased isotropy for the strength of the article and components fabricated from the latter.
- connection between the nonwoven plies ( 1 ) according to the invention can be achieved by simply stitching them together, or through renewed needling.
- other types of joining are also possible.
- At least one grid ply can be provided between two or more nonwoven plies ( 1 ) of the article according to the invention.
- the grid ply can be structured based on the reinforcing grid ( 3 ) according to the invention.
- Knits or scrims consisting of polyester threads are here preferred, since they are easy and inexpensive to manufacture.
- the flat textile structure ( 1 ) according to the invention or article according to the invention is impregnated with a polymer matrix, leading to the component according to the invention.
- Suitable materials for the polymer matrix usually include resins, such as polyester resins, epoxy resins and vinyl ester resins, which are used in the manufacture of fiber composite materials.
- Suitable methods for impregnating flat textile structures ( 1 ), for example resin injection or infusion methods, are known to the expert. Subsequent hardening, for example through exposure to an elevated temperature, yields a component in the desired form. As a result, it is most often necessary to drape the flat textile structure ( 1 ) on a rigid mold beforehand.
- the flat textile structure ( 1 ) according to the invention is here distinguished by an optimal draping ability due to its configuration.
- the component according to the invention is used to manufacture automobile parts. No special limitations are here placed on the type and functionality of the components. Non-load bearing parts are here preferred.
- Load-bearing parts in an automobile are highly stressable components.
- they consist of fiber composite materials use is usually made of woven matting or scrims, wherein the fiber bundles in the woven matting or scrims are aligned in such a way as to optimally absorb or divert acting forces, i.e., fiber bundles in the woven matting of scrims are preferably aligned in the direction of applied force.
- the strength is distributed in all directions owing to the structure, wherein the preferred directions generated by combing the pile can again elevate the anisotropy for the strength of the nonwoven material. This is why fiber composite materials fabricated out of nonwovens can be used in highly stressable components of a vehicle.
- the combined use of nonwoven materials and woven matting or scrims is also possible, for example in the form of nonwoven scrim complexes.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Inorganic Chemistry (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
- Woven Fabrics (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
Applications Claiming Priority (21)
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DE102010043349 | 2010-11-03 | ||
DE102010043300.4 | 2010-11-03 | ||
DE102010043346.2 | 2010-11-03 | ||
DE102010043300 | 2010-11-03 | ||
DE102010043347 | 2010-11-03 | ||
DE102010043345.4 | 2010-11-03 | ||
DE102010043349.7 | 2010-11-03 | ||
DE102010043345 | 2010-11-03 | ||
DE102010043346 | 2010-11-03 | ||
DE102010043347.0 | 2010-11-03 | ||
DE102011077881.0 | 2011-06-21 | ||
DE102011077880.2 | 2011-06-21 | ||
DE102011077879 | 2011-06-21 | ||
DE102011077881 | 2011-06-21 | ||
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DE102011078741.0 | 2011-07-06 | ||
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DE102011078739 | 2011-07-06 | ||
PCT/EP2011/069313 WO2012059538A1 (de) | 2010-11-03 | 2011-11-03 | Verstärkter vliesstoff |
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US13/704,121 Abandoned US20130209724A1 (en) | 2010-11-03 | 2011-11-03 | Pile layer with carbon-fiber encompassing bundles |
US13/704,104 Abandoned US20130209725A1 (en) | 2010-11-03 | 2011-11-03 | Reinforced nonwoven fabric |
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US13/704,121 Abandoned US20130209724A1 (en) | 2010-11-03 | 2011-11-03 | Pile layer with carbon-fiber encompassing bundles |
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US (3) | US9551098B2 (zh) |
EP (3) | EP2635733A1 (zh) |
JP (3) | JP5718462B2 (zh) |
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CN (3) | CN103025940B (zh) |
BR (1) | BR112012031770A8 (zh) |
CA (3) | CA2802301C (zh) |
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PT (1) | PT2635417E (zh) |
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2011
- 2011-11-03 WO PCT/EP2011/069313 patent/WO2012059538A1/de active Application Filing
- 2011-11-03 US US13/704,114 patent/US9551098B2/en active Active
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- 2011-11-03 WO PCT/EP2011/069316 patent/WO2012059540A1/de active Application Filing
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- 2011-11-03 KR KR1020127034299A patent/KR101577861B1/ko active IP Right Grant
- 2011-11-03 EP EP11782098.5A patent/EP2635733A1/de not_active Withdrawn
- 2011-11-03 MX MX2012014612A patent/MX2012014612A/es active IP Right Grant
- 2011-11-03 US US13/704,121 patent/US20130209724A1/en not_active Abandoned
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- 2011-11-03 ES ES11782097.7T patent/ES2554928T3/es active Active
- 2011-11-03 CN CN2011800327889A patent/CN103025494A/zh active Pending
- 2011-11-03 KR KR1020127034314A patent/KR101497788B1/ko active IP Right Grant
- 2011-11-03 BR BR112012031770A patent/BR112012031770A8/pt not_active Application Discontinuation
- 2011-11-03 CN CN201180032963.4A patent/CN103025942B/zh not_active Expired - Fee Related
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- 2011-11-03 WO PCT/EP2011/069315 patent/WO2012059539A1/de active Application Filing
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- 2011-11-03 JP JP2013521169A patent/JP5728577B2/ja not_active Expired - Fee Related
- 2011-11-03 US US13/704,104 patent/US20130209725A1/en not_active Abandoned
- 2011-11-03 KR KR1020127034277A patent/KR101494507B1/ko active IP Right Grant
- 2011-11-03 EP EP11782097.7A patent/EP2635417B1/de active Active
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2013
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