Textiles: weaving – Fabrics – Drier felts
Patent
1995-06-16
1998-03-31
Falik, Andy
Textiles: weaving
Fabrics
Drier felts
139420C, 139420A, 428225, 26 99, 100210, 28132, 28140, D03D 1500, D03D 300, D06C 1502
Patent
active
057327483
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
This invention relates to the field of textile structures intended for the production of composite materials. It more particularly relates to a warp and weft fabric produced, for greater part, from multifilament technical threads with a relatively high yarn count for a relatively low weight per unit area and to a corresponding method for producing the same.
It is known that composite materials have undergone a major expansion, because they combine excellent mechanical properties with low weight. Such materials essentially comprise a textile reinforcement and a resin matrix. Those skilled in the art know that the production of these materials presents some difficulties. In fact, for some uses, in particular in the aeronautical industry, the mechanical properties of the composite materials are strictly defined.
It is often required that the textile structures used in composite materials are sufficiently tightly woven so as to retain a regular geometry and an appropriate handling capacity, while at the same time allowing sufficient penetration of the resin during manufacture of the composite. This enables satisfactory mechanical properties to be obtained in the final composite. It is thus necessary to use sufficiently fine fibers to make such tightly woven structures.
As a function of the desired weight per unit area for the structure, a thread giving perfect covering is chosen, in other words a regular spread which does not leave visible porosities and which, correspondingly, leads to a high volume ratio. It is observed that the lower the weight per unit area of the textile structure, the more the yarn count of the fibers, in other words the linear mass of each fiber, must also be low.
However, fine threads are relatively expensive and this is particularly true for the carbon threads currently available on the market. For example, the price of 1K (1000 filaments) carbon threads is about four times that of 3K threads and six to eight times that of 6K threads. It should be understood that the higher the number of filaments in the threads, the higher the yarn count of the threads.
It is thus advantageous to use coarser threads whose price decreases as the coarseness thereof increases. For example, 6K (6000 filaments) carbon threads, which are twice as coarse as 3K threads, are approximately 30% less expensive. It is the same for 12K threads which are now available on the market and whose price is 30% lower than that of 6K threads.
In order to retain and increase their market share, composite materials must be available at prices lower than those currently in force. In particular in the aeronautical field, it is desirable that the price of a composite component should correspond to that of an aluminum component, which necessitates substantial cost reductions. Since the price of fibers and particularly carbon fibers has a direct effect on the cost of composite components, the choice of the type of fibers is critical.
It is in particular 6K and 12K threads which would enable the costs to be reduced. A fabric from 6K threads is about 30% cheaper than a fabric from 3K threads, for the same weight per unit area. A fabric produced from 12K threads is about 50% cheaper than a fabric of the same weight per unit area produced from 3K threads.
However, if fine threads are replaced by threads of a higher yarn count, while keeping the same weight per unit area, for example replacing four 3K threads with one 12K thread, holes generated in the resulting fabric are proportionately larger than for lower weights per unit area.
Coarser threads are thus unsuited for use in textile structures whose weight per unit area or unit area weight is relatively low, when conventional weaving methods are used. Effectively the structures obtained are too open, and in addition they cannot be easily handled as they leave the weaving loom.
The use of coarser threads is therefore currently limited to fabrics with relatively high weights per unit area. An analysis of the balanced carbon fabrics available on the market,
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Aucagne Jean
Bompard Bruno
Bruyere Alain
Debaille Christian
Germain Bertrand
Brochier S.A.
Falik Andy
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