Manufacture of a undirectional composite fabric

Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor

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156166, 156180, 156181, 156296, B32B 3120, D02J 1100

Patent

active

058912843

ABSTRACT:
A method and apparatus are provided for forming a fabric, suitable for mailing a finished composite product, using one or more composite strands. One embodiment of the apparatus comprises at least one bushing for forming reinforcing fibers; supply equipment for supplying matrix fibers; at least one applicator for applying bonding size (i.e., bonding chemical treatment) to the fibers; a gathering mechanism for gathering the treated fibers into at least one composite strand; a pulling mechanism for pulling the at least one composite strand; and a fabric forming mechanism for forming a fabric using the at least one composite strand. One embodiment of the method comprises the steps of drawing a plurality of reinforcing fibers; supplying a plurality of preformed matrix fibers; applying bonding size directly to the reinforcing fibers and the matrix fibers from one or more applicators at least before the reinforcing fibers are gathered together into a strand; gathering the fibers together into at least one composite strand; and forming the at least one composite strand into a unidirectional fabric. The resulting unidirectional fabric comprises a plurality of stitching threads and a continuous glass/polymer composite strand in the form of a plurality of transverse loops. The composite strand can comprise a plurality of first reinforcing fibers drawn from a bushing of molten glass, a plurality of preformed matrix fibers made from a polymer matrix material, and bonding size which bonds together the fibers of the composite strand.

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