Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Patent
1990-07-31
1992-09-22
Bell, James J.
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
66190, 66202, 428114, 428229, 428232, 428293, 428294, 428902, B32B 700
Patent
active
051495830
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to an oriented thread structure to be laminated into a fiber-resin composite and a method for manufacturing the oriented thread structure.
BACKGROUND ART
In accordance with known technology, a glass-fiber composite is manufactured by spreading resin on a glass-fiber mat that has been placed on top of or inside a mold. The glass-fiber can be bound into a glass-fiber mat as discontinuous fibers, or woven into a blanket structure. The problem with these is that air-bubbles tend to remain in the laminate. This phenomenon is especially problematic at corners. One blanket structure is known from the German patent application publication DE 3.304.345. U.S. Pat. No. 3,201,104 shows a circular knitting machine, in which metal wire, intended to reinforce a hose, is bound into knitted fabric. In this, however, the fabric is a fairly loose net. If the fabric is drawn tight, the reinforcing wire or thread will not remain straight, rendering it unsuitable for glass-fiber, for instance, which loses its strength when bent.
DISCLOSURE OF THE INVENTION
An object of the present invention is to create a new type of oriented thread structure which can be easily formed to the surface of a mold, and which avoids the aforementioned air bubbles in a laminate.
Another object of the invention is to use the so-called prepreg or commingled method in which a binder is contained in the support loop threads or fed next to it so that when it is heated it hardens into a knitting of a thin shell structure. Therein it is possible to use polyester thread as one kind of binder. When the support loop threads are of an elastic material, the knitted threads draw together so that the inelastic reinforcing threads project from the fabric. These projections are controlled by leaving openings from which the reinforcing thread is made to project at regular intervals in the knitted fabric. Further advantages of the invention are listed as follows: support loop thread filament and reinforcing thread filament materials; little formation of air bubbles in the laminate by means of a suitable choice of support loop thread filament (e.g. polyester); such a way that they carry most of the load that the laminate is intended to withstand; elastic or flexible in every direction, so that it is easy to laminate and to form it on a mold corresponding to its use; and with the direction of the oriented threads, which makes it possible to use the knitted element as a sheet element of a desired shape and/or size.
It is also intended to create a support loop thread structure that can be used for various protective purposes. In addition, the invention is intended to create a method of manufacturing the thread structure that can be used for any thread at all that is required to be oriented.
The main principle of the invention is the binding of the reinforcing threads to a double-sided knitted fabric, in a transverse direction to the wales. The method makes it possible to achieve a great output in production. A tube-like thread structure is particularly advantageous as, during lamination, it can be drawn directly onto a pipe, pin, or corresponding form. Generally, both support loop thread and reinforcing threads are filament threads, i.e. endless threads.
The method is used to create dense knitting with reinforcing threads. The form of application has the particular advantage that when resin is effectively sucked into the fabric, it is unlikely that air-bubbles will form. Many reinforcing threads do not withstand knots at all. The strength of aramide threads, on the other hand, is retained even after they have been bent to a reasonable extent, in which case the entire thread structure can be knitted with this thread. Similar experiments are also being made with spun glass-thread.
In place of only a single reinforcing thread, it is naturally possible to use several reinforcing threads, i.e. bunches of threads. On the other hand, it is not necessary to feed reinforcing threads to every course of loops. In this connection,
REFERENCES:
patent: 3819461 (1974-06-01), Saffadi
patent: 4948658 (1990-08-01), Halker
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