U.S. patent application number 16/435715 was filed with the patent office on 2020-12-10 for fabrics woven by spread tow yarns consisting of polymer matrix composite and method for producing the same.
The applicant listed for this patent is COREX MATERIALS CORPORATION. Invention is credited to SHAO-CHEN CHIU, PO-YUEH HSU, TSUNG-YING LIN, YU-CHEN LIN, CHENG-CHIU LIU.
Application Number | 20200385898 16/435715 |
Document ID | / |
Family ID | 1000004166973 |
Filed Date | 2020-12-10 |
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United States Patent
Application |
20200385898 |
Kind Code |
A1 |
CHIU; SHAO-CHEN ; et
al. |
December 10, 2020 |
FABRICS WOVEN BY SPREAD TOW YARNS CONSISTING OF POLYMER MATRIX
COMPOSITE AND METHOD FOR PRODUCING THE SAME
Abstract
A fabric woven by spread tow yarns has multiple spread tow
yarns. Each one of the multiple spread tow yarns is made of matrix
being thermoplastic polymer and having multiple fibers
unidirectionally arranged. The fiber areal weight of each one of
the multiple spread tow yarns is larger than or equal to 70
g/m.sup.2 and is less than or equal to 160 g/m.sup.2; the width of
each one of the multiple spread tow yarns is less than or equal to
100 cm; and the resin content of each one of the multiple spread
tow yarns is larger than or equal to 30% and is less than or equal
to 50%. The widths and the fiber areal weights and the resin
content of the spread tow yarns are low and are capable of
providing a thin fabric woven by the spread tow yarns.
Inventors: |
CHIU; SHAO-CHEN; (TAICHUNG
CITY, TW) ; LIN; YU-CHEN; (TAICHUNG CITY, TW)
; HSU; PO-YUEH; (TAICHUNG CITY, TW) ; LIU;
CHENG-CHIU; (TAICHUNG CITY, TW) ; LIN;
TSUNG-YING; (TAICHUNG CITY, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COREX MATERIALS CORPORATION |
Taichung City |
|
TW |
|
|
Family ID: |
1000004166973 |
Appl. No.: |
16/435715 |
Filed: |
June 10, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 15/0088 20130101;
D06M 15/71 20130101; D02J 1/18 20130101 |
International
Class: |
D03D 15/00 20060101
D03D015/00; D02J 1/18 20060101 D02J001/18 |
Claims
1. A fabric woven by spread tow yarns comprising: multiple spread
tow yarns, each one of the multiple spread tow yarns having a
matrix being thermoplastic polymer; and multiple fibers
unidirectionally arranged within the matrix, wherein the fiber
areal weight of each one of the multiple spread tow yarns is larger
than or equal to 70 g/m.sup.2 and is less than or equal to 160
g/m.sup.2; the width of each one of the multiple spread tow yarns
is thinner than or equal to 100 cm; and the resin content of each
one of the multiple spread tow yarns is larger than or equal to 30%
and is less than or equal to 50%.
2. The fabric woven by spread tow yarns as claimed in claim 1,
wherein the fiber areal weight of each one of the multiple tow
yarns is larger than or equal to 70 g/m.sup.2 and is less than or
equal to 100 g/m.sup.2.
3. The fabric woven by spread tow yarns as claimed in claim 1,
wherein the resin content is larger than or equal to 32% and is
less than or equal to 47%.
4. A method for producing the fabric woven by spread tow yarns as
claimed in claim 1 comprising: a tow expanding step: extending
multiple tows composed of multiple fibers unidirectionally arranged
through preheated spread bars to spread the multiple fibers and to
expand the tows; an impregnation step: impregnating the multiple
tows with thermoplastic resin to form a prepreg sheet; wherein the
viscosity of the thermoplastic resin is larger than or equal to
2000 cPs and is less than or equal to 30000 cPs; a forming step:
heating the prepreg sheet to dry the prepreg sheet and let the
prepreg set; a cutting step: cutting the dry prepreg sheet along
the direction of the multiple fibers of each tow of the prepreg
sheet and turning the prepreg sheet into multiple spread tow yarns;
wherein each one of the multiple spread tow yarns is shaped as a
strip; and a weaving step: weaving the spread tow yarns to form a
fabric and heating the fabric to accomplish the fabric woven by
spread tow yarns.
5. The method for producing the fabric woven by spread tow yarns as
claimed in claim 4, wherein the temperature of each one of the
spread bars is higher than or equal to 80.degree. C. and is less
than or equal to 120.degree. C.
6. The method for producing the fabric woven by spread tow yarns as
claimed in claim 4, wherein an angle defined between the horizon
and each one of the multiple fibers is larger than or equal to
10.degree. and is less than or equal to 70.degree. .
7. The method for producing the fabric woven by spread tow yarns as
claimed in claim 4, wherein multiple dry prepreg sheets with
different fiber directions are laminated and compressed before
being cut into multiple spread tow yarns shaped as strips in the
cutting step.
8. The method for producing the fabric woven by spread tow yarns as
claimed in claim 4, wherein a heating temperature in the weaving
step is higher than the glass transition temperature of the
thermoplastic resin.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a fabric made of polymer
matrix composite, and more particularly to fabrics woven by spread
tow yarns consisting of thermoplastic composite and the method for
production of the fabrics.
2. Description of Related Art
[0002] The conventional spread tow yarns manufactured with prepreg
sheets consisting of thermosetting composite has drawbacks as
follows. Since the thermosetting composite are sticky at room
temperature, the prepreg sheets made of thermosetting composite
requires release papers to prevent the thermosetting composite from
adhering together. The release papers have to be removed before
usage of the prepreg sheets consisting of thermosetting composite.
Producing steps thereafter have to be proceeded under low
temperature condition to avoid the prepreg sheets from setting.
Furthermore, the prepreg sheets consist of thermosetting composite
are not sticky after heating and cannot adhere to each other.
Additional impregnation and additional plastic have been provided
for laminating and compressing. Therefore, the producing process of
the conventional spread tow yarns manufactured of the prepreg
sheets consisting of thermosetting composite is inconvenient.
Moreover, conformance of dimensions of the conventional spread tow
yarns manufactured with the prepreg sheets consisting of
thermoplastic composite is unstable and cannot satisfy demands of
the market.
[0003] To overcome the shortcomings of the fabric woven by
conventional spread tow yarns, the present invention provides a
fabric woven by spread tow yarns to mitigate or obviate the
aforementioned problems.
SUMMARY OF THE INVENTION
[0004] The main objective of the present invention is to provide
fabrics woven by spread tow yarns consisting of polymer matrix
composite and the method for production of the fabrics to lower
fiber areal weight of each spread tow yarns and expand the width of
each spread tow yarn.
[0005] The fabric woven by spread tow yarns comprises multiple
spread tow yarns. Each one of the multiple spread tow yarns is made
of a thermoplastic matrix and having multiple fibers
unidirectionally arranged. The fiber areal weight of each one of
the multiple spread tow yarns is larger than or equal to 70
g/m.sup.2 and is less than or equal to 160 g/m.sup.2; the width of
each one of the multiple spread tow yarns is less than or equal to
100 cm; and the resin content of each one of the multiple spread
tow yarns is larger than or equal to 30% and is less than or equal
to 50%. The widths and the fiber areal weights and the resin
content of the spread tow yarns are low and are capable of
providing a thin fabric woven by the spread tow yarns.
[0006] Other objects, advantages, and novel features of the
invention will become more apparent from the following detailed
description when taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional side view of a prepreg sheet
produced by the method in accordance with the present
invention;
[0008] FIG. 2 is a block diagram of the method in accordance with
the present invention;
[0009] FIG. 3 is schematic diagram showing that a dry prepreg sheet
is cut into yarns and the yarns are wound;
[0010] FIG. 4 is a perspective view of a fabric woven by spread tow
yarns by the method in accordance with the present invention shown
in FIG. 2; and
[0011] FIG. 5 is a perspective view of another fabric woven by
spread tow yarns by the method in accordance with the present
invention shown in FIG. 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] With reference to FIG. 2, a method for producing fabrics
woven by spread tow yarns in accordance with the present invention
has a tow spreading step S1, an impregnation step S2, a forming
step S3, a cutting step S4, and a weaving step S5.
[0013] Each one of multiple tows has multiple fibers 10
unidirectionally arranged. In the tow expanding step S1, the
multiple tows extend through preheated spread bars. The spread bars
provide the multiple fibers 10 with tension to spread the multiple
fibers 10 and expand the width of each tow to a required value. The
temperature of each one of the spread bars is higher than or equal
to 80.degree. C. and is less than or equal to 120.degree. C. An
angle defined between the horizon and each one of the fibers 10 is
larger than or equal to 10.degree. and is less than or equal to
70.degree. . The multiple fibers 10 are spread, and each one of the
tows turns into a flat tow with unidirectional fibers 10.
[0014] In the impregnation step S2: multiple tows that have been
flattened and expanded are impregnated with matrix 20 to form a
prepreg sheet. The matrix 20 is thermoplastic resin. The viscosity
of the matrix 20 that is the thermoplastic resin is larger than or
equal to 2000 cPs and is less than or equal to 30000 cPs to provide
the matrix 20 with sufficient fluidity.
[0015] In the forming step S3: the prepreg sheet is heated to let
the prepreg sheet dry. In the forming step S3, the prepreg sheet
being dry is wound on a bobbin.
[0016] In the cutting step S4: the dry prepreg sheet is cut along
the direction of the fibers 10 into multiple spread tow yarns with
required width. In the cutting step S4, multiple prepreg sheets
with different fiber directions are laminated and compressed in
advance, and then cut into multiple spread tow yarns shaped as
strips.
[0017] With reference to FIG. 3, the prepreg sheet wound on the
bobbin is released for cutting. In the present invention, the width
W of each prepreg sheet 20 reaches 100 cm at most, and the width L
of each one of the spread tow yarns reaches 0.5 cm at least. The
width L of each one of the spread tow yarns is wider than or equal
to 0.5 cm and is thinner than or equal to 100 cm.
[0018] In the weaving step S5: the spread tow yarns are weaved
according to designs to form a fabric. The fabric is heated again
for maintaining the pattern of the fabric. In the weaving step S5,
the fabric is heated to a temperature for maintaining the pattern.
The temperature is higher than the glass transition temperature
(Tg) of the thermoplastic resin.
[0019] With reference to FIG. 1, a cross-sectional side view of the
prepreg sheet produced by the method in accordance with the present
invention is shown via a microscope. The white spots are fibers 10
distributed within the matrix 20. Two layers 30 disposed beside the
matrix 20 are Epoxy 30. The Epoxy 30 is added for convenience of
observation by the microscope. In FIG. 1, the matrix 20
sufficiently permeates the fibers 10.
[0020] With reference to FIG. 4, the spread tow yarns are dyed and
are perpendicularly weaved to turn into a fabric woven by spread
tow yarns made of polymer matrix composite.
[0021] With reference to FIG. 5, the spread tow yarns are weaved to
turn into another fabric woven by spread tow yarns made of polymer
matrix composite.
[0022] The fabric produced by the method in accordance with the
present invention is weaved by the spread tow yarns. Each one of
the spread tow yarns consists of multiple fibers 10 and the matrix
20. The multiple fibers 10 are unidirectionally arranged. Each one
of the multiple fibers 10 may be a carbon fiber, a glass fiber, or
other reinforcements. The matrix 20 is thermoplastic polymer. The
fiber areal weight (FAW) of each one of the spread tow yarns is
larger than or equal to 70 g/m.sup.2 and is less than or equal to
160 g/m.sup.2. The resin content (RC) of each one of the spread tow
yarns is larger than or equal to 30% and is less than or equal to
50% in weight. The width of each one of the multiple spread tow
yarns reaches 100 cm at most.
[0023] Preferably, the fabric produced by the method in accordance
with the present invention has the lowest thickness and the most
stable production yield as the fiber areal weight (FAW) of each one
of the spread tow yarns is larger than or equal to 70 g/m.sup.2 and
is less than or equal to 100 g/m.sup.2. The resin content (RC) of
each one of the spread tow yarns is larger than or equal to 32% and
is less than or equal to 47%.
[0024] The fiber areal weight (FAW) and the resin content (RC) of
each one of the spread tow yarns produced by the method in
accordance with the present invention is low and can lower down the
thickness of each one of the spread tow yarns and expand the width
of each one of the spread tow yarns. The spread tow yarn with low
fiber areal weight (FAW) and resin content (RC) make the fabric
made of polymer matrix composite thinner as well.
[0025] Since the prepreg sheets consisting of thermosetting
composite are sticky at room temperature, the prepreg sheets made
of thermosetting composite require release papers to prevent the
thermosetting composite from adhering to itself Moreover, the
prepreg sheets made of thermosetting composite are difficult to be
machined under lower temperature condition. Compared to the prepreg
sheets consisting of thermosetting composite, the prepreg sheets in
accordance with the present invention consisting of thermoplastic
composite are dry after heating in the forming step S3. Therefore,
the prepreg sheets in accordance with the present invention are not
sticky and are easy to be cut into strips. The cutting step S4 and
the weaving step S5 are capable of being processed at room
temperature to promote the efficiency of production.
[0026] In the tow spreading step S1, each one of the fibers 10
unidirectionally arranged contacts an adjacent one of the fibers 10
and is blocked by said one of the fibers 10. Therefore, the widths
of the multiple tows are equal. The widths and the fiber areal
weights of the spread tow yarns and fabrics produced by the method
in accordance with the present invention are even. The thickness of
each one of the spread tow yarns and the fabric made from said
spread tow yarns are fully tunable.
[0027] In the impregnation step S2, multiple tows being expanded
are impregnated with a thermoplastic polymer to create a
thermoplastic composite. Homogeneous impregnation of the fibers 10
is achieved. After improvements mentioned above, the width of each
one of the prepreg sheets in accordance with the present invention
reaches 100 cm at most and can be cut into more spread tow yarns
shaped as strips. The productions of the spread tow yarns and
fabric woven by the spread tow yarns are promoted. In addition, the
integrality of fibers 10 are promoted in the cutting step S4.
Errors in the cutting step S4 are reduced. Qualities of fabrics
woven by spread tow yarns are promoted.
[0028] The method in accordance with the present invention is
suitable for conventional apparatus for producing spread tow yarns.
Without massively modifying the conventional producing apparatus,
the purposes of reducing the fiber areal weight and the resin
content of each one of the spread tow yarns are achieved.
Consequently, the thickness of the fabric woven by spread tow yarns
is reduced and the width of said fabric is expanded.
[0029] Even though numerous characteristics and advantages of the
present invention have been set forth in the foregoing description,
together with details of the structure and features of the
invention, the disclosure is illustrative only. Changes may be made
in the details, especially in matters of shape, size, and
arrangement of parts within the principles of the invention to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
* * * * *