U.S. patent number 3,601,970 [Application Number 05/001,008] was granted by the patent office on 1971-08-31 for composite structure of metallic yarns.
This patent grant is currently assigned to Brunswick Corporation. Invention is credited to Joseph R. Quirk, John A. Roberts.
United States Patent |
3,601,970 |
Roberts , et al. |
August 31, 1971 |
COMPOSITE STRUCTURE OF METALLIC YARNS
Abstract
A metal yarn structure wherein the filaments are set under
pressure while in a substantially nonelastic state to be free of
residual torsion while having a preselected helical twist. The
setting of the filaments in the helical configuration is effected
by twisting the filaments in a matrix while concurrently effecting
constriction thereof to fluidize the filaments and permit the
setting thereof upon release of the constriction forces in the
torsion-free helical configuration.
Inventors: |
Roberts; John A. (North
Chelmsford, MA), Quirk; Joseph R. (Woburn, MA) |
Assignee: |
Brunswick Corporation
(N/A)
|
Family
ID: |
27356797 |
Appl.
No.: |
05/001,008 |
Filed: |
January 6, 1970 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
707162 |
Feb 21, 1968 |
3503200 |
|
|
|
464721 |
Jun 17, 1965 |
3378999 |
|
|
|
Current U.S.
Class: |
57/217; 57/213;
57/250; 57/248; 57/901 |
Current CPC
Class: |
D07B
7/027 (20130101); D07B 1/068 (20130101); D02G
3/12 (20130101); Y10S 57/901 (20130101); D07B
2401/2015 (20130101) |
Current International
Class: |
D02G
3/12 (20060101); D07B 1/06 (20060101); D07B
1/00 (20060101); D02g 003/12 () |
Field of
Search: |
;57/139,157,149,145,164,157AS ;161/47,88,175 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Petrakes; John
Parent Case Text
This application is a divisional application of the copending John
A. Roberts et al. application Ser. No. 707,162, filed Feb. 21,
1968, now U.S. Pat. No. 3,503,200, for "Twisted Structures and
Methods of Forming the Same" which was a divisional application of
copending application Ser. No. 464,721, filed June 17, 1965, which
is now U.S. Pat. No. 3,378,999, both applications owned by the
assignee hereof.
Claims
We claim:
1. A composite structure comprising:
a matrix body; and
a plurality of wrought, unannealed metallic elongated elements in
said matrix body, spaced at preselected distances from the
longitudinal axis of said composite structure in a substantially
coaxial helical arrangement, with the diameter of said elongated
elements being inversely proportional to the distance thereof from
said axis, wherein the composite structure is twisted while under
pressure in a substantially nonelastic state and set free of
residual torsion.
2. The composite structure of claim 1 wherein said elongated
elements are formed of stainless steel.
3. The composite structure of claim 1 wherein the total area of
said elongated elements transverse to the longitudinal axis of the
composite structure is substantially constant along said axis.
4. The composite structure of claim 1 wherein said elongated
elements are radially spaced at said preselected distances from the
axis of said composite structure, and defining substantially
cylindrical groups.
5. The composite structure of claim 4 wherein said composite
structure further includes an elongated element located along the
longitudinal axis of said composite structure, having a
substantially rectilinear transverse cross section and a diameter
larger than any one of the helically twisted elongated
elements.
6. The composite structure of claim 1 wherein the number of turns
per inch of the elongated elements in said helical arrangement is
greater than two.
7. The composite structure of claim 1 wherein each of said
elongated elements has an outer surface defining an interface
between the element and said matrix, at least a portion of said
interface defining a diffusion zone.
Description
This invention relates to twisted yarns, e.g. twisted bundles of
filaments, and more particularly to yarns and methods of forming
yarns of very small diameter filaments in twisted form.
There are many known or anticipated uses for high tensile strength,
highly flexible yarns. Such yarns may be formed of synthetic
plastic filaments or metal filaments adapted to be woven into
suitable textile materials such as sheets or strips, or be embedded
or otherwise disposed in other materials such as for reinforcement
thereof, providing antistatic characteristics, etc.
In one known method of forming yarns of filaments, a plurality of
filaments are disposed in parallel spaced relationship with matrix
material extending between the respective filaments. The bundle of
filaments is radially constricted such as by drawing of the bundle
through a drawing die whereby the individual filaments are reduced
in diameter. Alternately, the bundle may be radially constricted by
other constricting methods such as by hot or cold rolling. A
plurality of constricting steps may be employed so as to reduce the
filaments to an ultimate, extremely small diameter.
The final constricted bundle is then suitably treated to remove the
matrix material from the small diameter filaments thereby providing
a yarn comprised of a plurality of fine filaments. To provide
desirable yarn characteristics it is common to provide in such
yarns a twist of a number of turns per inch. One conventional
method of applying such a twist to the filaments is to feed each of
the filaments individually to a twisting apparatus which wraps the
filaments about each other in a generally helical fashion. This
method of providing a twist in the filaments of the yarns has the
serious defect of leaving in the filaments a resultant torsion
tending to untwist the filaments as a result of the natural
resiliency of the filamentary material. Thus the resultant twisted
yarn has a tendency to spring or curl to varying degrees depending
on the amount of twisting and the specific materials of which the
filaments are formed. One attempted solution to this problem has
been to wrap a plurality of the twisted yarns in reverse direction
so that the twist of one yarn offsets the twist of the next yarn
thereby providing a thread wherein the curling tendencies of the
respective yarn are counterbalanced. Such a solution, however, has
not proven completely satisfactory as the residual torsion forces
cannot be fully, accurately balanced.
The present invention comprehends an improved yarn structure and
method of forming the same which eliminates the above discussed
disadvantages of the known twisted yarns in an extremely simple and
novel manner. It is, therefore, a principal feature of the present
invention to provide new and improved twisted structures and
methods of forming the same.
Another feature of the invention is the provision of a twisted
structure having a plurality of filaments set free of residual
torsion in substantially coaxial, spaced helical relationship in a
matrix body.
Still another feature of the invention is the provision of a
twisted structure comprising a plurality of filaments disposed in
generally coaxial, helical configurations wherein the helical
configurations are permanently set in the filaments by delivering
the filaments to a constricting means while in a bundled
arrangement, the constricting means being suitably arranged to
constrict the bundled arrangement sufficiently to cause a
hydrostatic plasticizing of the filaments therein while the bundled
filaments are concurrently twisted to cause the filaments to be
repositioned within the constricting means in coaxial, spaced
helical relationship with each other, and withdrawing the helically
arranged filaments from the constricting means to release the
hydrostatic pressure whereby the filaments set in the helical
configuration free of residual torsion.
A further feature of the invention is the provision of a method of
making a twisted structure comprising the steps of providing a
plurality of parallel, spaced filaments with matrix material
therebetween, effecting a plasticizing of the filaments in the
bundle, providing a twist in the plasticized filaments in the
bundle, and discontinuing the plasticizing of the filaments to
cause the filaments to set in a substantially coaxial, spaced
helical configuration free of residual torsion.
A still further feature of the invention is the provision of a
method of making a twisted yarn from said twisted structure by
means of a further step of removing the matrix material.
Other features and advantages of the invention will be apparent
from the following description taken in connection with the
accompanying drawings wherein:
FIG. 1 is a schematic layout of an exemplary apparatus for carrying
out the method of forming yarn embodying the invention;
FIG. 2 is a perspective view of a rod from which a yarn may be
formed by said method;
FIG. 2a is a cross-sectional view of a rod enclosed in a sheath of
matrix forming material;
FIG. 3 is an enlarged diametric cross section of a die for use in
the method of the invention;
FIG. 4 is a transverse cross section of a bundle of the sheathed
rods of FIG. 2a;
FIG. 5 is a cross section of the bundle of rods of FIG. 4
subsequent to a constriction thereof to form the rods therein into
small diameter filaments;
FIG. 6 is a transverse cross section of the bundle of FIG. 5 having
a twist imparted to the filaments therein by the method of the
invention;
FIG. 7 is a diagrammatic view illustrating the method embodying the
invention for providing the twisted bundle of FIG. 6;
FIG. 8 is a diagrammatic view illustrating another method embodying
the invention for providing the twisted bundles;
FIGS. 9 through 14 are diagrammatic views of additional different
methods embodying the invention for providing the twisted
bundles;
FIG. 15 is a graph comparing the improved results of the invention
with prior results;
FIG. 16 is a graph comparing additional results of the invention
with prior results;
FIG. 17 is a fragmentary isometric view of a bundle of filaments
without the matrix material;
FIG. 18 is a transverse section taken substantially along the line
18--18 of FIG. 17;
FIG. 19 is a transverse section similar to that of FIG. 18, but
wherein the filaments assume a position somewhat different from
that of FIG. 18 but are still considered to be spaced;
FIG. 20 is an elevational view of a short length of yarn twisted
without a matrix material;
FIG. 21 is a cross-sectional view of a bundle of filaments twisted
in a die without matrix material;
FIG. 22 is a chart illustrating the comparison between the
mechanical properties of two bundles of yarn in a matrix subjected
to a twist at different times in the processing of the yarn;
FIG. 23 is a graph illustrating the comparison between the
mechanical properties of two bundles of yarn in matrices subjected
to different reductions in different dies; and
FIG. 24 is a graph illustrating the comparison between mechanical
properties of two bundles of yarn in matrices treated to a
different degree of cold working.
In the exemplary embodiments of the invention as shown and
described in the drawing, similar reference numerals refer to
similar parts throughout the several views, an elongated element or
filament 20 is provided with a sheath or coating of a matrix 22 of
a material different from the material of the elongated element or
filament 20. The elongated element or filament 20 is of a material
capable of becoming somewhat fluid or plasticized under pressure
such as the pressure created in a constricting die.
The matrix material 22 can be initially bonded to the rod or
filament 20 in many ways such as by passing the composite through a
constricting die 24 or by applying the matrix onto the rod 20 in a
fluid state whereby the sheath will become bonded to the filament
or rod 20 upon the solidification of the matrix material 22 around
the rod 20. Sometimes the sheathed rod or filament 20 is passed
through a few successively smaller dies to initially reduce the
diameter of the rod or filament 20.
A plurality of like sheathed rods or filaments 20 are assembled
together in a bundle of filaments 26 which bundle is then sheathed
or embedded in a matrix 28 preferably of the same matrix material
and the matrix bound bundle 26 of filaments 20 is fed consecutively
through successively smaller constricting dies 24 to reduce the
diameter of the bundle 26 and likewise to reduce the diameter of
the individual filaments 20 in the bundle. In some cases, just
before the last draw of the bundle 26 of filaments 20 through the
last constricting die 24, the bundle 26 of filaments 20 is wound
onto a roll 30. The roll 30 is positioned on a spindle 32 carried
by the frame 34 of the drawing machine 36 as shown in FIG. 1. A
payout device 38 is shown as having an arm 40 pivoted at 42 on the
same axis as the drum or roll 30 and includes an eyelet 44 through
which the bundle 26 of filaments 20 is fed. The arm 40 is driven
about the pivot axis in any well-known manner so as to provide a
twist to the bundle 26 and to guide the unwinding of the bundle 26
off the roll 30. The bundle 26 of filaments 20 is then passed
through the constricting or forming die 24, passed around a capstan
46, or other tensioning device and onto the rewinding roll 48.
As the capstan or tensioning device 46 pulls the bundle 26 of
filaments 20 through the die 24, the twist imparted to the
filaments in the bundle 26 is set into the bundle. That is, as the
bundle 26 of filaments 20 and matrix 22 is drawn through the die 24
the die working or constriction on each progressive or successive
increment of the bundle causes the material of the filaments 20 to
become plasticized as the particular increment is compressed under
the relatively high hydrostatic pressures of the die 24. In some
cases, the matrix material will also become fluid or plasticized.
With the increment of the bundle of filaments in a plastic state,
the twist imparted to the filaments by the payout device 38 will be
formed in the individual filaments 20 such that almost
instantaneously after the increment or segment of the bundle leaves
the die, the bundle of filaments takes a permanent set with the
twist set therein. The filaments will be set free of residual
torsion in substantially coaxial, spaced helical relationship. No
further heat treatment is required on the bundle; however,
subsequently processing can be performed on the bundle if the
ultimate use to be made of the bundle 26 of filaments so demands.
The twist can be added to the bundle of filaments in successive
steps a few twists at a time. Each time the constricting die
reduces the diameter of the bundle, produces instantaneous
plasticity and sets the twist imparted thereto by the twisting
device.
The twisted structure comprising the bundle of filaments with the
matrix material is next subjected to either chemicals, heat or the
like to remove the matrix material to produce the bundle of twisted
filaments, or yarn, ready for use. A bundle of twisted filaments of
the type just described is sometimes called a yarn or a hollow
yarn. With the matrix material removed from the bundle of
filaments, there will be an open space between each filament and
its adjacent filaments. FIGS. 17 and 18 illustrate the appearance
and form of a bundle of filaments without the matrix material. The
filaments are referred to as being spaced from their adjoining
filaments. The term "spaced " is intended to include the condition
when the filaments in a bundle assume a position somewhat similar
to the showing of FIG. 19. That is, the filaments without matrix
could not just suspend themselves, as shown in FIG. 18, and will
assume a position at rest wherein the filaments of each ring of
filaments will settle or sag onto the inside of the immediately
contiguous outside ring of filaments. Certain filaments will touch
certain other filaments at points along the length of the yarn, but
essentially the filaments will be spaced apart. Therefore, when the
filaments are referred to as being spaced apart, it is intended
that the incidental touching between filaments at spaced points
through the circumference, diameter and length of the yarn is to be
included within the scope of the term.
There are certain parameters that influence the ultimate properties
of the bundle or yarn 26 which has been twisted while it is passing
through a constricting device, such as a die 24. Specifically, the
die contour is important and, in particular, the percent of
reduction of area of the bundle to be effected in the die, the die
angle, the length of the die-bearing surface and the relief angle
of the die. The effect of the percent reduction of area of the
bundle due to the die will be discussed hereinafter with reference
to FIG. 21. If the die angle is too steep, the bundle will have a
tendency to wedge or block up at the die opening which can cause
rupturing of the bundle. If the die angle is too shallow, the
buildup of pressure will be over too great a distance and the
proper degree of plasticity for inducing the correct permanently
set twist into the bundle or yarn 26 will not be reached. The
relief radius of the die should be standard as established in the
trade. The die lubrication, the area of reduction of the cross
section of the die and surface characteristics of the die and wire
should be carefully controlled to produce the desired
characteristics in the resulting yarn. A controlled back pull on
the bundle of filaments entering the die effects better results in
the yarn produced by the draw.
One embodiment of our invention known as Example I used a
constricting device, in this case a die having a polished tungsten
carbide surface. The contour of the die included a die angle a of
12.degree., a bearing surface b of 4.4 mils which is 35 percent of
the diameter of the bundle being drawn, and a standard relief
radius c.The die was lubricated with Apex 201 sulfated or
chlorinated wire drawing oil. The die was designed to reduce the
area of the bundle 20 percent during the twisting.
A bundle of 271 filaments of 0.5-mil diameter No. 304 stainless
steel cold drawn wire was embedded in a matrix of Monel 400
material. The back pull on the bundle of filaments entering the die
was approximately plus or minus 8 ounces. Applying 7 turns per inch
to the bundle, as the bundle was advanced into the die, each
advancing increment of the bundle of filaments and matrix was
heated due to the die working to above the elastic limit of the
material of the filaments whereupon each increment of the bundle of
filaments became somewhat plastic such that the twist applied to
the bundle permanently realigned the individual filaments 20 in a
new angular orientation with respect to the axis of the bundle. As
each increment or discrete segment of the bundle 26 emerged from
the die 24, it immediately reset itself to the solid state
whereupon the bundle of filaments had a twist permanently set in
the filaments of the bundle. The bundle was then soaked in a
chemical bath or heated in a preselected level to remove the monel
metal matrix, whereupon a hollow bundle of filaments having a
tensile strength of 295,000 pounds per square inch resulted. The
resulting bundle of filaments or yarn is suitable for a wide
variety of uses requiring either strength or flexibility or
combinations of both. The optimum twist for the bundle of Example I
was 9 turns per inch which produced a yarn having a breaking
strength of 18.1 pounds.
FIG. 7 is a diagrammatic or schematic showing of the same process
as is illustrated in FIG. 1, that is, in FIG. 1 a twist is added to
the bundle of filaments as the bundle is unwound from the roll 30.
The twist of FIG. 1 is illustrated in FIG. 7 by a circular arrow 27
indicating a twist in a clockwise direction to the bundle 26 as it
is fed to the die or constricting device 24.
FIG. 8 shows a modified form of the invention wherein the takeup
roll 50 and its mount 52 are rotated in a clockwise direction about
the axis 54 of the mount 52. In this way, the twist is induced into
the bundle of filaments as each increment or discrete segment of
the bundle is in the plastic state in the die or constricting
device 24. The twist is set in the bundle of filaments immediately
upon releasing the hydrostatic pressure on the increment of the
bundle as each increment of the bundle emerges from the die. As the
bundle is continuously advanced and the twist is continuously
applied, a bundle of filaments will be produced with a continuous
spiral or helix permanently set therein.
FIG. 9 shows a modified form of the invention wherein the feed-in
roll 56 and takeup roll 58 are used only to unwind and wind the
bundle thereon respectively. A loop 60 is formed in the bundle on
the downstream or exit side of the die 24. The loop 60 is then
turned about the axis of the bundle as shown by the arrow 62. The
number of turns of the loop 60 about the axis of the bundle will
determine the number of twists induced in the bundle of filaments
which is being drawn through the die 24. The twists or turns will
be set in the bundle in the constricting die as set out in detail
above.
FIG. 10 is similar to FIG. 9 except that the loop 64 is on the
entrance or upstream side of the die 24. There are times when the
nature of the material making up the filaments 20 requires that the
twist be added to the bundle as the bundle enters the die instead
of as the bundle leaves the die. The process is flexible enough to
provide for both. Different and improved results are obtained with
different filament materials depending upon whether the twist is
applied during or after the bundle enters the die as will become
apparent hereinafter.
FIG. 11 shows a modified version of the invention wherein two dies
or constricting devices 24, 25 are spaced apart a short distance
with a loop 64 in the bundle or composite therebetween. As the loop
64 is rotated about the axis of the bundle as the bundle is pulled
through the successive dies, the twist will be added progressively
to the bundle, each die receiving and permitting permanently
induced twist to the bundle as it passes therethrough.
FIGS. 12, 13 and 14 show another set of modifications for inducing
twist into a bundle of filaments. In FIG. 12, a partial loop 66 is
created in the bundle by training the bundle over or through a
shaped path. As the bundle is pulled through the die and around the
shaped path forming the loop 66, the loop 66 is rotated about the
axis of the bundle to add a twist to the bundle as it is pulled
through the die 24.
FIG. 13 is similar to FIG. 10 and shows a method of twisting the
bundle by using the partial loop 66 in place of the complete loop
64 as the bundle is fed into the die, FIG. 14 is similar to FIG. 11
wherein a partial loop 66 is used between successive constricting
dies 24, 25 for inducing twist into the bundle.
It has been found that although when an increment or discrete
segment of the bundle of filaments is worked as it passes through
the constricting die without twisting, the diameters of each
filament in any cross section taken across the width of the bundle
will be substantially the same. That is, in each size reduction of
the whole bundle a proportionate size reduction will take place in
each and every filament such that the diameter of the center
filament will be substantially the same as the diameter of a
filament in the outermost circle of filaments in the bundle.
However, when a bundle such as shown in FIG. 4 is twisted as it
passes continuously through the die 24, the cross section shown in
FIG. 5 results, that is, the diameter of the filament at the center
will be reduced a smaller amount as compared to the reduction in
the diameter of the filament in the outer ring of filaments. There
will be a proportional gradation in the diameters extending from
the largest at the center of the bundle and gradually reducing in
diameter outward from the center until at the outer most ring of
filaments the smallest diameter of filaments will result. The
degree or ratio of reduction will be greater the greater the number
of turns or twists per inch is put into the bundle. It has been
found that the addition of twists to the bundle will elongate the
outermost filaments and reduce in diameter the outermost filaments
the most and will provide just enough elongation that there will
not be any lengthwise creep between concentric layers of filaments.
For example, a one foot long straight bundle of filaments will be
some amount longer than one foot after the bundle is passed through
the die with the twisting added, but the overall axial length of
the bundle will be the same even though the outermost filaments
will now be actually considerably longer due to the helix or spiral
than the length of the centermost filament. The twist can be added
a few degrees or a few turns per inch at a time by successive
passes through constricting dies, each pass adding additional twist
to the bundle. The average area or sums of the cross section of all
filaments is identical no matter whether the bundle is passed
through the die straight or by adding a twist to the bundle as it
passes through the die. This is true even though with a straight
bundle all of the filaments will have substantially identical cross
sections resulting from the straight pass while with a twisted
bundle the center filaments will be larger in cross section and the
filaments will gradually decrease in diameter outward from the
center. The radial distribution of cross section obtained in the
twisting process will produce a bundle of filaments or yarn having
improved flex properties compared with a twisted bundle or yarn
with no radial distribution of area of cross section. Adding the
twist while the bundle is in a state of plasticity in the die
inherently produces a bundle of filaments of extreme uniformity of
twist and extreme uniformity of weight per unit of length.
When tensile strength is an important factor, it has been found
that a much higher tensile strength can be obtained from a bundle
of filaments twisted in a matrix in a constricting device than can
be obtained from the same bundle of filaments twisted after the
matrix has been removed and without a constricting device. In
particular, the tensile strength of the bundle twisted in the
matrix is increased as the number of turns per inch is increased
until a maximum or optimum tensile strength s obtained at a
particular number of turns per inch. This, of course, varies with
the types and diameters of the materials of the filaments.
FIG. 15 illustrates in graphic form a set of comparison values for
the material used in our Example I above, namely a 304 stainless
filament. The horizontal calibration of the chart is in turns per
inch and the vertical calibration is the yarn-breaking load in
pounds. The curve labeled A is the yarn twisted without a matrix
and without a constricting die. It can be observed that the maximum
or optimum values are reached at 2.5 turns per inch and 9.75 pounds
breaking load. Curve B is based on Example I above and is the same
yarn as curve A embedded in a matrix of Monel 400 material and
twisted in a constricting die. The matrix is removed after the
twist is set in the bundle. A maximum breaking strength or load of
18.1 pounds was obtained at an optimum of 9 turns or twists per
inch. The values shown on the chart of FIG. 15 clearly indicate the
improved breaking strength that can be produced by providing the
twist to the bundle just prior to or as the bundle is being worked
in the constricting die together with the improved results based on
the number of turns per inch in the bundle as compared to the prior
system of twisting the bundle of filaments without a constricting
die.
At the optimum twist in a bundle, which will be different for
different sizes and numbers of filaments, the tensile strength of
the bundle will be almost equal to 100 percent of the individual or
single filament strength. This is contrary to the usual results
obtained when a bundle of filaments is reduced in diameter as by
passing through a constricting die. Normally there is a decrease in
the tensile strength greater than the proportionate decrease in the
diameters of each filament. Using our invention it has been found
that at the optimum twist condition for a particular bundle of
filaments the tensile strength of the bundle will be close to the
full tensile strength of the combined individual filament
strengths.
When there is a dependence of the individual filament strength on
the gauge length, the tensile strength of the bundle or yarn at
optimum twist corresponds to the zero gauge length tensile strength
of the individual filaments. In FIG. 16, a comparison is made
between single filament data, as shown by curve C, and a bundle or
yarn data, as shown by curve D, at optimum twist condition. The
vertical scale is the breaking load in pounds while the horizontal
scale is gauge length. It is to be observed that as the gauge
length of curve C increases, the breaking load falls off rather
sharply. In the case of a bundle or yarn at optimum twist, the
breaking load remains constant for any reasonable increases in the
gauge length.
With the bundle of yarn capable of producing maximum tensile
strengths and nearly 100 percent translation of individual filament
strengths, both at optimum twist per unit of length, a superior
bundle of filaments or yarn results which is tougher and stronger
and still has improved flex properties. It is contemplated within
the scope of the invention that a twisted filament yarn may be
formed by passing a bundle of filaments without matrix material
therebetween through the constricting device while twist is added
to the bundle. The resultant yarn has a permanently set twist free
of torsion as in the above described embodiments but has the
filaments set in engagement with each other. FIGS. 20 and 21 show a
side and cross-sectional view of a bundle of filaments with the
twist set therein during the pass of the bundle through the die.
The bundle does not contain any matrix material and has the
filaments set free of torsion by the pass through the die as the
twist is applied.
FIG. 22 illustrates graphically the different results obtained in
yarns that have been twisted in two different ways and either
annealed or not annealed. In the first case, using the teaching of
FIGS. 1 and 7, the twist was applied to the bundle as the bundle
entered the die and is shown in FIG. 22 as curve III. Curve I is
the bundle the same as FIGS. 1 and 7 only the bundle was annealed
prior to twisting as it passed into the die. In the second case,
using the teaching of FIG. 8, the twist was applied downstream of
the die or at the die exit as the bundle passed through the die and
is shown in FIG. 22 as the curve IV. Curve II is a bundle the same
as FIG. 8 only the bundle was annealed prior to passing through the
die and with the twist applied at the exit or downstream of the
die. FIG. 22 results from the following Example II: ##SPC1##
From these values and from the chart of FIG. 22, it can be seen
that for this type of material and matrix the addition of the twist
to the composite or bundle from the downstream side of the die or
on the exit end of the die produces varied results. Without
annealing the addition of the twist to the bundle as it enters the
die produces better results than adding the twist on the exit side
of the die. However, when the bundle is annealed before twisting in
the die, the results are phenomenally better no matter whether the
twist is added on the entrance or on the exit end of the die. The
annealed bundle when twisted from the exit end of the die produces
the strongest torsion-free yarn as is shown by curve I in FIG. 22.
The bundle that was annealed and twisted as it entered the die
produced very strong yarns also as shown by curve II in FIG.
22.
Example III illustrates the effect of the magnitude of reduction of
the area of the bundle in the twisting die on the optimum turns per
inch and breaking load of the bundle. FIG. 23 illustrates the
graphic results of twisting several bundles of filaments having the
following characteristics:
---------------------------------------------------------------------------
Material: 304 Stainless Steel Matrix 400 Monel Metal Total Cold
Work: 62 % No. of Filaments: 271 Filament Diameter: 0.593 mil
__________________________________________________________________________
Curve I is the result of values received from bundles twisted in a
die producing 36 percent reduction in the area of the bundle as the
bundle passed through the die. Curve II is the result of values
received from bundles twisted in a die producing 20 percent
reduction in the area of the bundle as the bundle passed through
the die. It will be noted that the total breaking load in both
cases reaches about the same maximum of about 23 pounds. The
difference is in the fact that the bundles receiving the greater
percent reduction in area during the twisting reached the optimum
breaking load with 5 turns per inch where the bundles receiving the
lesser reduction in area produced their maximum breaking load at 8
turns per inch.
Example IV illustrates the effect of yarn diameter on twisting
characteristics together with the effect of filament diameters on
the ultimate tensile strength. FIG. 24 illustrates the results of
twisting several bundles of filaments having the following
characteristics:
---------------------------------------------------------------------------
Material: 304 Stainless Steel Matrix: 400 Monel Metal Reduction in
die: 20% No. of Filaments: 301
__________________________________________________________________________
Curve I is the result of applying the twist to filaments having a
diameter of 1.005 mil, while curve II is the result of applying the
twist to filaments having a diameter of 0.580 mil. It will be noted
that an optimum ultimate tensile strength of 365,000 pounds per
square inch was reached at around 4.5 turns per inch using the
1.005 mil filament (curve I) while the optimum ultimate tensile
strength of 276,000 pounds per square inch was reached at about 8
turns per inch using the 0.580 mil filament (curve II).
The twisted torsion-free bundle or yarn may have many unique
geometrical configurations which will impart particularly desirable
properties to the yarn for specific applications. With the matrix
material removed, a twisted bundle of filaments or yarn has the
individual filaments in a torsion-free, uniaxial helical
configuration such that the bundle or yarn will have the property
of high elongation. That is, as the yarn is pulled lengthwise the
outer filaments will close in on the inner filaments permitting the
yarn to appear to stretch lengthwise which is desirable for certain
applications for which the yarn can be used.
The twisted yarn can have the individual filaments with high
surface roughness or wherein the surface chemical composition can
be different as a result of interdiffusion of the matrix with the
filament material during the repeated plasticized states caused by
the successive passes through the constricting die. The surface
condition, i.e., roughness or modified chemical composition,
together with the twist to the filaments, can radically influence
the transference or equalization of stress on the filaments of the
bundle and thus produce the high translation of single filament to
yarn strength.
Using the teaching of this invention, it is possible to induce the
torsion-free twist into the material of the filaments in a heavily
cold worked condition. No external heat need be added to the die
area to either create the plastic state of the material of the
filaments or to stress relieve the twisted bundles after the twist
has been induced therein in the die.
The method of producing the hydrostatic pressure on the filament or
bundle of filaments is by means of a constricting device. The
constricting device referred to hereinbefore is generally a
constricting die. However, there are other mechanical constricting
devices which can be used such as roller dies and rolls which can
be used on materials in either a hot or cold condition. It is also
possible to use a high-pressure fluid to maintain die pressure
sufficiently high to create a state of plasticity under the
hydrostatic pressure sufficient to induce and set a torsion-free
twist in a bundle of filaments to produce a torsion-free yarn of
desirable characteristics not heretofore contemplated.
While we have shown and described certain embodiments of our
invention, it is to be understood that it is capable of many
modifications. Changes, therefore, in the construction and
arrangement may be made without departing from the spirit and scope
of the invention as defined in the appended claims.
* * * * *