METHOD FOR PRODUCING UNIDIRECTIONAL HYBRID-BRAIDED FABRICS

Abstract

The present invention discloses a method for producing unidirectional hybrid-braided fabrics, including: preparing a first layer of 0° warps; preparing a second layer of 0° warps to a Nth layer of 0° warps; preparing an auxiliary layer of wefts; preparing binding yarns; laying and hybrid-braiding the materials prepared in steps 1-4 to obtain unidirectional hybrid-braided fabrics; and cutting and winding. The 0° warps and wefts of the invention are made of two or more layers of different fibers that are laid in a single direction and finally hybrid-braided. Therefore, two or more different types of materials can be laid, thereby ensuring the uniform distribution and thickness of the fibers in different areas of the hybrid-braided fabric. The grammage of different 0° warp fiber layers can be adjusted freely in a range of 30-3000 grams/m.sup.2, thereby realizing performance and cost designability of a composite material.

Claims

1. A method for producing unidirectional hybrid-braided fabrics, comprising step 1: preparing a first layer of 0° warp yarns (1); step 2: preparing a second layer of 0° warp yarns (2) to a Nth layer of 0° warp yarns, wherein N is a natural number greater than or equal to 2; step 3: preparing an auxiliary layer of weft yarns (3); step 4: preparing binding yarns (4); step 5: laying and hybrid-braiding the materials prepared in step 1 to step 4 to obtain unidirectional hybrid-braided fabrics; and step 6: cutting and winding.

2. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein in the step 1 and step 2, a method for preparing the first layer of 0° warp yarns (1) and the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns comprises: calculating the required number of fiber warps according to a design requirement of area weight of the unidirectional fabrics as well as specifications of selected fibers, and preparing a unidirectional tackified fiber tape on a fiber spreading tackification device.

3. The method for producing unidirectional hybrid-braided fabrics according to claim 2, wherein in the step 1 and step 2, the prepared unidirectional tackified fiber tape is winded on a warp beam provided with baffle plates on both sides thereof, and the warp beam on which the unidirectional tackified fiber tape is winded is placed on a warp beam creel for unwinding.

4. The method for producing unidirectional hybrid-braided fabrics according to claim 3, wherein in the step 1 and step 2, during unwinding tension is controlled by using a mechanical tension spring friction tape or an electronic constant torque.

5. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein in the step 2, a method for preparing the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns comprises: placing different types of fibers on creels, performing outer-ring unwinding or inner-ring unwinding according to product performance requirements, and calculating the required number of fiber warps according to a design requirement of area weight of the unidirectional fabrics as well as fiber specifications, and wrapping the fibers on a warp let-off roller, wherein the tension is controlled by a rotation speed of the warp let-off roller.

6. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein in the step 3, the auxiliary layer of weft yarns (3) are laid at an angle of 90°, ±M°, or at multiple angles, wherein M>0.

7. The method for producing unidirectional hybrid-braided fabrics according to claim 6, wherein in the step 3, the auxiliary layer of weft yarns (3) is laid by a weft insertion device, and the tension being controlled by using a mechanical tension spring friction tape or an electronic constant torque.

8. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein in the step 4, a method for preparing the binding yarns (4) comprises: placing binding yarn fibers on a creel to prepare a pan-head warp beam by using a warping machine, or controlling the tension of a single binding yarn on a creel by a yarn tensioner.

9. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein in the step 5, laying tension is controlled mechanically or electronically, and the materials are hybrid-braided on a bi-axial warp knitting machine, a multi-axial warp knitting machine, or a stitch-bonding machine.

10. The method for producing unidirectional hybrid-braided fabrics according to claim 1, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

11. The method for producing unidirectional hybrid-braided fabrics according to claim 2, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

12. The method for producing unidirectional hybrid-braided fabrics according to claim 3, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

13. The method for producing unidirectional hybrid-braided fabrics according to claim 4, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

14. The method for producing unidirectional hybrid-braided fabrics according to claim 5, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

15. The method for producing unidirectional hybrid-braided fabrics according to claim 6, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

16. The method for producing unidirectional hybrid-braided fabrics according to claim 7, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

17. The method for producing unidirectional hybrid-braided fabrics according to claim 8, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

18. The method for producing unidirectional hybrid-braided fabrics according to claim 9, wherein the first layer of 0° warp yarns (1), the second layer of 0° warp yarns (2) to the Nth layer of 0° warp yarns, and the auxiliary layer of weft yarns (3) are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber and nylon fiber, the warp yarns and weft yarns being of different materials, and different layers of 0° warp yarns being of different materials.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] To make it easier to clearly understand the content of the present invention, the present invention is described in further detail according to specific embodiments in combination with the accompanying drawing, wherein

[0026] FIG. 1 is a schematic diagram of a braiding method according to the present invention.

[0027] wherein: 1. a first layer of 0° warp yarns; 2. a second layer of 0° warp yarns; 3: an auxiliary layer of weft yarns; 4. binding yarns.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiment 1

[0028] Referring to FIG. 1, the embodiment 1 describes in detail a method for producing unidirectional hybrid-braided fabrics by using two layers of 0° warp yarns, the method comprises the following steps:

[0029] Step 1: Preparation of a First Layer of 0° Warp Yarns 1

[0030] Carbon fibers are used as the first layer of 0° warp yarns 1, with specifications as follows: 12 K, 800 tex, 100 g/m.sup.2, and 125 threads. An unidirectional tackified fiber tape is prepared on a fiber spreading tackification device, and the prepared unidirectional tackified fiber tape is winded on a warp beam provided with baffle plates on both sides thereof, the warp beam, on which the unidirectional tackified fiber tape is winded, is placed on a warp beam creel for unwinding, and during unwinding tension is controlled by using a mechanical tension spring friction tape or an electronic constant torque.

[0031] Step 2: Preparation of a Second Layer of 0° Warp Yarns 2

[0032] Glass fibers are used as the second layer of 0° warp yarns 2 with specifications as follows: 2400 tex, 1196 g/m.sup.2, and 635 threads. A method the same as that in step 1 may be used, or fibers of a type different from that of the fibers used in step 1 are placed on a creel, outer-ring unwinding or inner-ring unwinding is carried out according to product performance requirements, and the required number of fiber warps is also calculated according to the design requirement of area weight of the unidirectional fabrics in combination with fiber specifications, the fibers are wrapped on a warp let-off roller, and the tension is controlled by a rotation speed of the warp let-off roller.

[0033] Step 3: Preparation of an Auxiliary Layer of Weft Yarns 3

[0034] Glass fibers are used as the auxiliary layer of weft yarns 3 with specifications as follows: 136 tex, 40 g/m.sup.2, and 64 threads. The auxiliary layer of weft yarns 3 are laid at an angle of 90° by using a weft insertion device and the tension is controlled by using a mechanical tension spring friction tape or an electronic constant torque.

[0035] Step 4: Preparation of Binding Yarns 4

[0036] Low stretch yarns are used as the binding yarns 4 with specifications as follows: 83/36 F, 8 g/m.sup.2, and 141 threads. Binding yarn fibers are placed on a creel to prepare a pan-head warp beam by using a warping machine, or the tension of a single binding yarn on a creel is controlled by using a yarn tensioner.

[0037] step 5: laying the materials prepared in step 1 to step 4 laying tension is controlled mechanically or electronically, and the materials are hybrid-braided on a bi-axial warp knitting machine, a multi-axial warp knitting machine, or a stitch-bonding machine to obtain unidirectional hybrid-braided fabrics, wherein a hybrid braiding speed is 2 m/min.

[0038] Step 6: Cutting and Winding

[0039] The rear selvage of the fabric is cut, and the fabric is cut into pieces with a specific width, and finally the fabric is winded around a center or by means of friction, the width is 1.27 m.

[0040] The first layer of 0° warp yarns 1, the second layer of 0° warp yarns 2, and the auxiliary layer weft yarns 3 are selected from the group consisting of glass fiber, carbon fiber, basalt fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, polyimide polyamide fiber, polyphenylene sulfide fiber, polyimide fiber, polyester fiber, polypropylene fiber, or nylon fiber, the warp yarns and weft yarns are of different materials, and two layers of 0° warp yarns are of different materials.

[0041] The objectives, technical solutions, and beneficial effects of the present invention are described in further detail in combination with the above specific embodiment. It should be noted that, the above description is merely a specific embodiment of the present invention but is not intended to limit the present invention. Any modification, equivalent replacement, and improvement made without departing from the spirit and principle of the present invention shall fall within the protection scope of the present invention.