Multilayered Woven Fabric as well as Corresponding Production Method
20180216262 ยท 2018-08-02
Inventors
Cpc classification
D03D15/283
TEXTILES; PAPER
International classification
D03D15/00
TEXTILES; PAPER
Abstract
The invention relates to a woven fabric of warp and weft threads with a construction in warp thread direction of at least first, second and third warp threads (11, 13, 12) running above one another, wherein: the third warp threads (12) always extend between the first and second warp threads (11, 13), the weft threads (16) are guided through alternating loom sheds (35, 36, 37, 38) between as well as below and above these at least three warp threads (11, 13, 12), and the third warp threads (12) consist of a different material than the first and the second warp threads (11, 13).
Similarly the invention relates to a method for producing a multilayered woven fabric of warp and weft threads by means of a weaving machine.
Claims
1. Woven fabric of warp and weft threads with a construction in warp thread direction of at least first, second and third warp threads (11, 13, 12) running above one another, wherein: the third warp threads (12) always extend between the first and second warp threads (11, 13), the weft threads (16) are guided through alternating loom sheds (35, 36, 37, 38) between as well as below and above these at least three warp threads (11, 13, 12), and the third warp threads (12) consist of a different material than the first and second warp threads (11, 13).
2. Woven fabric according to claim 1, characterized in that the third warp threads (12) contain a high performance material, for example carbon or glass, and preferably consist completely of such a high performance material.
3. Woven fabric according to claim 1, characterized in that the third warp threads (12) are embodied as tapes or rovings.
4. Woven fabric according to claim 1, characterized in that the first and/or the second warp threads (11, 13) contain at least one thermoplastic material and preferably consist completely of at least one thermoplastic material.
5. Woven fabric according to claim 1, characterized in that the first and second warp threads (11, 13) are embodied as tapes.
6. Woven fabric according to claim 1, characterized in that at least some, preferably all, weft threads (16) contain at least one thermoplastic material and preferably consist completely of at least one thermoplastic material.
7. Woven fabric according to claim 1, characterized in that at least one of the warp threads and/or at least some of the weft threads contain at least one thermoplastic material that is selected from one or more members of the following group: olefin homo- or copolymers, for example polyethylene (PE) or polypropylene (PP), polyamide (PA), polyurethane (PU), acrylonitrile butadiene styrene (ABS), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK), polyvinyl chloride (PVC).
8. Woven fabric according to claim 1, characterized in that the first, second and third warp threads (11, 13, 12) as well as preferably also the weft threads (16) comprise such a width and are woven into the woven fabric in such a manner so that the third warp threads (12) are enclosed completely by the first and second warp threads (11, 13) as well as the weft threads (16).
9. Woven fabric according to claim 1, characterized in that the first and second warp threads (11, 13) are at least exactly as wide as the third warp threads (12) and in that the first and the second warp threads (11, 13) completely cover the third warp threads (12) in top plan view and in bottom plan view.
10. Woven fabric according to claim 1, characterized in that in addition to the first, second and third warp threads (11, 13, 12) at least fourth warp threads are present, which are arranged always between the first and second warp threads (11, 13) and always in the same constant position, that is to say either above or below, with respect to the third warp threads (12) in the woven fabric.
11. Method for producing a multilayered woven fabric of warp and weft threads by means of a weaving machine, wherein the method encompasses the following steps: a plurality of warp thread bundles that run next to one another in the weft thread direction and that at least consist of first, second and third warp threads (11, 13, 12) respectively running above one another, are supplied to a shedding arrangement, in its weaving cycles, the shedding arrangement opens alternating sheds between the respective at least three warp threads as well as below and above these, in order to guide weft threads (16) through these sheds, wherein the third warp threads (12) consist of a different material than the first and the second warp threads (11, 13), and wherein the first and second warp threads (11, 13) preferably contain a thermoplastic material, while the third warp threads (12) preferably contain a high performance material, for example carbon or glass.
12. Method according to claim 11, characterized in that as the material for the first and/or the second warp threads (11, 13) and/or the weft threads (16) at least one thermoplastic material is used, which is selected from one or more members of the following group: olefin homo- or copolymers, for example polyethylene (PE) or polypropylene (PP), polyamide (PA), polyurethane (PU), acrylonitrile butadiene styrene (ABS), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK), polyvinyl chloride (PVC).
13. Method according to claim 11, characterized in that in addition to several heddles (1) of the weaving machine arranged next to one another in weft direction (S), behind at least some of the abovementioned heddles (1), heddles (2, 3) arranged in the warp direction (K) behind at least some of the abovementioned heddles (1) are provided, and in that respectively at least one warp thread (11, 12, 13) is guided through each one of the heddles (1, 2, 3) respectively arranged behind one another in such manner, whereby several warp threads (11, 12, 13) are guided above one another in the warp direction (K), whereby the heddles (1, 2, 3) arranged behind one another respectively in a row are alternately repeatedly moved upward and downward and are thereby individually positioned in Z-direction, whereby one after another different loom sheds (35, 36, 37, 38) are realized between warp threads (11, 12, 13) running above one another, through which weft threads (16) are inserted.
14. Method according to claim 13, characterized in that it encompasses the following steps: at least one front heddle (1) arranged closer to the machine outlet in the running direction of the warp threads (11, 12, 13) with at least one, preferably exactly one, heddle eye (21) with smaller height for threading through a first warp thread (11) and deflecting this first warp thread (11) through a repeated upward and downward movement in Z-direction, and with at least one elongated hole (31a) with larger height that extends in Z-direction and that is arranged above or below the said at least one heddle eye (21) for the position-fixed or deflection-free through-guiding of at least one second warp thread (13), is provided, at least one rear heddle (3) arranged behind the front heddle (1) and closer to the machine inlet in the running direction of the warp threads (11, 12, 13) with at least one, preferably exactly one, heddle eye (23) with smaller height for threading through the said second warp thread (13) and deflecting this second warp thread (13) in Z-direction, and with at least one elongated hole (33b) with larger height that extends in Z-direction and that is arranged above or below the said at least one heddle eye (23) for the position-fixed or deflection-free through-guiding of at least the said first warp thread (11), is provided, at least one middle heddle (2) is provided in said rows of heddles (1, 2, 3) between the said front and rear heddle (1, 3) for the guiding in Z-direction of then in total at least three warp threads (11, 12, 13) running above one another, whereby this at least one middle heddle (2) comprises at least one, preferably exactly one, heddle eye (22) for the guiding and deflecting of an associated third warp thread (12) and an elongated hole (32a) above and an elongated hole (32b) below its respective said at least one heddle eye (22) for the deflection-free through-guiding of at least the first and second warp threads (11, 13), whereby the first and the second warp thread (11, 13) in running direction of the warp threads are threaded through the respective at least one heddle eye (21, 23) of the front or respectively rear heddle (1, 3) or of the rear or respectively front heddle (3, 1), and the remaining warp threads (12) lying between the first and second warp thread (11, 13), thus the third warp thread (12) in the case of only one middle heddle (2), are guided in increasing or decreasing sequence through the respective at least one heddle eye (22) of the middle heddle (2), loom sheds (35, 36, 37 38), alternately defined by repeated reciprocal relative movements of the front, the at least one middle and the rear heddle (1, 2, 3) in Z-direction, are formed between the at least three first, second and third warp threads (11, 13, 12) running above one another, for the purpose of the weft insertion.
15. Method according to claim 11, characterized in that the third warp threads (12) are covered completely from above and from below by the first and second warp threads (11, 13) as well as the weft threads (16).
16. Method according to claim 11, characterized in that the mass or volume ratio of third (12) to first and second warp threads (11, 13) is set to be constant over the entire woven fabric surface, wherein this ratio is especially adjustable by the selection of the thickness of the first and second warp threads (11, 13).
17. Method for processing a woven fabric according to claim 1, wherein the woven fabric (18) is applied by draping onto a curved or otherwise configured three-dimensional structure.
18. Method for processing a woven fabric according to claim 1, wherein the first and second warp threads (11, 13) as well as preferably at least some of the weft threads (16) contain at least one thermoplastic material, wherein through heating above the melting point of the at least one thermoplastic material, the woven fabric is transformed into a three-dimensional shaped structural component.
19. Shaped structural component produced by the method according to claim 18.
Description
[0055] In the following the invention will be explained in further detail in connection with drawings. The same reference numbers represent the same or comparable elements. It is shown by:
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
[0063] In
[0064] In the weaving section, three heddles 1, 2, 3 (in the following also abbreviated to heddles 1-3) are illustrated arranged corresponding to the invention behind or after one another in the warp direction K, whereby the front heddle 1 is positioned toward the machine outlet and the rear heddle 3 is positioned toward the machine inlet. For the sake of clarity, the heddles 1-3 are presently represented perspectively; in reality they are oriented perpendicularly to the warp direction K. In this regard, preferably there are several rows of heddles arranged next to one another (not shown), whereby these rows extend into the drawing plane (that is to say in the weft direction S, which is however represented also tilted obliquely in
[0065] For the sake of illustration it is presently sufficient if only one such row of three heddles 1-3 arranged behind one another in warp direction K is illustrated in the
[0066] Each one of the heddles 1-3 comprises respectively one heddle eye 21, 22, 23 (subsequently also abbreviated as heddle eyes 21-23) with a smaller height than respectively two elongated holes 31a, 31b, 32a, 32b, 33a, 33b (subsequently also abbreviated as elongated holes 31a-33b) arranged above and below these heddle eyes, wherein the elongated holes have a longitudinal extension or length that corresponds to a multiple of the height of the individual heddle eyes 21-23. Respectively one warp thread 11, 12, 13 (subsequently also abbreviated as warp threads 11-13) in the form of a tape is threaded through each one of the heddle eyes 21-23. The arrangement of the heddles 1-3 as well as the embodiment of the heddle eyes 21-23 as well as of the elongated holes 31a-33b behind one another necessitates that the warp threads 11-13 extend above or over one another as seen in the top plan view. In this regard, the elongated holes 31a-33b are all embodied equally wide and adapted to the width of the tape-shaped warp threads 11-13, so that these can run flat or planar in the heddle eyes 21-23 without becoming particularly wavy.
[0067] Presently, the first warp thread 11 threaded through the heddle eye 21 of the front heddle 1 is the lowest or bottom warp thread (whereby also the opposite sequence is possible without further difficulty, that is to say the front heddle can also be embodied and arranged so that the warp thread guided by it is the uppermost or top one). Then from the bottom to the top, there follow the third warp thread 12 and the second warp thread 13, whereby the uppermost or top (second) warp thread 13 is threaded through the heddle eye 23 of the rearmost heddle 3. Corresponding to the arrangement of the heddles 1-3 successively following one another in the warp direction K, the warp threads 11-13 run from the bottom to the top. In this regard, the position of the heddle eyes 21-23 is selected in such a manner so that the warp threads 11-13 do not extend in the same horizontal plane (and thereby being in the way of each other), but rather so thatwith an equally large deflection of the heddles 1-3a small vertical spacing distance is present between them.
[0068] The three heddles arranged one after another in warp direction are once again shown in
[0069] As can be seen in
[0070] In
[0071] In
[0072] In
[0073] In the next cycle the warp threads 11-13 are moved downwards preferably in the reversed sequencefirst lowering the heddle 1, then the heddle 2, then the heddle 3. Therefore a reciprocal overtaking of the warp threads 11-13 relative to one another is not possible; their sequence from the top to the bottom always remains the same.
[0074] It is of course also possible to simultaneously lift or lower more than one individual one of the heddles 1-3. For example, in the situation illustrated in
[0075] In
[0076]
[0077] In the top plan view of
[0078] In
[0079] It is also mentioned that, with the three or also more warp threads 11, 12, 13 guided above one another, the upward and downward motion of the heddles 1, 2, 3 can be controlled in such a manner so that the weft thread 16 is not visible in the finished woven fabric 18, neither from the front side nor from the back side, in at least one weft thread row. In this regard, several of such weft thread rows that do not fix the woven fabric can be present, which are separated from one another by conventional weft thread rows that bind the woven fabric. In this regard, in the cross-sectional illustration of
[0080] A second possible weave binding or interlacing principle for a woven fabric 18 according to the invention is illustrated in
[0081] The first, second and third warp threads 11, 13, 12 as well as the weft threads in the embodiments illustrated in the figures are especially preferably embodied as tapes or rovings. In this regard, the third warp threads 12 especially contain a high performance material, for example carbon or glass.
[0082] The first and the second warp threads 11, 13 as well as advantageously also the weft threads 16 in the embodiments illustrated in the figures especially preferably contain at least one thermoplastic material. Preferably they consist completely of at least one thermoplastic material, for example of an olefin homo- or copolymer, for example polyethylene (PE) or polypropylene (PP), of polyamide (PA), polyurethane (PU), acrylonitrile butadiene styrene (ABS), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonates (PC), polyethylene terephthalate (PET), polystyrene (PS), polyetheretherketone (PEEK) and/or polyvinyl chloride (PVC).
[0083] As can be seen in the figures, presently the first, second and third warp threads 11, 13, 12 as well as the weft threads 16 comprise such a tape width so that the third warp threads 12 are completely covered by the first and second warp threads 11, 13 as well as the weft threads 16. In this regard, the first and second warp threads 11, 13 as well as the weft threads 16 are at least exactly as wide as the third warp threads 12 and completely cover these in the top plan view and in the bottom plan view.
[0084] Thus, according to the above disclosure, a woven fabric can be realized, in which thermoplastic tapes in the form of first and second warp threads (or also further warp threads, then further warp threads running in the interior of the woven fabric) cover, from above and below, at least third warp threads in the form of tapes or rovings with a high performance material (preferably a composite material with carbon or glass in a synthetic plastic matrix, e.g. a carbon tape). Preferably by means of the above described method, the individual layers of the tapes forming the first, second and third warp threads are actuated via the heddles and form the respective loom shed (also generally named opening above), into which the weft thread that similarly preferably consists of thermoplastic material is inserted. By the selected binding or interlacing, the composite tape consisting of the third warp threads or the roving (namely the carbon or carbon fibers) can be bound into the thermoplastic woven fabric with more or less flotation. Through the selection of the thickness of the thermoplastic tape (first and second warp threads, weft threads), an exact fiber-matrix ratio can be selected. The resulting non-consolidated textile construction or textile fabric is flexible, whereby the composite components are fixed in their position or orientation by the binding or interlacing of the woven fabric. The woven fabric is drapable as far as the binding or interlacing allows. Through application of pressure with simultaneous heating above the melting point of the selected thermoplastic matrix system, the woven fabric is fixed in the desired form or shape. In this regard, the thermoplastic components melt and the molten material permeates, saturates or impregnates the composite fibers, that is to say for example carbon or glass fibers. Thereby there arises a homogeneous composite structural component, which, after drying and cooling, can be used for construction.
[0085] The invention was explained in detail in connection with example embodiments. Combinations, as far as they are technically possible, are similarly encompassed by the invention, just like derivations or modifications within the claims. Also, generally, no limitations are made with respect to the number of the heddles arranged behind one another in the warp direction and the arrangement of the rows arranged in the weft direction, whereby the rows consist of heddles arranged at least partially behind one another. In this regard, also warp threads that do not form the uppermost and lowermost warp threads (the first and second warp threads) of a warp thread stack may contain a thermoplastic material or also a different material as a high performance material.
REFERENCE NUMBER LIST
[0086] 1 front heddle
[0087] 2 middle heddle
[0088] 3 rear heddle
[0089] 11 first warp thread
[0090] 12 third warp thread
[0091] 13 second warp thread
[0092] 15 warp thread stack
[0093] 16 weft thread
[0094] 18 woven fabric
[0095] 21 heddle eye
[0096] 22 heddle eye
[0097] 23 heddle eye
[0098] 31a elongated hole
[0099] 31b elongated hole
[0100] 32a elongated hole
[0101] 32b elongated hole
[0102] 33a elongated hole
[0103] 33b elongated hole
[0104] 35 loom shed
[0105] 36 loom shed
[0106] 37 loom shed
[0107] 38 loom shed
[0108] 40 creel
[0109] 41 bobbins
[0110] 44 weaving reed
[0111] 45 take-up roll
[0112] K warp direction
[0113] S weft direction
[0114] SE weft insertion plane