Enhanced thickness fabric and method of making same

• US 20050136758A1
• Filed: 12/19/2003
• Published: 06/23/2005
• Est. Priority Date: 12/19/2003
• Status: Active Grant

• Current Assignee: Saint-Gobain Adfors Canada Ltd.
• Original Assignee: Saint-Gobain Technical Fabrics Europe
• Inventors: Tucker, Mark W., Newton, Mark J.
• Granted Patent: US 7,786,026 B2
• Time in Patent Office: Days
• US Class Current: 442/43
• CPC Class Codes: B29C 70/22 oriented in at least two directions forming a two dimensional structure woven fabrics per se D03D; knitted fabrics per se D04D; braid per se D04C
• CPC Class Codes: B29C 70/56 Tensioning reinforcements before or during shaping
• CPC Class Codes: D03D 15/267 Glass
• CPC Class Codes: D03D 19/00 Gauze or leno-woven fabrics
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 442/102 Woven scrim
• CPC Class Codes: Y10T 442/133 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/148 Including a coating or impregnation containing particulate material other than fiber
• CPC Class Codes: Y10T 442/171 Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/178 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/181 Bitumen coating or impregnation
• CPC Class Codes: Y10T 442/183 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/2861 Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/322 Warp differs from weft
• CPC Class Codes: Y10T 442/3301 Coated, impregnated, or autogenous bonded

Abstract

The present invention provides thickened fabrics and reinforcements for use as a spacer or reinforcement for a matrix system. The fabric includes in a first embodiment a woven fabric comprising weft and warp yarns containing glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin or bonding agent, for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making such fabric by increasing the thickness of a woven or non-woven material by such methods as applying tension during weaving operations, or using unbalanced yarns.

Claims

1. A fabric comprising:

an oriented layer containing polymeric or glass fibers wherein said at least a portion of said fibers are mechanically manipulated to increase the layer'"'"'s thickness by at least about 50%; and

a polymeric coating disposed over at least a portion of said fibers so as to retain said layer'"'"'s increased thickness.

2. The fabric of claim 1 wherein said porous containing layer comprises a woven or non-woven fabric, scrim, mesh, or a combination thereof.

3. The fabric of claim 1 wherein said porous layer comprises an open woven fabric comprising high strength, weft and warp yarns containing glass fibers.

4. The thickened fabric of claim 1 wherein said fibers are mechanically manipulated to increase the layer'"'"'s thickness by at least about 100%.

5. The fabric of claim 1 wherein said polymeric coating comprises a polymeric resin for substantially binding said fibers.

25. A composite comprising a matrix reinforced with the fabric of claim 1.

6. A corrosion-resistant fabric for use as a reinforcement in a matrix, comprising:

an open, woven, scrim-type or knitted fabric comprising high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are mechanically manipulated to increase the fabric'"'"'s thickness by at least about 50%, and a bonding agent for retaining said weft and warp yarns in a relatively fixed position.

7. The fabric of claim 6 wherein said fabric comprises a leno weave.

8. The fabric of claim 7 wherein said weft and warp yarns are spaced apart by at least about 1 mm.

9. The fabric of claim 7 wherein said bonding agent comprises a polymeric resin for substantially binding said yarns.

10. The fabric of claim 7 wherein said warp yarns are subjected to a tensile force which causes said weft yarns to become undulated to a height of at least 1 mm.

11. The fabric of claim 7 wherein said warp yarns have a combined weight which is greater than the combined weight of the weft yarns.

12. The fabric of claim 7 wherein a portion of said warp yarns are heavier than a portion of said weft yarns, said warp yarns are fewer in number than said weft yarns, or both.

13. A matrix reinforcement comprising:

an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, whereby a portion of said weft yarns are undulated, relative to said warp yarns, resulting in an increased thickness for said fabric;

said fabric coated with a polymeric resin for substantially binding said weft yarns in said undulated condition.

14. The reinforcement of claim 13 wherein said polymeric resin comprises styrene butadiene rubber, acrylic, styrene acrylic, or combinations or derivatives thereof.

15. The reinforcement of claim 14 bonded to a matrix comprising an organic or inorganic material.

16. The reinforcement of claim 14 wherein said undulated weft yarns comprise a substantially regular sinusoidal-like pattern.

17. The reinforcement of claim 14 wherein alternative ones of said weft yarns of said fabric have different sinusoidal-like patterns which are not overlapping when observed from the plane of the fabric.

18. A method of making a fabric having increased thickness comprising:

(a) providing a scrim-type, braided, woven or knitted fabric comprising weft and warp yarns containing glass fibers;

(b) applying a tensile force to said warp yarns, whereby a portion of said weft yarns become undulated resulting in an increased thickness for said fabric; and

(c) binding said fabric with a bonding agent whereby said undulated weft yarns become substantially fixed.

19. The method of claim 18 wherein said providing step (a) provides weft and warp yarns containing different weights, different numbers of fiber, or a combination thereof.

20. The method of claim 19 wherein said binding step (c) comprises applying said bonding agent to the cross over points between said weft and warp yarns.

21. The method of claim 19 wherein said applying a tensile force step (b) comprises employing a tenter frame to apply tension to said warp yarns.

22. The method of claim 19 wherein said applying a tensile force step (b) includes providing a sinusoidal shape to at least a portion of said weft yarns.

23. The method of claim 22 wherein said binding step (c) substantially fixes said sinusoidal shape.

24. The method of claim 19 wherein said glass fibers contain E glass, C glass, S glass, or AR glass compositions, or a combination thereof.

26. A composite comprising:

a matrix and reinforcement joined to said matrix, said reinforcement including a woven, braided, knitted or scrim-type fabric, said fabric including high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are undulated to a height of at least 1 mm and fixed by a resinous bonding agent.

27. The composite of claim 26 wherein said matrix comprises an organic or inorganic composition.

28. A building material comprising the composite of claim 26.

29. A polymer matrix composite comprising the composite of claim 26 embedded within a polymer matrix.

30. A soil reinforcement system comprising the composite of claim 26 embedded within a soil matrix.

31. A road reinforcement comprising the composite of claim 26 disposed below a road composition.

32. A cement or gypsum board comprising a cement or gypsum core faced with the composite of claim 26.

33. A cement or gypsum board comprising a cement or gypsum core and the composite of claim 26 embedded therein.

34. A water drainage system comprising the composite of claim 26.

35. A roofing membrane or shingle comprising the composite of claim 26.

36. A textile product comprising the composite of claim 26.

37. A cast for injured bones or joints comprising a resin and the composite of claim 26 embedded therein.