OFF-ANGLE LAID SCRIMS

• US 20130280477A1
• Filed: 03/26/2013
• Published: 10/24/2013
• Est. Priority Date: 03/26/2012
• Status: Abandoned Application

• Current Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Inventors: Davis, Peter C., Spanton, David L., Markle, Lee D., Steggall, Philip
• Application Number:
  US13/850,886
• Publication Number:
  US 20130280477A1
• Time in Patent Office: Days
• US Class Current: 428/109
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/10 Inorganic fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 3/045 for net manufacturing
• CPC Class Codes: Y10T 428/24091 with additional layer[s]

Abstract

A nonwoven laid scrim includes a first carrier, an angled scrim overlying the carrier, and a second carrier overlying the angled scrim. The angled scrim includes at least one assembly of carbon fiber filaments. The nonwoven laid scrim has a main direction and a cross direction. The at least one assembly of carbon fiber filaments is oriented at an off-angle measured relative to the cross direction. The nonwoven laid scrim optionally includes a uni-directional fabric including a plurality of filaments, where the first carrier overlies the uni-directional fabric. At least two assemblies of filaments and a first cross direction yarn of the carrier also can define a multi-sided shape with at least three sides.

Claims

1. A nonwoven laid scrim, comprising:

a first carrier;

an angled scrim overlying the first carrier, the angled scrim comprising at least one assembly of carbon fiber filaments; and

a second carrier overlying the angled scrim, wherein the nonwoven laid scrim has a main direction and a cross direction, and wherein the at least one assembly of carbon fiber filaments is oriented at an off-angle measured relative to the cross direction.

2. The nonwoven laid scrim of claim 1, wherein:

the first carrier comprises a first scrim;

the at least one assembly of carbon fiber filaments is not stitched to the first scrim; and

the second carrier comprises a second scrim, wherein the second scrim is not stitched to the at least one assembly of carbon fiber filaments.

3. The nonwoven laid scrim of claim 1, wherein the at least one assembly of carbon fiber filaments comprises greater than 50 carbon fiber filaments, such as greater than 200 carbon fiber filaments, such as greater than 500 carbon fiber filaments or greater than 1,000 carbon fiber filaments, or such as within a range of 1,000 to 50,000 carbon fiber filaments.

6. The nonwoven laid scrim of claim 1, wherein at least one of the first carrier and the second carrier comprises a coating to provide a bond between the carrier and the angled scrim.

7. The nonwoven laid scrim of claim 6, wherein the coating comprises a thermosetting adhesive binder, a thermoplastic adhesive binder, or any combination thereof.

8. The nonwoven laid scrim of claim 1, wherein at least one of the first carrier and the second carrier comprises a 0/90 scrim, and wherein the 0/90 scrim comprises:

a first set of yarns extending generally parallel to the main direction; and

a second set of yarns extending generally parallel to the cross direction and generally perpendicular to the main direction.

9. The nonwoven laid scrim of claim 1, wherein at least one of the first carrier and the second carrier comprises polyester, aramid, or combinations thereof.

10. The nonwoven laid scrim of claim 1, wherein the off-angle lies within a range of values between 20 and 80 degrees.

11. The nonwoven laid scrim of claim 10, wherein the off-angle further comprises a positive value, a negative value, or combination thereof.

12. The nonwoven laid scrim of claim 1, wherein a majority of the carbon fiber filaments of the at least one assembly of carbon fiber filaments are oriented at the off-angle.

15. The nonwoven laid scrim of claim 1, wherein the at least one assembly of carbon fiber filaments comprises a flattened, substantially untwisted tow.

16. The nonwoven laid scrim of claim 15, wherein the flattened, substantially untwisted tow includes less than 0.5 twists per centimeter, such as less than 0.25 twists per centimeter, or less than 0.1 twists per centimeter.

17. The nonwoven laid scrim of claim 15, wherein the flattened, substantially untwisted tow comprises a cross-section with an aspect ratio, wherein the aspect ratio is defined as a ratio of the width of the at least one assembly of carbon fiber filaments to the height of the at least one assembly of carbon fiber filaments, and wherein the aspect ratio has a value less than 50:

1, such as 10;

1.

18. The nonwoven laid scrim of claim 1, wherein the at least one assembly of carbon fiber filaments comprises:

a first assembly of carbon fiber filaments, wherein the first assembly of carbon fiber filaments comprises a plurality of filaments that are generally parallel to each other and that overlie the first carrier at a positive value of the off-angle; and

a second assembly of carbon fiber filaments, wherein the second assembly of carbon fiber filaments comprises a plurality of filaments that are generally parallel to each other and that overlie the first carrier at a negative value of the off-angle, and wherein the second assembly of carbon fiber filaments cross over the first assembly of carbon fiber filaments at a crossing angle.

19. The nonwoven laid scrim of claim 18, wherein the crossing angle is defined as (180 degrees−

2*(the absolute value of the off-angle)), and wherein the crossing angle lies within a range of values between 0 and 140 degrees.

21. The nonwoven laid scrim of claim 1, further comprising at least one second assembly of carbon fiber filaments overlying the first carrier and oriented in a direction parallel to the main direction.

22. The nonwoven laid scrim of claim 1, wherein at least one of the angled scrim and the nonwoven laid scrim is symmetrical about an axis.

23. The nonwoven laid scrim of claim 22, wherein the axis is parallel to the main direction or the cross direction of the nonwoven laid scrim.

24. The nonwoven laid scrim of claim 1, further comprising a uni-directional fabric comprising a plurality of filaments, wherein the first carrier overlies the uni-directional fabric.

4. (canceled)

5. (canceled)

13. (canceled)

14. (canceled)

20. (canceled)

25. A nonwoven laid scrim, comprising:

a uni-directional fabric comprising a plurality of filaments;

a first carrier overlying the uni-directional fabric;

an angled scrim overlying the first carrier, the angled scrim comprising at least one assembly of carbon fiber filaments; and

a second carrier overlying the angled scrim, wherein the nonwoven laid scrim has a main direction and a cross direction, and wherein the at least one assembly of carbon fiber filaments is oriented at an off-angle measured relative to the cross direction.

26. (canceled)

27. (canceled)

28. (canceled)