Bias cut, continuous fabric of ceramic or synthetic fibers

• US 4,299,878 A
• Filed: 12/31/1979
• Issued: 11/10/1981
• Est. Priority Date: 12/31/1979
• Status: Expired due to Term

• Current Assignee: Textile Products, Inc. (Haci Ömer Sabanci Holding AS)
• Original Assignee: Textile Products, Inc. (Haci Ömer Sabanci Holding AS)
• Inventors: Rheaume, Walter A.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US06/108,582
• Time in Patent Office: 680 Days
• Field of Search: 156/148, 156/149, 156/256, 156/555, 156/174, 156/426, 156/393, 139/387 R, 139/DIG. 1, 139/11, 139/13 R, 139/291 C, 428/36, 428/245, 428/257, 428/260, 428/343, 428/408, 428/426, 428/902, 428/910
• US Class Current: 428/40.1
• CPC Class Codes: D06H 7/12 cutting a tubular fabric helically
• CPC Class Codes: Y10S 428/902 High modulus filament or fiber
• CPC Class Codes: Y10S 428/91 Product with molecular orientation
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/1741 Progressive continuous bonding press [e.g., roll couples]
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

An apparatus and process for producing a unique, continuous and endless, bias cut fabric employing ceramic and synthetic fibers is disclosed. The apparatus comprises a take up roll system positioned at the output of a tubular weaving operation.

The roll system takes up the tube evenly and ensures a uniform movement of the tube through the system to maintain a uniform weave oriented at 90° to the fabric length.

This permits the tube, as it leaves the system, to be cut diagonally and to be unwound as a lay flat fabric having a uniform weave pattern oriented at a bias to the fabric length.

Claims

1. A lay flat, continuous length of fabric having a weave oriented at a bias to the direction of the fabric length, the fabric being produced by the steps, comprising:

(a) weaving a fabric selected from the class consisting of ceramic or synthetic fibers into a tubular shape having a square of rectangular weave pattern oriented at 90°

to the fabric length;

(b) immediately and continuously following the weaving step, passing the tubular woven fabric through at least one pair of matched offset take up rolls driven by matched gears, the rolls having a one way grain in the direction of roll travel;

(c) applying a uniform take up pressure to opposite sides of the tubular woven fabric by offset contact with a roll to an opposite side of the tube employing an equal roll force for sufficient surface contact of a respective roll circumference, thereby maintaining the 90°

weave pattern uniform;

(d) cutting the tube diagonally to form a lay flat, continuous fabric having a uniform weave biased along its length; and

,

(e) applying a removable adhesive backing sheet to the lay flat fabric to reduce weave distortion when applied to a substrate.

2. The fabric of claim 1, in which the fibers are selected from the class consisting of:

graphite, glass, quartz, aramid, polyester, nylon, saran and polyolefine.

3. The fabric of claim 1, in which each roll contacts the fabric for about 20%-35% of a roll circumference.

4. The fabric of claim 1, in which each roll is coated with a card clothing screen.

5. The fabric of claim 1 in which the fabric is graphite and the backing sheet is selected from the class consisting of:

paper, cloth, polymer, fiberglass cloth and tape.

6. A process for converting woven, tubular fabric selected from the class consisting of ceramic or synthetic fibers into a continuous, endless length of lay flat fabric having a bias oriented weave, which comprises:

(a) weaving the fibers into a tubular fabric shape having a square or rectangular weave pattern oriented at 90°

to the fabric length;

(b) immediately and continuously following the weaving step, passing the tubular woven fabric through at least one pair of matched offset take up rolls driven by matched gears, the rolls having a one way grain in the direction of roll travel;

(c) applying a uniform take up pressure to opposite sides of the tubular woven fabric by offset contact with a roll to opposite sides of the tube and employing an equal roll force for sufficient surface contact of a respective roll circumference, thereby maintaining the 90°

weave pattern uniform;

(d) cutting the tube diagonally to form a lay flat, continuous fabric having a uniform weave biased along its length; and

,

(e) applying a removable adhesive backing sheet to the lay flat fabric to reduce weave distortion when applied to a substrate.

7. The process of claim 6, in which the take up rolls are covered by a card clothing screen.

8. The process of claim 6, in which each roll contacts a corresponding side of the tubular fabric for about 20%-35% of a roll circumference.

9. An apparatus for a 90°

woven tubular ceramic or synthetic fabric from a tubular woven shape into a lay flat fabric length oriented at a bias to the fabric length, which comprises;

(a) means for forming a tubular fabric selected from the class consisting of ceramic and synthetic fibers having a weave pattern oriented at 90°

to the direction of fabric length;

(b) means for immediately and continuously taking up the woven tubular fabric after leaving the weaving means while maintaining the weave pattern uniform, including;

i. at least one pair of matched offset take up rolls for the tubular fabric, the rolls being driven by matched gears and having a one way grain in the direction of roll travel; and

,

ii. the rolls being adapted to apply a uniform take up pressure to opposite sides of the tubular woven fabric by offset contact with a roll to opposite sides of the tube employing an equal roll force for sufficient surface contact of a respective roll circumference, thereby maintaining the 90°

weave pattern uniform; and

,

(c) cutting means for the tube;

whereby the tube may be cut diagonally to form a lay flat, continuous fabric having a uniform weave biased along its length, the lay flat fabric bearing a removable adhesive backing sheet to reduce weave distortion when applied to a sustrate.

10. The apparatus of claim 9, in which the backing material is selected from the class consisting of:

glass cloth, graphite, aramid, polyester, nylon, saran, quartz and polyolefin.

11. The apparatus of claim 9, in which the rolls are adjustably separated and each roll contacts a corresponding side of the tubular fabric for about 20%-35% of a roll circumference.

12. The apparatus of claim 11, in which the rolls are separated by a distance of about 0.025 to 0.25 inches.