Woven fabric and process for reinforced structural composites
First Claim
1. A high-strength structural composite of the type which includes a fabric impregnated with a polymeric setting material wherein said fabric comprises:
- a multi-layer fabric having uniform directional flexibility, said fabric having a first outer face, and a second outer face spaced from said first outer face, and a plurality of fabric layers between said first and second outer faces;
a plurality of warp yarns extending in a first direction in said fabric;
a plurality of weft yarns extending in a second direction in said fabric transverse to said first direction;
said plurality of warp yarns being woven in said first direction in undulations which run between said first and second outer faces;
said plurality of weft yarns being woven in said second direction in undulations which run between said first and second outer faces of said fabric;
said plurality of warp yarns and said second plurality of weft yarns being interwoven together in a prescribed pattern and mesh which provides uniform flexibility in both said first and second directions; and
said polymeric setting material occupying said mesh of said fabric to set said fabric in a shape of a desired structure with said runs of said warp and weft yarns extending between said outer faces facilitating effective impregnation of said fabric with said setting material.
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Accused Products
Abstract
A structure multi-layer fabric (A) is disclosed having a prescribed weave pattern and mesh which provides uniform flexibility and which can be used as structural fabric or impregnated with a resin in a structural composite. The flexibility of the fabric facilitates conforming of the fabric to a desired shape. The rising and sinking warp yarns in the warp and weft directions facilitate effective impregnation by defining trough-like structures in the fabric, as well as enhancing the fabric flexibility. The fabric is characterized as having (N) layers, 2N basic warp yarns woven in a 2N yarn repeat, and 2N-2) basic weft yarns woven in a (2N-2) yarn repeat. In the illustrated embodiment, there are 10 basic weft yarn picks (60,62,64,66,68,70,72,74,76,78) and twelve basic warp yarns (34,36,38,40,42,44,46,48,50,52,54,56) woven in 6 layers (D,E,F,G,H,I). Warp yarns (B) and weft yarns (C) rise and sink in the fabric between outer face (30) and outer face (32). A first plurality of weft spaces (80) are defined in the fabric by rising pairs and sinking pairs of warp yarns (B). A first plurality of warp spaces (86) are defined in the fabric by rising pairs and sinking pairs of weft yarns (C). Two warp yarns (B) are disposed in the first plurality of weft spaces (80), and two weft yarns (C) are disposed in the first plurality of warp spaces (86). A single weft yarn (C) is disposed in the second plurality of warp spaces (88,90).
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Citations
46 Claims
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1. A high-strength structural composite of the type which includes a fabric impregnated with a polymeric setting material wherein said fabric comprises:
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a multi-layer fabric having uniform directional flexibility, said fabric having a first outer face, and a second outer face spaced from said first outer face, and a plurality of fabric layers between said first and second outer faces; a plurality of warp yarns extending in a first direction in said fabric; a plurality of weft yarns extending in a second direction in said fabric transverse to said first direction; said plurality of warp yarns being woven in said first direction in undulations which run between said first and second outer faces; said plurality of weft yarns being woven in said second direction in undulations which run between said first and second outer faces of said fabric; said plurality of warp yarns and said second plurality of weft yarns being interwoven together in a prescribed pattern and mesh which provides uniform flexibility in both said first and second directions; and said polymeric setting material occupying said mesh of said fabric to set said fabric in a shape of a desired structure with said runs of said warp and weft yarns extending between said outer faces facilitating effective impregnation of said fabric with said setting material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A multi-layer structural fabric having uniform directional flexibility, a first outer face, and a second outer face spaced from said first outer face, and a plurality of fabric layers between said first and second outer faces wherein said fabric comprises:
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N layers, where N is the number of layers; 2N basic warp yarns woven in a 2N yarn repeat; (2N-2) basic weft yarns woven in a (2N-2) yarn repeat; and 2N×
2N total warp and weft yarns in a complete pattern. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A woven multi-layer structural fabric comprising:
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a first outer face and a second outer face spaced from said first outer face; a plurality of yarn layers arranged between said first and second outer faces; said layers including warp yarns and weft yarns woven generally transverse to one another; said warp yarns rising and sinking in a warp yarn repeat pattern between said first and second outer faces; said weft yarns rising and sinking in a weft yarn repeat pattern between said first and second outer faces; at least two picks of said weft yarn being inserted in a space between pairs of rising and pairs of sinking warp yarns; and at least two of said warp yarns disposed in a space between pairs of rising and pairs of sinking weft yarns. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A process for weaving a structural multi-layer fabric having generally uniform flexibility in the warp and weft directions and sufficient thickness to form three-dimensional structures and the like, said thickness being defined by a first outer face, a second outer face, and a plurality of fabric layers between said first and second outer faces, said process comprising:
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weaving a plurality of warp yarns in a longitudinal direction; weaving a plurality of picks of a weft yarn in a weft direction in said fabric transverse to said warp direction; weaving said warp yarns in undulations rising and sinking between said first and outer faces; weaving said weft yarn picks in said weft direction in undulations rising and sinking between said first and second outer faces; weaving said warp yarns in pairs of rising and pairs of sinking paris of warp yarns between said first and second outer faces; weaving said weft yarns in rising and sinking pairs between said first and second outer faces; inserting at least a pair of said weft yarns between pairs of rising and pairs of sinking warp yarns; and arranging at least a pair of said warp yarns between pairs of rising and pairs of sinking weft yarns. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41)
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42. A process of constructing a reinforced composite structure having increased structural integrity comprising:
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utilizing a multi-layer woven fabric having a pair of outer faces between which multiple layers are woven, said multiple layers including warp yarns woven in a first direction which rise and sink between said outer faces, said warp yarns being interwoven with weft yarns woven in a second direction transverse to said first direction which rise and sink between said first and second outer faces so that uniform flexibility is provided is said first and second directions; conforming said multi-layer flexible fabric to the shape of said structure; and impregnating said fabric with a shape-setting material which sets said fabric in said desired structural shape. - View Dependent Claims (43, 44, 45, 46)
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Specification