Systems and methods for reduced crimp carbon fiber helical fabric

• US 10,648,106 B2
• Filed: 03/05/2012
• Issued: 05/12/2020
• Est. Priority Date: 03/05/2012
• Status: Active Grant

• Current Assignee: Goodrich Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Goodrich Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Lecostaouec, Jean-Francois, Perea, Paul
• Primary Examiner(s): Piziali, Andrew T
• Application Number:
  US13/412,321
• Publication Number:
  US 20130231024A1
• Time in Patent Office: 2,990 Days
• Field of Search: 442203, 442208, 442209, 442210, 442211
• CPC Class Codes: D03D 15/43 with differing diameters
• CPC Class Codes: D03D 15/68 Scaffolding threads, i.e. threads removed after weaving
• CPC Class Codes: D03D 3/08 Arched, corrugated, or like fabrics
• CPC Class Codes: D03D 49/20 Take-up motions; Cloth beams
• CPC Class Codes: D10B 2101/12 Carbon; Pitch
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2201/04 Linen
• CPC Class Codes: D10B 2201/20 Cellulose-derived artificial fibres
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2211/04 Silk
• CPC Class Codes: D10B 2321/022 polypropylene
• CPC Class Codes: D10B 2321/10 polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/063 high strength
• CPC Class Codes: D10B 2403/02412 including several arrays of unbent yarn, e.g. multiaxial fabrics
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: Y10T 442/322 Warp differs from weft
• CPC Class Codes: Y10T 442/3244 Including natural strand material [e.g., cotton, wool, etc.]
• CPC Class Codes: Y10T 442/3252 Including synthetic polymeric strand material

Abstract

Systems and methods for weaving helical carbon fabrics with minimum fiber crimp are provided herein. In various embodiments, small denier natural or synthetic yarns are used in the warp direction to interlace the carbon fiber wefts with minimum deformation. Specific weave designs are used in combination with the small denier yarn to maintain the primary carbon fiber weft and warp un-crimped.

Claims

1. A textile, comprising:

a first interlocking warp yarn;

a first weft tow;

a second weft tow; and

a first primary warp tow,

wherein the first weft tow, the second weft tow, and the first primary warp tow comprise a carbon fiber precursor,

wherein the first primary warp tow comprises from about 6 thousand (K) to 50 K fibers,

wherein the first weft tow comprises from about 6 K to 50 K fibers,

wherein the second weft tow comprises from about 6 K to 50 K fibers,

wherein the first primary warp tow passes below the first weft tow and above the second weft tow,

wherein the first interlocking warp yarn passes above the first weft tow and below the second weft tow,

wherein the first interlocking warp yarn is adjacent to the first primary warp tow in a warp direction,

wherein the first interlocking warp yarn has a diameter that is less than the diameter of the first primary warp tow,

wherein the first interlocking warp yarn is sacrificial and consists of at least one of cotton, wool, linen, polyester, silk, nylon, rayon, polypropylene, and acrylic.

2. The textile of claim 1, wherein the first interlocking warp yarn comprises a cotton yarn of denier of between about 10 denier to 100 denier.

3. The textile of claim 1, wherein the textile is an annular configuration having an inner diameter (ID) and an outer diameter (OD).

4. The textile of claim 3, wherein the first interlocking warp yarn is disposed closer to the OD than the first primary warp tow and wherein a second interlocking warp yarn is disposed closer to the ID than the first primary warp tow.

5. The textile of claim 3, wherein the first interlocking warp yarn is disposed closer to the OD than the first primary warp tow and wherein a second primary warp tow is disposed closer to the ID than the first primary warp tow.

6. The textile of claim 5, wherein a third primary warp tow is disposed closer to the ID than the second primary warp tow and wherein a second interlocking warp yarn is disposed closer to the ID than the third primary warp tow.

7. The textile of claim 1, further comprising a third weft tow, wherein the first primary warp tow passes below the third weft tow.

8. The textile of claim 7, further comprising a fourth weft tow, wherein the first primary warp tow passes above the fourth.

9. The textile of claim 1, wherein the first interlocking warp yarn comprises a 40 denier cotton yarn.

10. The textile of claim 1, wherein the first weft tow, the second weft tow, and the first primary warp tow consist of at least one of oxidized polyacrylonitrile (PAN) fibers, carbonized PAN fibers, or stabilized pitch fibers.

11. The textile of claim 1, wherein the first interlocking yarn runs at least one of parallel or substantially parallel to the first primary warp tow.

12. The textile of claim 10, wherein the first interlocking yarn runs at least one of parallel or substantially parallel to the first primary warp tow.