SYSTEMS AND METHODS FOR REDUCED CRIMP CARBON FIBER HELICAL FABRIC

• US 20130231024A1
• Filed: 03/05/2012
• Published: 09/05/2013
• 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
• Granted Patent: US 10,648,106 B2
• Time in Patent Office: Days
• US Class Current: 442/211
• 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 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 has a diameter that is less than the diameter of the first weft tow.

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 and first primary weft tow comprises at least one of a carbon fiber and a carbon fiber precursor of tow size between about 6 k and about 50 k.

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 1, wherein the first weft tow, the second weft tow, and the first primary warp tow comprise at least one of a carbon fiber material and a carbon fiber precursor material.

5. The textile of claim 2, wherein the first interlocking warp yarn sacrificial and comprises at least one of cotton, wool, linen, polyester, silk, nylon, rayon, polypropylene, and acrylic.

6. 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.

7. 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.

8. The textile of claim 7, 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.

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

10. The textile of claim 9, further comprising a fourth weft tow, wherein the first primary warp tow passes above the fourth.

11. A method of making a textile comprising

placing a first primary warp tow and a first interlocking warp yarn on a weaving device;

disposing a first weft tow above the first primary warp tow and below the first interlocking warp yarn;

disposing a second weft tow below the first primary warp tow and above the first interlocking warp yarn.

12. The method of claim 11, wherein the first interlocking warp yarn is sacrificial.

13. The method of claim 11, wherein the first interlocking warp yarn comprises at least one of cotton, wool, linen, polyester, silk, nylon, rayon, polypropylene, and acrylic.

14. The method of claim 11, wherein the first weft tow, the second weft tow, and the first primary warp tow comprise at least one of carbon fiber precursor material and a carbon fiber material.

15. The method of claim 14, wherein the textile is an annular configuration having an inner diameter (ID) and an outer diameter (OD).

16. The method of claim 14, further comprising placing a second interlocking warp yarn closer to the OD than the first primary warp tow, wherein the first interlocking warp yarn is disposed closer to the ID than the first primary warp tow.

17. The method of claim 14, further comprising placing a second primary warp tow closer to the OD than the first primary warp tow, wherein the first interlocking warp yarn is disposed closer to the ID than the first primary warp tow.

18. The method of claim 17, further comprising placing a second interlocking warp yarn closer to the OD than the second primary warp tow.

19. The method of claim 18, wherein the weaving device comprises a weaving loom equipped with conical take-off rollers.

20. The method of claim 11, further comprising disposing a third welt tow adjacent to the second weft tow.