# US 2014/0150922 A1 · Spiral textile and system for weaving the same

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- Number: US 2014/0150922 A1
- Document ID: US20140150922A1
- Status: Published application
- Kind: A1
- Application number: 13/706,168
- Filed: 2012-12-05
- Published: 2014-06-05
- Earliest claimed: 2012-12-05
- Assignees: Goodrich Corporation
- Inventors: Jean-Francois Lecostaouec; Felix Binder
- Web page: https://patentgrep.com/patent/US20140150922A1

## CPC

- D03D 1/00: Woven fabrics designed to make specified articles
- D03D 3/005: {Tapes or ribbons not otherwise provided for (D03D1/0005, D03D1/0011, D03D1/06, D03D1/08, D03D1/0094 take precedence)}
- D03D 3/08: Arched, corrugated, or like fabrics
- D03D 13/008: {characterised by weave density or surface weight}
- D03D 35/00: Smallware looms, i.e. looms for weaving ribbons or other narrow fabrics (D03D47/00 takes precedence)
- D03D 41/00: Looms not otherwise provided for, e.g. for weaving chenille yarn; Details peculiar to these looms
- D03D 49/00: Details or constructional features not specially adapted for looms of a particular type
- D03D 49/20: Take-up motions; Cloth beams
- F16D 69/023: {Composite materials containing carbon and carbon fibres or fibres made of carbonizable material}
- D10B 2101/12: Carbon; Pitch
- D10B 2505/02: Reinforcing materials; Prepregs
- D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES

## Abstract

Loom configurations and methods for efficiently manufacturing unique spiral-shaped fabrics. The loom introducing two weft yarn segments in the form of a continuous loop in each shed may be configured with one or two weft needles and is equipped with a knitting system to form a knitted selvedge along the outside circumference of the fabric. The knitted edge is used as reference to form weft yarn loops of different lengths. The opposite weft yarn loops are permanently secured around selected warp yarns. Alternatively intermediate length weft yarn loops may be created where the extremity of the loop is not bound to any warp yarn. Fiber architectures may be designed and woven which exhibit uniform fiber volume across the width of the fabric. Fiber architectures with greater fiber volume along the outside circumference of the fabric may also be prepared.

## Claims

### Claim 1

A helical textile comprising:
warp fibers spaced in a weft direction;
first weft fibers spaced in a warp direction and extending from a first edge of the textile to a second edge of the textile;
second weft fibers shorter than the first weft fibers, wherein the first weft fibers and the second weft fibers alternate in the warp direction, and wherein the second weft fibers extend from the first edge and are secured between the first edge and the second edge of the textile; and
a plurality of knitted loops along the first edge, wherein the plurality of knitted loops formed with a binder thread secures at least the first weft fibers at the first edge.

### Claim 2 (depends on 1)

The textile of claim 1, further including a substantially uniform weft fiber concentration from the first edge to the second edge.

### Claim 3 (depends on 1)

The textile of claim 1, further including a content of weft fibers near the first edge that is higher than a content of weft fibers near the second edge, wherein a thickness of the textile is substantially constant.

### Claim 4 (depends on 1)

The textile of claim 1, wherein the warp fibers and the weft fibers include carbon or graphite tows at least one of equal to and greater than 6K.

### Claim 5 (depends on 1)

The textile of claim 1, wherein the warp fibers and the weft fibers include carbon or graphite tows of at least one of 6K, 12K, 24K, 48K, and 50K.

### Claim 6 (depends on 5)

The textile of claim 5, wherein the warp fibers and the first weft fiber are interlaced to form at least one of a plain weave, a twill weave, and a satin weave.

### Claim 7 (depends on 1)

The textile of claim 1, further comprising third weft fibers, fourth weft fibers, fifth weft fibers, sixth weft fibers, seventh weft fibers, and eighth weft fibers, wherein the first, second, third, fourth, fifth, sixth, seventh, and eighth weft fibers all have different lengths in order to obtain a tailorable fiber architecture.

### Claim 8 (depends on 1)

The textile of claim 1, further comprising a shed opening, wherein two or more ends of the second weft fibers are inserted in the shed opening.

### Claim 9 (depends on 1)

The textile of claim 1, further comprising a shed opening and third weft fibers, wherein the third weft fibers are a different length than the second weft fibers, and wherein at least one of the second weft fibers and the third weft fibers is inserted in the shed opening.

### Claim 10 (depends on 1)

The textile of claim 1, further comprising third weft fibers having a different length than the first weft fibers and the second weft fibers.

### Claim 11 (depends on 1)

The textile of claim 1, further comprising a selvedge edge proximate at least one of the first edge of the textile and the second edge of the textile.

### Claim 12 (depends on 1)

The textile of claim 1, further comprising a radial to circumferential fiber content ratio between the first edge and the second edge of between about 2 and about 4.

### Claim 13

A helical textile, comprising:
warp fibers spaced in a weft direction;
first weft fibers spaced in a warp direction and extending from a first edge of the textile to a second edge of the textile;
second weft fibers shorter than the first weft fibers;
the first edge having a first fiber concentration and the second edge having a second fiber concentration;
wherein the first weft fibers and the second weft fibers alternate in the warp direction, and wherein the second weft fibers are secured between the first edge and the second edge of the textile.

### Claim 14 (depends on 13)

The textile of claim 13, wherein the first fiber concentration and the second fiber concentration are substantially uniform.

### Claim 15 (depends on 13)

The textile of claim 13, further comprising a third fiber concentration substantially uniform with the first fiber concentration and the second fiber concentration.

### Claim 16 (depends on 13)

The textile of claim 13, wherein the first fiber concentration is greater than the second fiber concentration, and wherein the first edge is proximate an outside diameter of the textile.

### Claim 17

A helical textile, comprising:
warp fibers spaced in a weft direction;
first weft fibers spaced in a warp direction and extending substantially across a width of the textile;
second weft fibers shorter than the first weft fibers, wherein the first weft fibers and the second weft fibers alternate in the warp direction, wherein respective ends of the second weft fibers are proximate an edge of the textile; and
a selvedge proximate an outside diameter of the textile, wherein the selvedge comprises a plurality of knitted loops along the first edge, wherein the plurality of knitted loops formed with a binder thread secures at least the first weft fibers at the first edge and act as reference point for the first and second weft fibers.

### Claim 18

A loom for manufacturing a spiral-shaped textile, comprising:
a needle drive mechanism coupled to the loom to reciprocate a weft needle, the weft needle for inserting first weft fibers in a textile from a first edge of the textile to a first point between the first edge of the textile and a second edge of the textile, the weft needle for inserting second weft fibers in the textile from the first edge of the textile to a second point between the first edge of the textile and the second edge of the textile;
a knitting head for knitting at least one of: the first weft fibers at the first point, and the second weft fibers at the second point; and
a conical take-off roller that receives the spiral-shaped textile.

### Claim 19 (depends on 18)

The loom of claim 18, further comprising a knitting system, wherein the conical take-off roller comprises a large diameter and a small diameter, and wherein the knitting system is proximate the large diameter of the conical take-off roller.

### Claim 20 (depends on 18)

The loom of claim 18, wherein the weft needle is proximate at least one of the first edge of the textile and the second edge of the textile.

### Claim 21 (depends on 18)

The loom of claim 18, further comprising a knitting system for creating a selvedge edge proximate at least one of the first edge of the textile and the second edge of the textile.

### Claim 22 (depends on 21)

The loom of claim 21, wherein the selvedge edge comprises a plurality of knitted loops formed by a knitting system and an auxiliary binder thread, wherein the selvedge edge captures a weft fiber loop.

### Claim 23 (depends on 22)

The loom of claim 22, wherein the selvedge edge is a reference point for the weft fiber.

### Claim 24 (depends on 18)

The loom of claim 18, wherein the first point and the second point are different distances from the first edge of the textile.

### Claim 25 (depends on 24)

The loom of claim 24, wherein the weft needle inserts:
third weft fibers in the textile from the first edge of the textile to a third point between the first edge of the textile and the second edge of the textile;
fourth weft fibers in the textile from the first edge of the textile to a fourth point between the first edge of the textile and the second edge of the textile;
fifth weft fibers in the textile from the first edge of the textile to a fifth point between the first edge of the textile and the second edge of the textile;
sixth weft fibers in the textile from the first edge of the textile to a sixth point between the first edge of the textile and the second edge of the textile;
seventh weft fibers in the textile from the first edge of the textile to a seventh point between the first edge of the textile and the second edge of the textile; and
eighth weft fibers in the textile from the first edge of the textile to an eighth point between the first edge of the textile and the second edge of the textile, wherein the first, second, third, fourth, fifth, sixth, seventh, and eighth points are all different distances from the first edge of the textile.

### Claim 26 (depends on 23)

The loom of claim 23, further comprising:
a second weft needle and a weft feeding system situated along the first textile edge;
a first movable finger that temporarily holds the first weft fibers at the first point between the first edge of the textile and the second edge of the textile; and
a second movable finger that temporarily holds the second weft fibers at the second point between the first edge of the textile and the second edge of the textile.

### Claim 27 (depends on 25)

The loom of claim 25, wherein the weft needle inserts two ends of the first weft fibers into one shed opening in the textile.

### Claim 28 (depends on 25)

The loom of claim 25, further comprising a movable finger to capture a loop of the first weft fibers at the first point between the first edge of the textile and the second edge of the textile.

### Claim 29

A method for manufacturing a spiral-shaped textile comprising:
inserting first weft fibers in warp fibers of the textile, wherein the first weft fibers extend from a first edge of the textile to a second edge of the textile;
knitting the first weft fibers at the first edge of the textile to create a first knit;
inserting second weft fibers in the warp fibers of the textile, wherein the second weft fibers extend from the first edge of the textile to a point between the first edge of the textile and the second edge of the textile;
securing the second weft fibers at the point between the first edge of the textile and the second edge of the textile; and
knitting the second weft fibers at the first edge of the textile to create a second knit.

### Claim 30

A method for manufacturing a spiral-shaped textile comprising:
inserting first weft fibers in warp fibers of the textile using a first weft needle, wherein the first weft fibers extend from a second edge of the textile to a first edge of the textile;
knitting the first weft fibers at the first edge of the textile to create a first knit;
inserting second weft fibers in the warp fibers of the textile using a second weft needle, wherein the second weft fibers extend from the first edge of the textile to a point between the first edge of the textile and the second edge of the textile;
securing the second weft fibers at the point between the first edge of the textile and the second edge of the textile; and
looping the second weft fibers about the first edge of the textile.

### Claim 31

A reel for winding a helical textile as it is woven, comprising:
a first hub and a second hub between which the spiral textile is wound; and
a barrel upon which the spiral textile is wound, wherein the barrel is disposed between the first hub and the second hub, and wherein the barrel comprises a first end having a first diameter and a second end having a second diameter different than the first diameter.

### Claim 32 (depends on 31)

The reel of claim 31 wherein the barrel is a frustum of a cone, and wherein the spiral textile unwinds from the barrel and is disposed on a circular needle loom in substantially the same orientation and direction as the spiral textile is wound on the barrel.

### Claim 33 (depends on 31)

The reel of claim 31, wherein a face of the textile is substantially parallel to the barrel.

### Claim 34 (depends on 31)

The reel of claim 31, wherein the first hub and second hub allow the reel to store an amount of the spiral textile sufficient to produce a circular preform.

### Claim 35 (depends on 31)

The reel of claim 31, wherein the barrel comprises an articulated element rotatably associated with the first hub, wherein the second hub comprises a first slot and a second slot, wherein the articulated element is movable between the first slot and the second slot, and wherein a radial element disposed on the second hub comprises the first slot and the second slot.

### Claim 36 (depends on 31)

The reel of claim 31, further comprising:
a plurality of articulated elements that facilitate winding the spiral textile upon the plurality of articulated elements in a frusto-conical manner; and
a plurality of radial elements disposed on the second hub, wherein each of the plurality of articulated elements are movable between a plurality of positions on the plurality of radial elements.

### Claim 37

A spool for receiving a spiral textile tape, comprising:
a first barrel cone element rotatably attached to a first hub; and
a second hub comprising a first slot and a second slot, wherein the first barrel cone element is movable between the first slot and the second slot to create a textile slope, and wherein the spiral textile tape is wound around the first barrel cone element and a second barrel cone element.

### Claim 38 (depends on 37)

The spool of claim 37, wherein the first barrel cone element is positioned in the first slot based on an inside diameter and an outside diameter of the spiral textile tape to facilitate receiving the spiral textile tape substantially parallel to the textile slope.

### Claim 39 (depends on 38)

The spool of claim 38, wherein the first barrel cone element is positioned in the second slot in response to at least one of: a geometry of a second spiral textile tape, and a weave of the second spiral textile tape.

### Claim 40 (depends on 37)

The spool of claim 37, further comprising:
a first articulated element, a second articulated element, and a third articulated element, wherein the first articulated element is the first barrel cone element and wherein the second articulated element is the second barrel cone element; and
a first radial element that receives the first articulated element, a second radial element that receives the second articulated element, and a third radial element that receives the third articulated element, wherein the first radial element, the second radial element, and the third radial element are disposed on the second hub,
wherein the first articulated element is movable between the first slot and the second slot on the first radial element, wherein the second articulated element is movable between a third slot and a fourth slot disposed on the second radial element, and wherein the third articulated element is movable between a fifth slot and a sixth slot disposed on the third radial element.