Method and apparatus for producing blends of resinous, thermoplastic fiber, and laminated structures produced therefrom
AssigneeTextile Products, Incorporated
InventorFrederick H. Curzio
Life of this patent
Estimating the term…
Abstract
Reinforced structures of graphite, fiberglass, and the like, together with thermoplastic resinous fibers such as in ribbon, filament and monofilament form are produced. The graphite fiber is combined or blended with a resinous fiber to form a single yarn. The blended yarn is then woven into a soft, supple and flexible fabric having the appropriate concentration of graphite and resin, and with good uniform characteristics. Hybrid fabrics produced by interweaving graphite and the polymeric fibers, ribbon, etc., may be utilized instead of the blended yarn. The fabric is finally shaped to conform with a mold or substrate and heated to melt the resin and produce the resin-graphite laminate.
Claims24
A process for producing laminates from graphite fibers, and the like, and a plurality of resinous thermoplastic fibers, comprising:
- (a) combining or blending the graphite and thermoplastic fibers into yarn;
- (b) controlling the graphite/resin weight ratio during the blending step;
- (c) weaving the yarn into a flexible, dry fabric adapted for dry storage without refrigeration in which adjacent thermoplastic fibers or yarn, and graphite fibers, and the like, are adapted for sufficient movement relative to each other, thereby enabling the fabric to be conformed to a mold or substrate, the yarn and fibers having a controlled alignment in the fabric due to weaving or blending;
- (d) shaping the fabric in a dry, solvent-free form by conforming the fabric onto said mold or substrate;
- and,
- (e) heating the fabric under pressure to melt the resin and produce a shaped, graphite-resin laminate in which the graphite and resin are intimately combined in the laminate at the controlled graphite/resin ratio to produce uniform characteristics.
A woven fabric for conversion into a laminate, the fabric being produced by:
- (a) combining or blending graphite and resinous thermoplastic fibers into yarn;
- (b) controlling the graphite/resin weight ratio during blending:
- and,
- (c) weaving the yarn into a flexible, dry fabric adapted for dry storage without refrigeration in which adjacent thermoplastic fibers or yarn, and graphite fibers, and the like, are adapted for sufficient movement relative to each other, thereby enabling the fabric to be conformed to a mold or substrate, the yarn and fibers having a controlled alignment in the fabric due to weaving or blending;
- whereby, i. the fabric is adapted to be shaped in a dry, solvent-free form by conforming the fabric onto said mold or substrate;
- ii. the resin in the fabric is adapted to melt under heat and pressure to produce a graphite-resin laminate;
- and, iii. the graphite and resin are intimately combined in the laminate at the controlled graphite/resin weight ratio to produce uniform characteristics.
A laminate containing a fabric of woven graphite fibers, and the like, and a resinous, thermoplastic fiber, the laminate being formed by the steps of:
- (a) combining or blending the graphite and thermoplastic fibers into yarn, the graphite fibers being surrounded by at least a portion of the thermoplastic fibers;
- (b) weaving the yarn into flexible, dry fabric adapted for dry storage without refrigeration, in which adjacent thermoplastic fibers or yarn, and graphite fibers, and the like, are adapted for sufficient movement relative to each other, thereby enabling the fabric to be conformed to a mold or substrate, the yarn and fibers having a controlled alignment in the fabric due to weaving or blending;
- (c) shaping the fabric in a dry, solvent-free form by conforming the fabric onto said mold or substrate;
- and,
- (d) heating the fabric under pressure to melt the resin and produce a graphite-resin laminate;
- whereby,
- (i) the combining or blending step includes controlling the graphite-resin ratio;
- and, ii. the graphite and resin are intimately combined in the laminate to produce uniform characteristics.
Dependencies are inferred from the claim text.