A high-elasticity carbon fiber yarn and three-dimensional fabric tape

Abstract

A high-elasticity carbon fiber yarn and three-dimensional tape are disclosed, comprising a main elastic core, elastic binding threads, and chopped carbon fiber filaments. Several chopped carbon fiber filaments are crimped end-to-end onto the outer surface of the main elastic core, and each chopped carbon fiber filament is fixed to the main elastic core by the elastic binding threads. The chopped carbon fiber filaments are impregnated with silicone resin. The carbon fiber tape woven by this invention uses high-elasticity carbon fiber yarn, which has strong elasticity, enabling the tape to fully adhere to the core during winding. The composite product after resin impregnation and curing is wrinkle-free. The elastic warp yarn made of chopped carbon fiber filaments, after resin impregnation and curing, can also provide significant tensile strength, just like filament yarns, to tightly cross-link the weft yarns.

Description

Technical Field

[0001] This invention belongs to the field of composite material technology, specifically relating to a high-elasticity carbon fiber yarn and a three-dimensional fabric tape. Background Technology

[0002] Carbon fiber possesses a series of advantages, including high strength, high modulus, high temperature resistance, and low density, making it one of the most important basic materials in the modern aerospace industry. However, carbon fiber has very poor ductility, and the spun yarn and woven fabric have almost no elasticity. Especially when using a fabric-tape winding process to manufacture solid-state ablation-resistant inner liner tubes, if there is an angle between the fabric tape surface and the winding surface, the side with the larger winding diameter will always be tighter and the side with the smaller winding diameter will be looser, and the side with the smaller winding diameter cannot adhere tightly to the mandrel. Even with flat winding, the poor compressibility of the interwoven fabric surface will cause wrinkles on the outer fabric surface during the curing process. Summary of the Invention

[0003] The purpose of this invention is to provide a high-elasticity carbon fiber yarn and a three-dimensional fabric tape to solve the problem that when the fabric tape surface and the axis form a large angle, the two sides of the fabric tape are always tight on the outside and loose on the inside, and the inner side of the fabric tape cannot be tightly attached to the mandrel and the fabric tape winding component will have serious wrinkles after curing.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A high-elasticity carbon fiber yarn includes a main elastic core, elastic binding wire, and carbon fiber chopped strands; several carbon fiber chopped strands are crimped together on the outer surface of the main elastic core, and each carbon fiber chopped strand is fixed to the main elastic core by the elastic binding wire; the carbon fiber chopped strands are coated with silicone resin.

[0006] Furthermore, the elastic binding thread consists of one or two elastic wires.

[0007] Furthermore, when the elastic binding thread is a single elastic filament, the elastic filament is bound to the end of each segment of chopped carbon fiber filament.

[0008] Furthermore, when the elastic binding line consists of two elastic threads, one elastic thread is bound to the middle of the carbon fiber chopped filament and fixed to the main elastic core line; the other elastic thread is fixed and bound to the reversed carbon fiber chopped filament next to the first elastic thread after one side of the carbon fiber chopped filament is reversed.

[0009] Furthermore, the main elastic core is made of multiple thin elastic filaments twisted together.

[0010] A high-elasticity carbon fiber three-dimensional tape includes a high-elasticity carbon fiber yarn and a carbon fiber untwisted filament bundle; the high-elasticity carbon fiber yarn is used as the warp yarn, and the carbon fiber untwisted filament bundle is used as the weft yarn. According to the shallow cross-bending structure, each group of warp yarns is alternately wound between each two adjacent layers of weft yarn to form a 2.5D three-dimensional woven tape.

[0011] Furthermore, the fiber hair direction of the high-elasticity carbon fiber yarn is the same as the warp feed direction of the loom.

[0012] Furthermore, during weaving, tension is applied to the high-elasticity carbon fiber yarn, with the maximum tension not exceeding three-quarters of the maximum tension that the main elastic core yarn can withstand.

[0013] Furthermore, the number of warp yarns in different layers of the high-elasticity carbon fiber tape varies along the thickness direction, and the number of weaving layers on both sides of the fabric cross-section is less, and the thickness is thinner than that in the middle.

[0014] Compared with the prior art, the present invention has the following technical effects:

[0015] The carbon fiber tape woven in this invention uses highly elastic carbon fiber yarn, which has strong elasticity and can fully adhere to the mandrel during winding. The composite product after impregnation and curing is wrinkle-free. The elastic warp yarn made of chopped carbon fiber filaments can also provide a large force to tightly crosslink the weft yarns, just like long filaments, after impregnation and curing. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the longitudinal section structure of a three-layer 2.5D three-dimensional high-elasticity carbon fiber tape.

[0017] Figure 2 This is a schematic diagram of the rear end face structure of a three-layer 2.5D unequal thickness three-dimensional high elastic carbon fiber tape.

[0018] Figure 3 This is a schematic diagram of a high-elasticity carbon fiber yarn made of single-end, single-layer wound short carbon fiber filaments.

[0019] Figure 4 This is a schematic diagram of a high-elasticity carbon fiber yarn with double-layered winding of short carbon fiber filaments.

[0020] Wherein: 1—main elastic core yarn, 2—short carbon fiber filaments, 3—elastic yarn, 7—warp yarn, 8—weft yarn, 9—layer I weft yarn, 10—layer II weft yarn, 11—layer III weft yarn, 12—group I warp yarn, 13—group II warp yarn, 14—group III warp yarn, 15—group IV warp yarn. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] Please see Figures 1 to 4 A high-elasticity carbon fiber tape, wherein the warp yarn is made of high-elasticity carbon fiber yarn and the weft yarn is made of untwisted carbon fiber filament bundles and manufactured using a 2.5D jacquard loom, wherein the number of weft yarn layers is at least 2 layers.

[0025] The high-elasticity carbon fiber yarn is produced using a wrapping spinning process. Short carbon fiber filaments 2 are laid on the outside of the high-elasticity main elastic core 1 and tied tightly to the main elastic core 1 with an elastic filament 3. Then, the elastic filament 3 is knotted and cut at the tip. After one section is completed, the main elastic core 1 is moved forward a bit before the next section is wrapped. The spun yarn is impregnated with a silicone resin with weak adhesion and bundled, dried, and then wound into rolls.

[0026] The high-elasticity carbon fiber yarn is produced using a wrapping spinning process. A ring of pre-wetted carbon fiber chopped filaments 2, which are soaked in water-based silicone resin, is applied to the outside of the high-elasticity main elastic core yarn 1. Then, an elastic filament 3 is used to tie the middle of the carbon fiber chopped filament 2 to the main elastic core yarn 1. After reversing one side of the carbon fiber chopped filament 2, another elastic filament 3 is used to wrap the carbon fiber several times next to the previous elastic filament 3. The elastic filament is then melted and cut. After one section is completed, the main elastic core yarn 1 is moved forward a short distance before the next section is laid and wrapped. After being straightened and dried by several fine-hole yarn guides, it is wound into a roll.

[0027] The high-elasticity carbon fiber yarn is produced using a wrapping spinning process. A ring of pre-wetted carbon fiber chopped filaments 2 is laid around the main elastic core 1. Then, an elastic filament 3 is wrapped around the main elastic core 1 several times to tie the middle of the carbon fiber chopped filament 2 tightly to the main elastic core 1. After reversing one side of the carbon fiber chopped filament 2, another elastic filament 3 is wrapped around the carbon fiber several times next to the previous elastic filament 3 and then a knot is tied around the elastic filament. After one section is completed, the main elastic core 1 is moved forward a short distance before the next section is laid and wrapped. The spun yarn is then coated with silicone resin, dried, and wound into a roll.

[0028] The high-elasticity carbon fiber yarn is made using a warp knitting process, in which several sets of fine carbon fiber filaments are woven onto a taut elastic core using a braiding machine.

[0029] When weaving high-elasticity carbon fiber tape, the fiber hairs of the high-elasticity carbon fiber warp yarns should point towards the shed. A certain tension should be applied to the high-elasticity carbon fiber warp yarns during weaving, with the maximum tension not exceeding three-quarters of the maximum tension that the main elastic core yarn 1 can withstand.

[0030] The weft yarn is made of carbon fiber filaments with high linear density.

[0031] To accommodate the tightness of the tape winding inside the tube, the number of warp yarns in different layers of the high-elasticity carbon fiber tape varies along the thickness direction. The number of weaving layers on one or both edges of the fabric cross-section is less, and the thickness is thinner than in the middle.

[0032] Example 1:

[0033] See Figure 1 , Figure 3A three-layer 2.5D high-elasticity carbon fiber tape is woven using a three-dimensional shuttleless weaving machine. The weft yarn consists of three layers: layer i (weft yarn 9), layer ii (weft yarn 10), and layer iii (weft yarn 11). The warp yarn is divided into four groups: group I (warp yarn 12), group II (warp yarn 13), group III (warp yarn 14), and group IV (warp yarn 15). The warp yarn uses a high-elasticity yarn blended from 400tex low-linear-density chopped carbon fiber and spandex. The weft yarn uses 800tex high-linear-density untwisted carbon fiber filament bundles (T700-12K). During weaving, the tension of each warp yarn is controlled at approximately 0.2N, and the weft yarn tension at approximately 0.5N. The weft density is 3 yarns / 10mm, the warp density is 2 yarns / 10mm, and the free thickness is 2-3mm. The weft yarn is coarse and stiff with minimal bending, while the warp yarn is fine and soft with greater bending. The three-dimensional weaving machine employs a three-layer shed, three-hook weft insertion mechanism for synchronous weft insertion.

[0034] The structure of the high-elasticity yarn made of short-cut carbon fiber and spandex is as follows: a 25mm long T700-3K carbon fiber short filament 2 is laid outside a 0.6mm diameter high-elasticity main elastic core 1, and one end of the carbon fiber short filament 2, which is wetted with water-based organosilicon resin, is tied to the main elastic core 1 with an elastic thread 3; after one section of carbon fiber is tied, the main elastic core 1 moves forward 10mm, and then the next section of carbon fiber is laid; the spun yarn is coated with organosilicon resin, dried, and then wound into a roll for later use.

[0035] Example 2:

[0036] See Figure 1 and Figure 2 A three-layer 2.5D unequal thickness three-dimensional high-elasticity carbon fiber tape is woven using a three-dimensional jacquard rapier loom. The weft yarn consists of three layers: layer i (weft yarn 9), layer ii (weft yarn 10), and layer iii (weft yarn 11). The warp yarn is divided into four groups: group I (warp yarn 12), group II (warp yarn 13), group III (warp yarn 14), and group IV (warp yarn 15). Group I (warp yarn 12) and group II (warp yarn 13) have a larger number of yarns, while group III (warp yarn 14) and group IV (warp yarn 15) have fewer yarns than group I (warp yarn 12) and group II (warp yarn 13). The warp yarn uses 400tex carbon fiber with an spandex core to weave high-elasticity yarn, and the weft yarn uses 1600tex high-linear-density carbon fiber untwisted filament bundles T700-24K. During weaving, the tension of each warp yarn is controlled at approximately 0.2N, and the weft yarn tension at approximately 0.5N. The weft density is 3 yarns / 10mm, the warp density is 2 yarns / 10mm, and the free thickness is 2-3mm. The weft yarns are thick and stiff with minimal bending, while the warp yarns are thin and soft with greater bending. The three-dimensional jacquard rapier loom uses a three-layer shed and three rigid rapier weft insertion mechanism for synchronous weft insertion.

[0037] The 400tex carbon fiber braided high-elasticity yarn with a spandex core is woven using a braiding machine with eight T700-500 carbon fiber filaments of approximately 40tex in diameter, surrounding a 0.7mm diameter high-elasticity main elastic core yarn 1. During weaving, the spandex core is subjected to a tension of approximately 0.8N. The elastic main elastic core yarn 1 can be made by twisting together multiple finer elastic filaments; the specific material can be spandex or a high-elasticity, low-aging-rate material such as TPU thermoplastic polyurethane elastomer rubber.

[0038] Example 3:

[0039] See Figure 4 The structure of the high-elasticity yarn, which is a blend of chopped carbon fiber and spandex, involves laying three T700-3k carbon fiber filaments outside the high-elasticity main elastic core 1. A 0.2mm diameter elastic thread 3 is used to tie the middle of the chopped carbon fiber filaments 2, which are soaked in water-based silicone resin, to the 0.6mm diameter TPU main elastic core 1. Then, simultaneously, the three carbon fibers are folded back 25mm and each is hooked. Immediately afterward, a 0.2mm diameter fine TPU crystal elastic thread is used to tie the carbon fibers tightly near the back of the previous fine TPU crystal elastic thread 3. Then, the three carbon fibers are folded forward and tied tightly to the main elastic core 1 10mm before the previous elastic thread 3's binding point using a 0.2mm diameter fine TPU crystal elastic thread 3. Finally, the carbon fiber filaments are cut at the hook to become chopped carbon fiber filaments 2. This process is repeated. The spun yarn is then straightened and bundled through multiple yarn guides, dried, and wound into rolls for later use. The yarn spun in this way is used as warp yarn when weaving fabric tape, resulting in fabric tape with significant elasticity along the length corresponding to the warp yarn. The silicone resin coating serves two purposes: first, its weak adhesive force helps to bundle the elastic yarn coated with chopped carbon fibers for easier weaving; second, the low strength of the dried silicone resin allows it to release the binding force on the carbon fibers when the elastic yarn is subjected to a certain tension, enabling the chopped carbon fibers to slide relative to each other.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-elasticity carbon fiber yarn, characterized in that, It includes a main elastic core wire (1), elastic binding wire and carbon fiber short filaments (2); several carbon fiber short filaments (2) are crimped together and laid on the outer surface of the main elastic core wire (1), and each section of carbon fiber short filament (2) is fixed to the main elastic core wire (1) by elastic binding wire; the carbon fiber short filaments (2) are coated with silicone resin. The elastic binding thread consists of one elastic wire (3) or two elastic wires (3); When the elastic binding thread is a single elastic filament (3), the elastic filament (3) is bound to the end of each section of carbon fiber stub filament (2); When the elastic binding line consists of two elastic wires (3), one elastic wire (3) is bound to the middle of the carbon fiber chopped filament (2) and fixed to the main elastic core wire (1); the other elastic wire (3) is bound to the reversed carbon fiber chopped filament (2) next to the first elastic wire (3) after one side of the carbon fiber chopped filament (2) is reversed. The main elastic core (1) is made of multiple thin elastic wires twisted together.

2. A highly elastic carbon fiber three-dimensional fabric tape, characterized in that, It includes a high-elasticity carbon fiber yarn and a carbon fiber untwisted filament bundle as described in claim 1; the high-elasticity carbon fiber yarn is used as the warp yarn and the carbon fiber untwisted filament bundle is used as the weft yarn. According to the shallow cross-bending structure, each group of warp yarns is alternately wound between each two adjacent layers of weft yarn to form a 2.5D three-dimensional woven tape.

3. The high-elasticity carbon fiber three-dimensional tape according to claim 2, characterized in that, The fiber hair direction of the high-elasticity carbon fiber yarn is the same as the warp feed direction.

4. The high-elasticity carbon fiber three-dimensional tape according to claim 2, characterized in that, During weaving, tension is applied to the high-elasticity carbon fiber yarn, with the maximum tension not exceeding three-quarters of the maximum tension that the main elastic core yarn (1) can withstand.

5. The high-elasticity carbon fiber three-dimensional tape according to claim 2, characterized in that, The number of warp yarns in different layers of the high-elasticity carbon fiber tape varies along the thickness direction. The number of weaving layers on both sides of the cross-section of the fabric is less, and the thickness is thinner than that in the middle.

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