A high-elasticity carbon fiber yarn and elastic mesh fabric reinforced felt

Abstract

A high-elasticity carbon fiber yarn and elastic mesh reinforcement felt includes an elastic core, elastic binding wire, 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 wire. The chopped carbon fiber filaments are impregnated with silicone resin. This invention uses a high-strength elastic mesh as the load-bearing material. A certain thickness of randomly oriented chopped carbon fiber filaments is laid on both sides of the mesh, and the chopped carbon fiber filaments and the mesh are bonded together using needle punching or hydroentangling methods to create an elastic composite industrial felt with a certain tensile strength. The industrial felt reinforced with mesh has a certain tensile strength and can be wound under tension like a fabric tape. It can replace fabric tape in composite material production, with significantly lower material costs and winding time compared to fabric tape.

Description

Technical Field

[0001] This invention belongs to the field of composite material technology, specifically relating to a high-elasticity carbon fiber yarn and an elastic mesh fabric reinforcing felt. Background Technology

[0002] In the manufacture of composite solid rocket motor nozzles, carbon fiber tape or high-silica tape is often used to produce ablation-resistant liners and heat shields. Although the tape has high mechanical properties, the heat shield requires very low tensile strength, primarily focusing on low thermal conductivity. This means the high strength of the expensive tape material is not essential. Furthermore, the low compressibility of the tape in all directions contributes to wrinkling during curing. The tape is also relatively thin, requiring more time to wind a heat shield of the same volume. While industrial felt is cheaper, its low tensile strength prevents tight winding. Summary of the Invention

[0003] The purpose of this invention is to provide a high-elasticity carbon fiber yarn and elastic mesh fabric reinforced felt to solve the problem that traditional felt has too low tensile strength to be tightly wound.

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

[0005] A high-elasticity carbon fiber yarn includes an elastic core, elastic binding wire, and carbon fiber chopped strands; several carbon fiber chopped strands are crimped together end to end 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 impregnated with silicone resin.

[0006] Furthermore, the elastic binding thread can be used for single-end binding or middle binding.

[0007] Furthermore, when the elastic binding thread is used for single-end binding, the elastic wire is bound to one end of each section of chopped carbon fiber.

[0008] Furthermore, when using elastic binding thread for middle binding, first use an elastic thread to bind the middle of the carbon fiber chopped filament, fixing the carbon fiber chopped filament to the main elastic core thread; after reversing one side of the carbon fiber chopped filament, use another elastic thread to fix and bind it to the reversed carbon fiber chopped filament next to the first elastic thread.

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

[0010] An elastic mesh reinforcement felt includes high-elasticity carbon fiber yarn and chopped strands; the high-elasticity carbon fiber yarn serves as warp and weft yarns, interlacing to form an elastic mesh fabric, and randomized chopped strands of a predetermined thickness are laid on both sides of the mesh fabric to form an elastic mesh reinforcement felt.

[0011] Furthermore, chopped strands are combined with elastic mesh fabric by needle punching or hydroentangling.

[0012] Furthermore, the materials for the chopped filaments are carbon fiber, quartz fiber, high silica fiber, or basalt fiber.

[0013] Furthermore, when weaving a high-elasticity mesh fabric, the fiber hairs of the high-elasticity carbon fiber warp yarns are oriented in the same direction as the warp feed direction.

[0014] Furthermore, the elastic composite felt strip used for winding the expansion section of the solid rocket engine nozzle uses carbon fiber elastic mesh as the load-bearing skeleton. According to the requirements of the tape winding process, the composite felt is cut into a certain width of felt strip along the length direction. During the felt making process, short filaments or unidirectional cloth are laid according to the cut position of the adhesive tape. The part used for ablation resistance is carbon fiber unidirectional cloth perpendicular to the length direction and a small amount of carbon fiber short filament mesh. The part used for heat insulation is high silica medium-length fiber and high silica glass fiber short filament mesh, mainly in the longitudinal direction. Through needle punching or hydroentangling, some short fibers in the carbon fiber mesh and high silica glass fiber mesh are inserted into the felt so that the various fibers on both sides of the mesh cloth are combined with the elastic mesh cloth in the middle into a whole that is not easy to disperse.

[0015] Compared with the prior art, the present invention has the following technical effects:

[0016] This invention uses a high-strength elastic mesh fabric as the load-bearing material. A certain thickness of randomly oriented chopped filaments is laid on both sides of the mesh fabric. The chopped filaments and the mesh fabric are then bonded together using needle punching or hydroentangling methods to create an elastic composite industrial felt with a certain tensile strength. The industrial felt reinforced with the mesh fabric has a certain tensile strength and can be wound under tension like a fabric tape. It can replace fabric tape in composite material production, with significantly lower material costs and winding time compared to fabric tape. In particular, the industrial felt reinforced with elastic mesh fabric can ensure full adhesion between felts and between felt and the mandrel when winding complex curved surfaces, resulting in wrinkle-free composite products after resin impregnation and curing. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of an industrial felt structure reinforced with a mesh fabric.

[0018] Figure 2 This is a schematic diagram of an industrial felt structure of unequal thickness with non-single fiber type reinforced with mesh fabric.

[0019] Figure 3 This is a schematic diagram of a high-elasticity, high-strength yarn.

[0020] Figure 4 This is a schematic diagram of another type of high-elasticity, high-strength yarn.

[0021] Among them: 1 - main elastic core wire, 2 - chopped carbon fiber, 3 - elastic yarn, 5 - warp yarn, 6 - weft yarn, 7 - chopped yarn, 8 - needle-punched wire nail, 9 - carbon fiber, 10 - high silica glass fiber. Detailed Implementation

[0022] 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.

[0023] 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.

[0024] 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.

[0025] Please see Figures 1 to 4 Using high-strength elastic mesh fabric as the load-bearing material, a certain thickness of randomly oriented short shreds are laid on both sides of the mesh fabric. The short shreds and the mesh fabric are combined into one piece by needle punching or hydroentangling to make an elastic composite industrial felt with a certain tensile strength.

[0026] An elastic mesh reinforcement felt is provided, wherein the warp or weft yarns of the elastic mesh are made of high-strength, high-elasticity yarns. The high-strength, high-elasticity yarns are manufactured using a wrapping spinning process. Short chopped filaments 2 are laid outside the main elastic core 1 and tied tightly to the main elastic core 1 with an elastic filament 4. Then, the elastic filament 4 is knotted and cut at the tip. After one section is completed, the main elastic core 1 is moved forward a certain distance before the next section is wrapped. The spun yarn is impregnated with silicone resin, dried, and then wound into a roll.

[0027] The high-elasticity, high-strength yarn is produced using a wrapping spinning process. A ring of pre-wetted short filaments 2 is applied to the outside of the high-elasticity main elastic core yarn 1. Then, an elastic yarn 3 is used to tie the middle of the high-strength short filaments 2 to the main elastic core yarn 1. After reversing one side of the high-strength short filaments 2, another elastic yarn 3 is used to wrap the high-strength yarn around the first elastic yarn 3 several times. After the elastic yarn is heated and melted, it is cut off. 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. The spun yarn is then coated with silicone resin, dried, and wound into a roll.

[0028] The high-elasticity, high-strength yarn is produced using a warp knitting process, where several sets of fine, high-strength filaments are woven onto a taut elastic core using a knitting machine.

[0029] The materials for the chopped short filaments 7 of the felt are carbon fiber, quartz fiber, high silica fiber, and basalt fiber; the warp and weft fibers of the mesh fabric are carbon fiber, quartz fiber, or basalt fiber, and the elastic materials are spandex, TPU thermoplastic polyurethane elastomer rubber, or other rubbers.

[0030] When weaving high-elasticity mesh fabric, the fiber hair direction of the high-elasticity carbon fiber warp yarn is the same as the warp feed direction.

[0031] The industrial felt reinforced with mesh fabric has an uneven thickness structure. Short chopped fibers of different thicknesses are laid in sections along the weft direction of the mesh fabric according to the designed width. A flat needle punching machine is used to needle the short chopped fibers on both sides of the mesh fabric and the mesh fabric together from the top and bottom directions. Finally, it is cut into long felt strips that are thicker on one side and thinner on the other.

[0032] An elastic composite felt is made on both sides of a carbon fiber elastic mesh, with one side being ablation-resistant fiber and the other side being heat-insulating fiber. The elastic mesh inside the composite felt is elastic in the length direction of the felt strip.

[0033] The elastic composite felt tape used for winding solid rocket engine nozzles uses carbon fiber elastic mesh as the load-bearing skeleton. According to the requirements of the winding process, the composite felt is cut into felt tapes of a certain width along its length. During the felt making process, short filaments or unidirectional cloth are laid according to the cut position of the adhesive tape. The part used for ablation resistance is carbon fiber unidirectional cloth perpendicular to the length direction and a small amount of carbon fiber short filament mesh. The part used for heat insulation is high silica medium-length fiber and high silica glass fiber short filament mesh, mainly in the longitudinal direction. Through needle punching or hydroentangling, some short fibers in the carbon fiber mesh and high silica glass fiber mesh are inserted into the felt, so that the various fibers on both sides of the mesh and the elastic mesh in the middle are combined into a whole that is not easy to disperse.

[0034] Specifically:

[0035] An industrial felt reinforced with a mesh fabric is made by using a high-strength mesh fabric as the load-bearing material, laying random short filaments of a certain thickness on both sides of the mesh fabric, and combining the short filaments on both sides of the mesh fabric with the mesh fabric by needle punching or hydroentangling to make a composite industrial felt with a certain tensile strength.

[0036] To broaden the application of mesh-reinforced industrial felt, a new type of elastic mesh-reinforced felt is proposed. The warp or weft yarns of the high-strength elastic mesh are made of high-strength, high-elasticity yarns, which are manufactured using a wrapping spinning process or woven with filaments outside the elastic core.

[0037] The materials of the short chopped filaments 7 are carbon fiber, quartz fiber, high silica fiber, and basalt fiber; the warp and weft fibers of the mesh fabric are carbon fiber, quartz fiber, or basalt fiber, and the elastic material is spandex, TPU thermoplastic polyurethane elastomer rubber, or other rubbers; when weaving the high elastic mesh fabric, the direction of the fiber hairs of the high elastic carbon fiber warp is the same as the direction of warp feed.

[0038] In cases where the final product does not require the elastic yarn in a certain direction of the mesh fabric in the felt belt to function, the elastic yarn in that direction can be directly replaced by rubber filaments.

[0039] Example 1:

[0040] See Figure 1 A high-silica glass fiber mat reinforced with quartz fiber mesh, used as a replacement for high-silica fabric tape, wherein the reinforcing material uses 80 g / m² of silica fiber. 2 A 10mm×10mm high-strength quartz fiber mesh is used, with a layer of 120g / m² layer laid on each side of the mesh. 2 Randomized 50mm chopped high-silica fibers are used to bond the chopped fibers on both sides of the mesh fabric to the mesh fabric through needle punching in both vertical and horizontal directions on a flat needle punching machine, forming a high-silica glass fiber composite felt with a thickness of approximately 2.5mm. This felt has an operating temperature of 1700℃ and a low thermal conductivity, and can replace pre-impregnated high-silica tape in the winding process for the thermal insulation layer of solid rocket motor nozzles. Flat winding with this felt not only has high production efficiency, but also makes it easy to perform non-penetrating blind seams, and the overall impregnation is also more convenient. The finished product also has better thermal insulation performance due to the higher adhesive content. In addition, wrinkles are less likely to occur during the curing process, and the material cost is much lower than that of pre-impregnated high-silica tape winding.

[0041] Example 2:

[0042] See Figure 1 , Figure 3 and Figure 4A type of chopped carbon fiber felt reinforced with an elastic mesh fabric, wherein the elastic mesh fabric uses high-strength elastic carbon fiber wrapped around elastic yarns as warp yarns. It has an areal density of 80 g / m². 2 A layer of 6mm×6mm carbon fiber elastic mesh with a layer density of 100g / m² is laid on each side. 2 Randomized 70mm short-cut carbon fibers are bonded to the mesh fabric on both sides using a planar needle punching machine, creating a length-direction elastic carbon fiber felt with a thickness of approximately 2mm. This felt has a service temperature exceeding 3000℃ and strong erosion resistance, and can replace pre-impregnated carbon fiber tape in the winding process for fabricating the ablation layer of solid rocket motor nozzles. Using this felt instead of tape winding not only increases production efficiency but also provides excellent overall impregnation of the preform. The finished product also exhibits better ablation resistance and thermal insulation properties due to its higher adhesive content. Furthermore, the curing process is less prone to delamination and wrinkling, and the material cost is significantly lower than that of carbon fiber tape winding. The key to manufacturing carbon fiber felt reinforced with elastic mesh is the production of elastic warp yarns. The elastic warp yarns are manufactured using a wrapping spinning process. High-strength chopped strands 2 are laid outside the high-elasticity main elastic core 1 and tied tightly to the main elastic core 1 with an elastic thread. Then the elastic thread 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 then coated with silicone resin, dried, and wound into rolls. To prevent the chopped carbon fibers from slipping, a longer chopped carbon fiber high-strength chopped filament 2 is applied to the outside of the high-elasticity main elastic core 1. Then, an elastic filament 3 is used to tie the middle of the high-strength chopped filament 2 tightly to the main elastic core 1. After reversing one side of the high-strength chopped filament 2, the elastic filament is wrapped around the elastic filament 3 several times. After the elastic filament is heat-melted, it is cut. After one section is completed, the main elastic core 1 is moved forward a short distance before the next section is laid and wound. The spun yarn is then coated with silicone resin, dried, and wound into a roll. High-elasticity, high-strength yarn can also be produced using warp knitting technology, for example, by using a braiding machine to weave eight T300-500 carbon fiber filaments onto a taut TPU crystal elastic filament with an outer diameter of 0.8mm.

[0043] Example 3:

[0044] See Figure 2A type of elastic mesh reinforced unequal-thickness high-silica glass fiber / carbon fiber double chopped strand mat is disclosed. The elastic mesh is manufactured using a method of intermittently rotating warp yarns and twisting weft yarns. The warp yarns are double-stranded 600tex high-strength elastic carbon fiber wrapped around elastic bands, and the weft yarns are T700-12K carbon fiber filaments, with a surface density of 80g / m² and a mesh spacing of 8mm×8mm. On both sides of the carbon fiber elastic mesh, a layer of chopped strands is laid in the weft direction in the order of 30mm carbon fiber and 50mm high-silica glass fiber, following the warp direction. The chopped strands on both sides of the mesh are then needled together in both upward and downward directions using a flatbed needle punching machine, creating an unequal-thickness elastic composite mat with a minimum thickness of approximately 2mm on the carbon fiber side and a maximum thickness of 5mm on the high-silica glass fiber side. This mat is then cut into strips of a certain width along the weft direction and connected end-to-end to form a wound felt strip. On a tape winding machine, the carbon fiber side of this felt is wound around the inside of the mandrel, and the ablation-resistant layer and the heat insulation layer of the long tail tube of a solid rocket motor are wound in one go using an oblique winding method. The inner carbon fiber composite felt serves as the ablation-resistant layer, and the outer high-silica composite felt serves as the heat insulation layer. Using this felt instead of tape winding not only has high production efficiency, but also excellent overall impregnation of the preform. The finished product also has better ablation resistance and heat insulation performance due to its higher adhesive content. The product density is also lower, and the curing process does not result in delamination and has fewer wrinkles. The production efficiency is high, and the product cost is far lower than that of "carbon fiber + high-silica" tape winding. To further reduce the ablation rate of the carbon fiber felt in the ablation layer and the thermal conductivity of the high-silica felt in the heat insulation layer, more than half of the short carbon fibers in the carbon fiber felt are woven in the longitudinal direction, and more than half of the short high-silica glass fibers in the high-silica felt are warp-oriented. The carbon fiber felt portion of this composite felt is achieved by sandwiching a carbon fiber chopped short fiber mesh between carbon fiber unidirectional fabrics. The carbon fiber direction of the carbon fiber unidirectional fabric is parallel to the weft yarn, and after being fused with the high silica short fiber portion, it is needle-punched into one piece.

[0045] Example 4

[0046] See Figure 4The structure of the high-elasticity yarn, which is a blend of chopped carbon fiber and spandex, consists of three evenly distributed T300-1k carbon fiber filaments on a 0.8mm outer diameter TPU main elastic core 1. A 0.2mm diameter fine TPU crystal elastic thread 3 is used to tie the water-soaked chopped carbon fiber filaments 2 tightly to the main elastic core 1. Then, simultaneously, the three carbon fibers are pulled back 25mm and each is hooked. Immediately afterward, a 0.2mm diameter fine TPU crystal elastic thread 3 is used to tie the carbon fibers tightly near the back of the fine TPU crystal elastic thread 3. Then, the three carbon fibers are folded forward and tied tightly to the outside of 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 of the warp yarns. When carbon fiber is soaked in water, the sizing agent on the weft surface loses its adhesiveness, allowing it to be bent freely without fiber breakage or pilling. After drying, the original affinity between the sizing agent and resin remains unchanged, which is beneficial during the weaving process and subsequent winding process.

[0047] Example 5

[0048] See Figure 2A type of elastic mesh reinforced unequal-thickness high-silica glass fiber / carbon fiber double chopped fiber felt is disclosed. The elastic mesh is manufactured using a method of intermittently rotating warp yarns and twisting weft yarns. Multiple 200tex spandex yarns are used as warp yarns, and T700-12K carbon fiber filaments are used as weft yarns, with an areal density of 80g / m² and a mesh spacing of 6mm×6mm. On both sides of the carbon fiber elastic mesh, a layer of chopped fibers is laid in the weft direction in the order of 30mm carbon fiber and 50mm high-silica glass fiber, following the warp direction. The chopped fibers on both sides of the mesh are then needled together using a planar needle punch in both upward and downward directions to form a single unit. This results in an elastic composite felt with unequal thickness on both sides, exhibiting weft elasticity, with a minimum thickness of approximately 2mm on one side of the carbon fiber felt and a maximum thickness of 5mm on the high-silica glass fiber side. This felt is then cut into long strips of a certain width along the warp direction of the mesh for winding. On a tape winding machine, the carbon fiber side of this felt is wound around the inside of the mandrel, and the ablation-resistant layer and heat insulation layer of the long tail tube and nozzle expansion section of a solid rocket motor are formed in one go using an oblique winding method. The inner carbon fiber composite felt serves as the ablation-resistant layer, and the outer high-silica composite felt serves as the heat insulation layer. On this basis, a blind stitching machine is used to make non-penetrating stitches near the high-silica area of ​​the carbon fiber felt, forming a quasi-three-dimensional preform. Using this felt instead of tape winding not only has high production efficiency, but also excellent overall resin penetration of the preform. The finished product also has better ablation resistance and heat insulation performance due to the higher resin content. The product density is also lower, and the curing process does not result in delamination and fewer wrinkles. The production efficiency is high, and the product cost is much lower than that of carbon fiber tape winding. To further reduce the ablation rate of the carbon fiber felt in the ablation layer and the thermal conductivity of the high-silica felt in the heat insulation layer, more than half of the chopped carbon fibers in the carbon fiber felt are in the weft direction, and more than half of the chopped high-silica glass fibers in the high-silica felt are in the warp direction. The carbon fiber felt portion of this composite felt is achieved by sandwiching a carbon fiber chopped short fiber mesh between carbon fiber unidirectional fabrics. The carbon fiber direction of the carbon fiber unidirectional fabric is parallel to the weft yarn, and after being fused with the high silica short fiber portion, it is needle-punched into one piece.

[0049] 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 an 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 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. Elastic binding tape can be used for single-end binding or middle binding; When the elastic binding thread is used for single-end binding, the elastic wire (3) is bound to one end of each section of carbon fiber short shred (2); When the elastic binding wire is used for middle binding, one elastic wire (3) is bound to the middle of the carbon fiber short filament (2) and fixed to the main elastic core wire (1); after one side of the carbon fiber short filament (2) is reversed, another elastic wire is used to fix and bind it to the reversed carbon fiber short filament (2) next to the first elastic wire (3).

2. An elastic mesh reinforced felt, characterized in that, It includes the high-elasticity carbon fiber yarn and chopped strands (7) as described in claim 1; the high-elasticity carbon fiber yarn serves as the warp and weft yarns, which are interwoven to form an elastic mesh fabric, and random chopped strands (7) of a predetermined thickness are laid on both sides of the mesh fabric to form an elastic mesh fabric reinforcing felt.

3. The elastic mesh reinforcement felt according to claim 2, characterized in that, The chopped filaments (7) are combined with the elastic mesh fabric by needle punching or hydroentangling.

4. The elastic mesh reinforcement felt according to claim 2, characterized in that, The material of the short filaments (7) is carbon fiber, quartz fiber, high silica fiber or basalt fiber.

5. The elastic mesh reinforcement felt according to claim 2, characterized in that, When weaving high-elasticity mesh fabric, the fiber hair direction of the high-elasticity carbon fiber warp yarn is the same as the warp feed direction.

6. The elastic mesh reinforcement felt according to claim 2, characterized in that, Elastic mesh reinforced felt is used for wrapping the expansion section of solid rocket motor nozzles.

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