A metal component-containing combined elastic fabric and a method for manufacturing the same

Abstract

The application discloses a preparation method of a combined elastic fabric containing metal components, the fabric comprising upper and lower surface layers and a core layer, the core layer comprising a filling layer, the filling layer comprising metal component-containing fibers or metal components, the preparation method comprising the following steps: step 1, according to the design requirements of the fabric, it is determined whether the core layer needs to be provided with a connecting layer according to whether the softness of the metal component-containing fibers or metal components of the filling layer can meet the requirements of bending, looping and looping-off on a loom; if the requirements are met, the metal component-containing fibers directly participate in weaving without the connecting layer, otherwise, the connecting layer structure is further designed according to the distribution area of the metal components; step 2, the structure of the upper and lower surface layers of the fabric is designed, and a weaving method is designed; and step 3, the weaving and forming of the combined elastic fabric are developed. The core layer structure of the fabric can be designed according to the fabric requirements, the flexible introduction of the metal components can be realized, and the content and position of the fibers and the metal components in the fabric can be controlled according to the design requirements.

Description

Technical Field

[0001] This invention relates to the field of high-performance fiber knitting technology, specifically to an elastic fabric containing metal components and its preparation method. Background Technology

[0002] With the continuous development of fiber-reinforced composite material technology and the expansion of its application fields, knitted structures have attracted widespread attention due to their excellent deformability and energy absorption. They can be divided into warp-knitted fabrics and weft-knitted fabrics based on different processing characteristics. Warp-knitted structures, due to their good dimensional stability, relatively lower elongation compared to weft-knitted fabrics, and higher fabric strength and modulus, account for a large proportion in the field of composite material reinforcement. In particular, the development of biaxial and multiaxial warp-knitted fabrics has further optimized the performance of warp-knitted fabrics. Weft-knitted fabrics, on the other hand, feature low production costs, short production processes and high production efficiency, strong structural designability, excellent formability, good elongation and drape, making them more suitable for molding complex components. They have been successfully used in aerospace, transportation, construction, biomedicine, and sports industries.

[0003] With the continuous development of advanced spacecraft, the demand for advanced and innovative structural materials operating at ultra-high temperatures is also constantly increasing. Components such as rocket engine heads and rudders of morphing vehicles operate in harsh environments, requiring materials with ablation resistance, high-temperature resistance, and a certain degree of deformability. Knitted fabrics possess high plasticity, and weft-knitted fabrics, as reinforcements in composite materials, exhibit excellent performance in elasticity and elongation. Combined with the high strength, high modulus, and low density of high-performance fibers, they possess advantages that other composite materials cannot match. Compared to other textile composite structures, weft-knitted fabrics have a mesh structure with good deformability, but their higher porosity results in lower ablation resistance. The introduction of refractory metals can effectively improve the ablation resistance of composite components. Summary of the Invention

[0004] The purpose of this invention is to provide a composite elastic fabric containing metal components and its preparation method. The formed composite elastic fabric has high designability, and the metal components are introduced into it to make it a whole.

[0005] To achieve the purpose of the appeal, the present invention provides the following technical solution:

[0006] A method for preparing a composite elastic fabric containing metal components, the fabric comprising upper and lower surface layers and a core layer, the core layer comprising a filling layer comprising fibers or metal components containing metal components, the preparation method comprising the following steps:

[0007] Step 1: Based on the fabric design requirements, determine whether a connecting layer is needed for the core layer, depending on whether the softness of the fibers or metal components in the filling layer can meet the requirements for loop formation and loop release on the machine. If the softness of the fibers or metal components can meet the requirements for loop formation and loop release on the machine, they can directly participate in weaving without a connecting layer. If the softness of the fibers or metal components cannot meet the requirements for loop formation and loop release on the machine, a connecting layer structure is further designed based on the distribution area of ​​the metal components.

[0008] Step 2: Design the upper and lower surface structure of the fabric, and design the distribution area of ​​the metal components and the weaving method according to the fabric structure and size.

[0009] Step 3: According to the weaving method, unfold and shape the combined elastic fabric.

[0010] Furthermore, the core layer is provided with a connecting layer, and steps 2 and 3 specifically involve:

[0011] The fabric is designed with plain knit for the top and bottom layers and tuck knit for the connecting layer. The first fiber is introduced transversely into the front and rear needle beds, and the top and bottom layers are knitted using plain knit. The second fiber is then introduced transversely into the needle beds in a tuck knit pattern to complete the first connecting layer. A positive yarn feed method is then used to feed the metal components into the needle beds. After the metal components are fed in along the width of the fabric, the second connecting layer is introduced, forming a second connecting layer that is offset from the first connecting layer to fix the introduced metal components, thus completing the first row of loops. After the first row of loops is completed, the top and bottom layers and the first and second connecting layers in tuck knit form are suspended on the front and rear needle beds respectively. On the crochet hook, the hook begins to unwind, pulling the first row of loops from the hook to the needle bar. Then, the yarn is padded and bent to form the upper and lower layers of the second row of loops inside the hook. Through looping and unlooping, the first row of loops is removed from the needle. At this point, only the upper and lower layers of the second row of loops remain on the needle. The first connecting layer of the second row of loops is then woven. The metal component yarn is fed into the weft again through active yarn feeding, introducing the second connecting layer of the second row of loops. This forms the second connecting layer of the second row of loops, which is offset from the first connecting layer of the second row of loops, and is used to fix the introduced metal component. This completes the weaving of the second row of loops. This process is repeated until the entire fabric is woven and formed.

[0012] Furthermore, the core layer does not have a connecting layer, and steps 2 and 3 specifically involve:

[0013] The first fiber is introduced into the front needle bed to complete the knitting of the surface plain knit structure, that is, to complete the knitting of the first row of loops. The first row of loops is suspended on the hook in the front needle bed. After loop removal, yarn padding, yarn bending, looping, and loop release, the first row of loops is released from the needle and forms the second row of loops. At this time, there are only the second row of loops on the needle. This loop knitting process is repeated until the fabric is knitted to the designated metal area. Fibers containing metal components are inserted into the hook in the form of weft inserts. At this time, there are only the first row of loops on the needle. After loop removal, yarn padding, yarn bending, looping, and loop release, the first row of loops is released from the needle and forms the current row of loops. After the current row of loops is formed, the filling layer exists on the surface of the fabric in the form of a weft insert structure.

[0014] Furthermore, the upper and lower surface yarns and the connecting layer yarns are at least one of carbon fiber, quartz fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber.

[0015] Furthermore, the fiber containing metal components is a high-performance fiber treated with carbides or borides of metal elements, and the metal components are one or more, single or multiple metal wires.

[0016] Furthermore, the connecting layer includes V-shaped bends.

[0017] Furthermore, the fabric is a trapezoidal elastic quartz fiber knitted fabric, and the metal component is a tungsten wire with a diameter of 0.3 mm.

[0018] Furthermore, an active yarn feeding method is used to feed tungsten wire into the needle bed in a measured amount under the clamping of the yarn feed wheel and the drive belt.

[0019] Furthermore, the metal-containing fiber is formed by treating the surface of 3K carbon fiber with nano-sized ZrC through a spraying process.

[0020] An elastic fabric containing metal components, characterized in that the fabric is prepared by the method described above.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. This method combines the advantages of short production process and fast forming of weft knitting technology, and combines positive yarn feeding to introduce metal components. The forming method is simple and can realize the integrated forming of combined elastic fabrics containing metal components.

[0023] 2. The fabric core structure of the present invention can be designed according to the fabric requirements, and can realize the flexible introduction of metal components. The content and position of fibers and metal components in the fabric can be controlled according to the design requirements.

[0024] 3. The connecting layer proposed in this invention can stably fix the position of the metal components in the fabric structure, prevent the metal components from slipping in the fabric, effectively improve the stability of the fabric, and the form and location of the connecting layer can be flexibly varied according to the location of the metal components, with strong design flexibility. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the metal distribution in a trapezoidal elastic knitted fabric.

[0026] Figure 2 This is a schematic diagram of various connection layer connection methods.

[0027] Figure 3 This is a structural diagram of a trapezoidal elastic quartz fiber knitted fabric.

[0028] Figure 4 This is a schematic diagram of the active yarn feeding principle.

[0029] Figure 5 This is a schematic diagram of the metal component distribution of a square carbon fiber elastic fabric.

[0030] Figure 6 This is a schematic diagram of a square carbon fiber elastic fabric structure. Detailed Implementation

[0031] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The present invention can be better understood from the following embodiments. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0032] Example 1

[0033] Combination Figure 1 , Figure 2 , Figure 3 The present invention describes a method for preparing an elastic fabric containing metal components, taking a trapezoidal elastic quartz fiber knitted fabric with uniformly distributed metal components as an example.

[0034] Step 1: The metal component introduced into the trapezoidal elastic quartz fiber knitted fabric is a 0.3mm diameter tungsten wire. The tungsten wire is fine but has high hardness and poor deformability, so it cannot participate in the knitting needle loop formation and loop release. The tungsten wire exists as a filling layer in the core layer of the fabric. Further design of a connecting layer is required to fix the position of the tungsten wire in the fabric.

[0035] Step 2: Combine with the attached Figure 1In the trapezoidal elastic quartz fiber knitted fabric, the filling layer tungsten filaments 1 are uniformly distributed along the length direction within the fabric plane. Based on the distribution of the tungsten filaments, the distribution and form of the fabric connecting layer are further designed, as shown in the appendix. Figure 2 As shown in Figure (1), the connection layer structure uses a "V" shape as the basic unit to complete the design of the upper connection layer;

[0036] Step 3: Further design the fabric surface layer structure as plain knit, design the fabric connecting layer as tuck knit, and draw the trapezoidal elastic quartz fiber knitted fabric knitting program according to the fabric structure and external dimensions.

[0037] Step 4: According to the knitting program for trapezoidal elastic quartz fiber knitted fabric, introduce 195tex quartz fiber into the front and back needle beds transversely along the fabric. Use plain knit to complete the upper and lower surface layers. Introduce 72tex quartz fiber into the needle beds transversely along the fabric in a tufting manner to complete the first connecting layer knitting, as shown in the attached diagram. Figure 2 As shown in Figure (1)a, the loops are tucked in a “V” shape. Since the tungsten wire introduced as a filling layer has a high hardness, an active yarn feeding method is required during the introduction of the tungsten wire into the needle bed under the clamping of the yarn feed wheel and the drive belt. The working principle is as follows: Figure 4 As shown. After the tungsten wire is fed in along the width of the fabric, it is introduced again into the bonding layer, as shown in the attached diagram. Figure 2 As shown in Figure (1)b, a connecting layer is formed that is offset from the first connecting layer to fix the introduced tungsten wire, thus completing the first row of the fabric. After the first row of the fabric is completed, the upper and lower surface layers and the tucked structure are suspended on the hooks in the front and rear needle beds, respectively. At this time, the hook begins to perform the unhooking action, pulling the first row of loops that were originally hanging on the hook to the needle bar. Then, the yarn padding and bending actions are performed to form a new loop in the hook. The old loops of the first row are then removed from the needle through looping and unhooking. At this time, there are only the second row of loops on the needle. The tungsten wire is fed into the knitting hole again by actively feeding the yarn. This process is repeated until the entire fabric is knitted and formed. The fabric structure is as follows: Figure 3 As shown, the connection layer can also be used. Figure 2 The form in (2)-(5) of the figure.

[0038] The prepared trapezoidal elastic fabric has a height of 200 mm, with upper and lower side lengths of 100 mm and 200 mm respectively. The fiber volume content is not less than 25%, of which the metal component content is 28.3%. The component content in each region varies uniformly along the length of the fabric, and the fabric elasticity can reach 40%.

[0039] Example 2

[0040] Combined with appendix Figure 5 Appendix Figure 6The present invention describes a method for preparing an elastic fabric containing metal components, taking a square carbon fiber knitted fabric with unevenly distributed metal components as an example.

[0041] Step 1: The metal component selected for this square carbon fiber knitted fabric is nano-sized ZrC. Nano-sized ZrC is applied to the surface of 3K carbon fiber through a spraying process. The treated carbon fiber is introduced as the filling layer of the fabric core. Since the 3K carbon fiber treated with ZrC can complete the looping and unlooping action of the knitting needles, there is no need for a connecting layer.

[0042] Step 2: Combine with the attached Figure 5 The metal components are irregularly distributed in the square carbon fiber knitted fabric. Based on the distribution of the metal components, the method and location of introducing the fabric filling layer are further designed.

[0043] Step 3: Design the fabric structure as plain knit, with the filling layer being 3K carbon fiber containing nano-sized ZrC after treatment. The filling layer is directly inserted into the surface structure by weft insertion.

[0044] Step 4: According to the knitting program for square elastic carbon fiber knitted fabric, introduce 6K carbon fiber into the front needle bed to complete the surface plain knit structure. After the first row is completed, the formed loops are suspended on the hooks in the front and rear needle beds. After a series of actions such as loop removal, yarn padding, yarn bending, looping, and loop formation, the old loops of the first row are removed from the needles and new loops are formed. At this time, only the second row of formed loops are on the needles. Repeat this loop formation process until the fabric is knitted to the designated metal area. At this time, 3K carbon fiber treated with ZrC is inserted into the hooks as a weft insert. After the new loops are formed, the filling layer exists on the surface of the fabric in the form of a weft insert structure. The fabric structure is shown in the attached figure. Figure 6 As shown.

[0045] The prepared square elastic carbon fiber knitted fabric has a length and width of 200mm, a fiber volume content of not less than 25%, an introduced metal component content of 10%, and a uniform component content in each region. The fabric elasticity can reach 42.5%.

[0046] This invention provides a composite elastic fabric containing metal components and its preparation method based on weft knitting forming technology. It can flexibly control the fabric structure parameters according to the fabric design needs, enhance the flexibility of the performance design of composite elastic fabrics, and modify the corresponding equipment to realize the smooth introduction of metal components.

[0047] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing an elastic fabric containing metal components, the fabric comprising upper and lower surface layers and a core layer, the core layer comprising a filling layer comprising fibers or metal components containing metal components, characterized in that, The preparation method includes the following steps: Step 1: Based on the fabric design requirements, determine whether a connecting layer is needed for the core layer, depending on whether the softness of the fibers or metal components in the filling layer can meet the requirements for loop formation and loop release on the machine. If the softness of the fibers or metal components can meet the requirements for loop formation and loop release on the machine, they can directly participate in weaving without a connecting layer. If the softness of the fibers or metal components cannot meet the requirements for loop formation and loop release on the machine, a connecting layer structure is further designed based on the distribution area of ​​the metal components. Step 2: Design the upper and lower surface structure of the fabric, and design the distribution area of ​​the metal components and the weaving method according to the fabric structure and size. Step 3: According to the weaving method, unfold and shape the combined elastic fabric; The core layer is provided with a connecting layer, and steps 2 and 3 are specifically as follows: The fabric is designed with plain knit for the upper and lower surface layers and tuck knit for the connecting layer. The connecting layer consists of a first connecting layer and a second connecting layer. The first fiber is introduced transversely into the front and rear needle beds, and the upper and lower surface layers are knitted using plain knit. The second fiber is then introduced transversely into the needle beds in a tuck knit manner, completing the first connecting layer. A positive yarn feed method is then used to feed the metal components into the needle beds. After the metal components are fed in along the width of the fabric, the second fiber is knitted into the second connecting layer in a tuck knit manner, forming a second connecting layer that is offset from the first connecting layer to fix the introduced metal components, thus completing the first row of loops. After the first row of loops is completed, the resulting upper and lower surface layers and tuck knit structure... The first and second connecting layers are suspended on the hooks in the front and rear needle beds, respectively. At this time, the hooks begin to perform the unhooking action, pulling the first row of loops originally hanging on the hook to the needle bar. Then, the yarn padding and bending actions are performed to form the upper and lower surfaces of the second row of loops inside the hook. The first row of loops is then removed from the needle through looping and unhooking. At this time, only the upper and lower surfaces of the second row of loops remain on the needle. The first connecting layer of the second row of loops is then woven. The metal component yarn is fed into the weaving hole again through active yarn feeding, introducing the second connecting layer of the second row of loops. This forms the second connecting layer of the second row of loops, which is offset from the first connecting layer of the second row of loops, and is used to fix the introduced metal component. This completes the weaving of the second row of loops. This process is repeated until the entire piece of fabric is woven and formed. The connecting layer is formed by the second fiber forming multiple rows of loops with V-shaped bends between the upper and lower surfaces. The V-shaped bends come into contact with the metal components, thereby causing the first connecting layer and the second connecting layer to be staggered.

2. The method for preparing a metal-containing composite elastic fabric according to claim 1, characterized in that, The upper and lower surface yarns and the connecting layer yarns are at least one of carbon fiber, quartz fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber.

3. The method for preparing a metal-containing composite elastic fabric according to claim 1, characterized in that, Fibers containing metal components are high-performance fibers treated with carbides or borides of metal elements. The metal components are one or more, single or multiple metal wires.

4. The method for preparing a metal-containing composite elastic fabric according to claim 1, characterized in that, The fabric is a trapezoidal elastic quartz fiber knitted fabric, and the metal component is a tungsten wire with a diameter of 0.3 mm.

5. The method for preparing a metal-containing composite elastic fabric according to claim 4, characterized in that, The positive yarn feeding method is used to feed the tungsten wire into the needle bed in a quantitative manner under the clamping of the yarn feed wheel and the drive belt.

6. The method for preparing a metal-containing composite elastic fabric according to claim 1, characterized in that, The fiber containing the metal component is formed by treating the surface of 3K carbon fiber with nano-sized ZrC through a spraying process.

7. An elastic fabric containing metal components, characterized in that, The fabric is prepared by the method according to any one of claims 1-6.

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