Hybrid fabric

Abstract

Described herein are carbon fiber and glass fiber hybrid fabrics having a total weight per unit area of less than about 500 g / m2.

Description

Technical Field

[0001] The present invention relates to hybrid fabrics comprising carbon fibres and glass fibres, in particular hybrid fabrics which can be used in combination with reinforcement elements in structural components such as wind turbine blades or related components such as spar caps. Background Art

[0002] Carbon fiber reinforced materials are electrically conductive and exhibit good mechanical properties, including stiffness and tensile strength, at low density. Therefore, carbon fiber reinforced materials can be used to reinforce structural components such as wind turbine blades or related components.

[0003] It is well known to use pultruded carbon fiber to reinforce structural components such as wind turbine blades or related components such as spar caps. These structural components are typically formed by laying up a carbon pultruded sheet into a mold, filling the mold with resin, and curing the resin to form the component.

[0004] Traditionally, wind turbine blades are made of non-conductive materials such as glass fiber reinforced polymers / plastics. However, incorporating conductive reinforcement components (such as carbon components) in wind turbine blades in order to minimize damage to wind turbine blades during lightning strikes has created new challenges.

[0005] Carbon fiber reinforced materials (such as pultruded carbon fiber panels) used in the production of wind turbine blades or related components can be bonded together using a hybrid fabric containing carbon fiber and glass fiber that can be more easily infused with resin than carbon reinforced materials (such as pultruded carbon fiber panels), as well as providing a conductive layer between the pultruded carbon fiber panels.

[0006] It would be desirable to provide a hybrid fabric that is lightweight, dimensionally stable and also resistant to handling, to allow for improved production efficiency of wind turbine blades or related components. Summary of the invention

[0007] In most general terms, the present invention provides a carbon fiber and glass fiber hybrid fabric having a weight of less than about 1000 g / m 2 , for example less than about 500 g / m 2 The hybrid fabric may include: a first layer comprising first fibers, the first fibers comprising carbon fibers oriented in a first direction; and a second layer comprising second fibers, the second fibers being stabilizing fibers oriented in a second direction, the first fibers and the second fibers being held in their respective orientations by stitching yarns, the fabric having a unit area weight of less than about 1000 g / m 2 , for example less than about 500 g / m 2 .

[0008] The inventors have discovered that the present invention allows for the provision of a low total basis weight (i.e., less than about 1000 g / m 2 , for example less than about 500 g / m 2 The present inventors have also found that providing such a hybrid fabric improves the production efficiency of wind turbine blades or related components.

[0009] In a first aspect, the present invention provides a carbon fiber and glass fiber hybrid fabric comprising:

[0010] a first layer comprising first fibers oriented in a first direction;

[0011] a second layer comprising second fibers oriented in a second direction;

[0012] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0013] wherein the second direction is within about 45 degrees to about 90 degrees of the first direction,

[0014] The first fiber comprises a carbon fiber,

[0015] The second fibers include stabilizing fibers,

[0016] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0017] The first fibers comprise at least about 15% by weight of the fabric, and

[0018] The second fibers comprise less than about 50% by weight of the fabric.

[0019] In a second aspect, the present invention provides a method for producing a carbon fiber and glass fiber hybrid fabric, the method comprising:

[0020] providing a first layer comprising first fibers oriented in a first direction, the first fibers comprising carbon fibers;

[0021] providing a second layer comprising second fibers oriented in a second direction, the second fibers comprising stabilizing fibers, the second layer being disposed on the first layer, the second direction being within about 45 degrees to about 90 degrees of the first direction;

[0022] The first layer and the second layer are stitched together using a stitching yarn to form a layer having a thickness of less than about 500 g / m 2 The unit area weight of mixed fabrics,

[0023] The first fibers comprise at least about 15% by weight of the fabric and the second fibers comprise up to about 50% by weight of the fabric.

[0024] In a third aspect, the present invention provides a composite article comprising a hybrid fabric as described herein.

[0025] In a fourth aspect, the present invention provides a wind turbine blade comprising a hybrid fabric as described herein or a composite article as described herein.

[0026] In a fifth aspect, the present invention provides a texturized yarn for providing a yarn having a weight of less than about 500 g / m 2 Used in carbon fiber and glass fiber mixed fabrics with a unit area weight of 1.

[0027] The present invention includes any combination of aspects and preferred features described herein except where such a combination is expressly impermissible or expressly avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Embodiments and experiments illustrating the principles of the present invention will now be discussed with reference to the accompanying drawings, in which:

[0029] Figure 1 is a schematic diagram showing a fabric according to an embodiment of the present invention;

[0030] Figure 2 yes Figure 1 An enlarged view of section A is shown;

[0031] Figure 3a is a photograph of a fabric formed from Example 1;

[0032] Figure 3b is a photograph of a fabric formed from Example 2;

[0033] Figure 3c is a photograph of a fabric formed from Example 3; and

[0034] Figure 4 is a schematic diagram of a cross section through a texturized yarn. DETAILED DESCRIPTION

[0035] Various aspects and embodiments of the present invention will now be discussed with reference to the accompanying drawings. Additional aspects and embodiments will be apparent to those skilled in the art. All documents mentioned herein are incorporated herein by reference.

[0036] The term "glass fiber" is used herein to refer to a plurality of continuous glass filaments (the term "continuous" as used herein is used to refer to fibers / filaments having a length that is many times its diameter, such as at least about 5000 times its diameter, such as at least about 10,000 times its diameter). The glass fibers used in the fabrics described herein may be provided as glass fiber strands (or tows). The glass fibers described herein (e.g., the glass fibers of the second fibers and / or the third fibers) may have a sizing agent on their surface, such as the second fibers and / or the third fibers may have a sizing agent applied to the glass fibers during fiber formation. The sizing agent may include components that promote the formation of the glass fibers and / or their use in the matrix resin, such as film formers, lubricants, coupling agents (to promote compatibility between the glass fibers and the resin used to form the composite product comprising the hybrid fabric described herein), etc. In some embodiments, the glass fibers of the first fibers and / or the third fibers include a polyester compatible sizing agent or an epoxy resin compatible sizing agent.

[0037] As used herein, the term "glass fiber strand" or "glass fiber tow" refers to a bundle of continuous glass filaments. In an embodiment, the glass fiber strand or tow is a plurality of bundles of untwisted glass filaments.

[0038] In an embodiment, the glass fiber strands or glass fiber bundles are provided by glass fiber direct rovings. Glass fiber direct rovings consist of a bundle of continuous untwisted (ie, substantially parallel or parallel) glass filaments bonded (when forming glass filaments) into a single strand and wound onto a bobbin.

[0039] The term "textured yarn" refers to a strand of fiber, such as fiberglass, that comprises, consists essentially of, or consists of a bundle of continuous filaments (eg, an unbonded bundle of continuous filaments) that has been texturized in a turbulent flow of compressed air. Figure 4 A schematic diagram of a cross section through a "textured yarn" (eg, a textured glass yarn) is shown.

[0040] The term "textured glass yarn" refers to a strand of glass fibers that comprises, consists essentially of, or consists of a bundle of continuous glass filaments (e.g., an unbonded bundle of continuous glass filaments) that have been texturized in a turbulent stream of compressed air. The glass filaments forming the texturized glass yarn may be made of E glass, E-CR glass (such as Advantex TM Glass), H glass, S glass or AR glass types. An example of a suitable crimped textured glass yarn is ECT9 T140 K252C (available from Vetrotex TM ). Figure 4 A schematic diagram of a cross section through a "textured glass yarn" is shown in FIG.

[0041] Figure 4A textured yarn, such as textured glass yarn 104a, is shown, which includes an enlarged section B, such as having a diameter d B When a bundle of continuous filaments, such as glass filaments (a strand of filaments, such as a strand of glass filaments) passes through the turbulent flow of compressed air, the expanded section B of the crimped yarn is formed. Figure 4 The texturized yarn (eg, texturized glass yarn) 104a shown in FIG. 1 shows a yarn having a diameter d B The expanded section B has a diameter d S The unexpanded sections S are interspersed together. Diameter d S The minimum diameter of the crimped glass yarn. B The diameter d may be at least 10% greater than the smallest diameter of the textured yarn. Thus, in embodiments, a "textured yarn" (e.g., a textured glass yarn) refers to a strand of fiber (e.g., a strand of glass fiber) that includes a plurality of bulked sections (e.g., bulked sections formed when a strand of fiber is exposed to turbulent flow of compressed air). The diameter d B or S It can be determined by placing a strand of texturized yarn (e.g., a strand of texturized glass yarn) in a straight line on a flat surface with no tension applied to the texturized yarn and measuring the diameter in the bulked or unbulked section, respectively, using, for example, a measuring tape, by measuring the width of the texturized yarn perpendicular to the length of the texturized yarn. The minimum diameter can be taken as the minimum diameter of a given length of texturized yarn (e.g., a strand of texturized glass yarn), such as the minimum diameter of a 10 cm length of texturized yarn (e.g., a strand of texturized glass yarn), or the minimum diameter of texturized yarn (e.g., a strand of texturized glass yarn) along the length of the texturized yarn (e.g., a strand of texturized glass yarn) in a hybrid fabric.

[0042] The term "carbon fiber" is used herein to refer to a plurality of continuous carbon filaments (the term "continuous" as used herein is used to refer to a fiber / filament having a length that is many times its diameter, such as at least about 5000 times its diameter, such as at least about 10 000 times its diameter). The carbon fibers used in the fabrics described herein may be provided as carbon fiber tows (or strands), which are bundles of continuous carbon filaments. The carbon fibers described herein (e.g., the carbon fibers of the first fiber and / or the fourth fiber) may have a sizing agent on their surface, such as the first fiber and / or the fourth fiber may have a sizing agent applied to the carbon fibers during fiber formation. The sizing agent may include components that promote the formation of carbon fibers and / or their use in a matrix resin, such as a film former, a lubricant, a coupling agent (to promote compatibility between carbon fibers and a resin used to form a composite product comprising a hybrid fabric described herein), etc. In some embodiments, the carbon fibers of the first fiber and / or the fourth fiber include a polyester compatible sizing agent or an epoxy resin compatible sizing agent.

[0043] The present invention provides a kind of carbon fiber and glass fiber hybrid fabric, it comprises the first layer and the second layer, the first layer comprises the first fiber oriented in the first direction, and the second layer comprises the second fiber oriented in the second direction.This hybrid fabric is a wrinkle-free fabric, and the first fiber and the second fiber are maintained at their corresponding orientation (rather than the first fiber and the second fiber are woven together, i.e. the wrinkle-free fabric is a nonwoven fabric) by stitching yarn.The second direction is within about 45 degrees to about 90 degrees in the first direction, for example, the second direction can be within about 60 degrees to about 90 degrees in the first direction, within about 70 degrees to about 90 degrees in the first direction, within about 80 degrees to about 90 degrees in the first direction, within about 85 degrees to about 90 degrees in the first direction, within about 88 degrees to about 90 degrees in the first direction, or within about 90 degrees in the first direction.In an embodiment, the second direction is substantially perpendicular to the first direction.

[0044] The first layer comprises first fibers oriented in a first direction, the first fibers comprising carbon fibers. In an embodiment, the first layer comprises, consists essentially of, or consists of first fibers. In an embodiment, the first fibers comprise, consist essentially of, or consist of carbon fibers. In an embodiment, the first fibers are carbon fibers.

[0045] In an embodiment, the first layer comprises the first fiber and the third fiber, is basically composed of the first fiber and the third fiber, or is composed of the first fiber and the third fiber, the first fiber is oriented along the first direction and the third fiber is oriented along the third direction. The third fiber may include glass fiber. In an embodiment, the third fiber comprises glass fiber, is basically composed of glass fiber, or is composed of glass fiber. In an embodiment, the third fiber is glass fiber. In an embodiment, the first layer comprises carbon fiber (the first fiber) and glass fiber (the third fiber), is basically composed of carbon fiber and glass fiber, or is composed of carbon fiber and glass fiber. In an embodiment, the first direction and the third direction are the same direction (i.e. the third direction can be aligned with the first direction).

[0046] In an embodiment, the first fibers, such as carbon fibers oriented in a first direction, have a thickness of about 100 tex to about 5000 tex, such as about 200 tex to about 5000 tex, about 400 tex to about 5000 tex, about 600 tex to about 5000 tex, about 800 tex to about 5000 tex, about 100 tex to about 4800 tex, about 200 tex to about 4800 tex, 400 tex to about 4800 tex, about 600 tex to about 4800 tex, tex, about 800 tex to about 4800 tex, about 100 tex to about 2400 tex, about 200 tex to about 2400 tex, about 400 tex to about 2400 tex, about 100 tex to about 2000 tex, about 200 tex to about 2000 tex, about 400 tex to about 2000 tex, about 600 tex to about 2000 tex, about 800 tex to about 2000 tex, or about 1200 tex.

[0047] In an embodiment, the first fibers, such as carbon fibers oriented in the first direction, have a diameter in a range from about 5 μm to about 15 μm, such as from about 5 μm to about 11 μm.

[0048] In an embodiment, the first layer comprises a plurality of first fiber strands. In an embodiment, the first fiber strands are carbon fiber tows. In an embodiment, the size of the carbon fiber tows ranges from 6K to 50K, such as 6K to 24K or 6K to 12K. For example, the first fibers may be fed from one or more carbon fiber tows ranging in size from 6K to 50K, such as 6K to 24K or 6K to 12K. The designation #K means that the carbon tow is composed of #×1,000 individual carbon filaments, i.e., a carbon fiber tow of size 6K is composed of approximately 6000 carbon fiber filaments / fibers.

[0049] In an embodiment, the first layer comprises a plurality of first fiber strands, the first layer having a first fiber strand count in the range of about 0.25 to about 5 tows per cm, or about 0.25 to about 2.5 tows per cm. In an embodiment, the first layer comprises a plurality of carbon fiber tows (e.g., a plurality of carbon fiber tows, and each of the plurality of carbon fiber tows has a size in the range of 6K to 50K, e.g., 6K to 24K, or 6K to 12K), the first layer having a carbon fiber tow count in the range of about 0.25 to about 5 tows per cm, or about 0.25 to about 2.5 tows per cm. The number of carbon fiber tows per cm is measured in a direction substantially perpendicular to the first direction, e.g., measured in the second direction.

[0050] In an embodiment, the third fibers, e.g., glass fibers (or glass fiber strands) oriented in the first direction, have a linear mass density in a range of about 50 tex to about 5000 tex, e.g., about 50 tex to about 2000 tex, about 50 tex to about 1200 tex, about 500 tex to about 1200 tex.

[0051] Any suitable glass reinforcing fiber can be used as the third fiber. For example, E glass, E-CR glass (such as Advantex TM Glass), H glass, S glass, and AR glass types. The glass fiber used as the third fiber may have a diameter in the range of about 7 μm to about 25 μm, for example, about 9 μm to about 17 μm.

[0052] The first fibers (e.g., carbon fibers oriented in a first direction) may comprise at least about 15 weight percent of the fabric, e.g., at least about 20 weight percent, at least about 25 weight percent, at least about 30 weight percent, at least about 35 weight percent, at least about 40 weight percent, at least about 45 weight percent, or at least about 50 weight percent of the total weight of the fabric. In an embodiment, the first fibers (e.g., carbon fibers oriented in a first direction) comprise from about 15% to about 80% by weight of the total weight of the fabric, for example, from about 15% to about 70% by weight, from about 15% to about 60% by weight, from about 20% to about 75% by weight, from about 25% to about 75% by weight, from about 25% to about 70% by weight, from about 25% to about 60% by weight, from about 30% to about 75% by weight, from about 30% to about 70% by weight, from about 30% to about 60% by weight, from about 35% to about 75% by weight, from about 35% to about 70% by weight, from about 35% to about 60% by weight, from about 40% to about 75% by weight, from about 40% to about 70% by weight, from about 40% to about 60% by weight, from about 50% to about 75% by weight, from about 50% to about 70% by weight, from about 50% to about 60% by weight. In an embodiment, the first fibers (e.g., carbon fibers oriented in a first direction) may comprise from about 15% to about 80% by weight of the fabric, e.g., from about 15% to about 70% by weight of the fabric, from about 15% to about 60% by weight of the fabric, from about 20% to about 75% by weight of the fabric, from about 20% to about 70% by weight of the fabric, from about 20% to about 60% by weight of the fabric.

[0053] The third fibers (e.g., glass fibers oriented in a third direction) can account for up to about 70% by weight of the total weight of the fabric, such as up to about 50% by weight, up to about 40% by weight, up to about 30% by weight, or up to about 20% by weight of the total weight of the fabric. In an embodiment, the third fibers (e.g., glass fibers oriented in a first direction) account for about 0% by weight to about 70% by weight of the total weight of the fabric, such as about 2% by weight to about 50% by weight, about 5% by weight to about 30% by weight, or about 2% by weight to about 20% by weight.

[0054] In an embodiment, the fibers of the first layer (e.g., first fibers oriented in a first direction and, if present, third fibers oriented in a third direction) account for up to about 90% by weight of the total weight of the fabric, such as up to about 85% by weight of the fabric, or up to about 80% by weight of the fabric. In an embodiment, the fibers of the first layer (e.g., first fibers and, if present, third fibers) account for about 20% to about 90% by weight of the total weight of the fabric, such as about 25% to about 85% by weight of the total weight of the fabric, or about 25% to about 80% by weight.

[0055] In an embodiment, the first fibers in the fabric, such as carbon fibers (or carbon fiber tows) oriented in a first direction, have a thickness of less than about 200 g / m 2 , for example less than about 150 g / m 2 , less than about 100g / m 2 , less than about 90g / m 2 , or less than about 80g / m 2 In an embodiment, the first fibers in the fabric, such as carbon fibers (or carbon fiber tows) oriented in a first direction, have a weight per unit area of ​​at least about 10 g / m 2 , for example at least about 20 g / m 2 , at least about 30g / m 2 , at least about 40g / m 2 , at least about 50g / m 2 , at least about 60g / m 2 , at least about 70g / m 2 , or at least about 75g / m 2 In an embodiment, the first fibers in the fabric, such as carbon fibers (or carbon fiber tows) oriented in a first direction, have a weight per unit area of ​​about 10 g / m 2 About 200g / m 2 , for example about 20g / m 2 About 150g / m 2 , about 30g / m 2 About 100g / m 2 , about 50g / m 2 About 100g / m 2 , about 50g / m 2 About 80g / m 2 , about 50g / m 2 About 70g / m 2 , about 60g / m 2 About 70g / m 2 , about 10g / m 2 About 100g / m 2 , about 10g / m 2 About 80g / m 2 , about 10g / m 2 About 60g / m 2 , or about 10g / m 2 About 50g / m 2 The weight per unit area is within the range of.

[0056] In an embodiment, the first layer comprises, consists essentially of, or consists of: about 50% to about 100% by weight of the first fibers (e.g., carbon fibers) and 0% to about 50% by weight of the third fibers (e.g., glass fibers), such as about 60% to about 100% by weight of the first fibers (e.g., carbon fibers) and 0% to about 40% by weight of the third fibers (e.g., glass fibers), or about 70% to about 100% by weight of the first fibers (e.g., carbon fibers) and 0% to about 30% by weight of the third fibers (e.g., glass fibers). In an embodiment, the first layer comprises, consists essentially of, or consists of: about 50% to about 95% by weight of the first fibers (e.g., carbon fibers) and 5% to about 50% by weight of the third fibers (e.g., glass fibers), such as about 60% to about 95% by weight of the first fibers (e.g., carbon fibers) and 5% to about 40% by weight of the third fibers (e.g., glass fibers), or about 70% to about 95% by weight of the first fibers (e.g., carbon fibers) and 5% to about 30% by weight of the third fibers (e.g., glass fibers).

[0057] In an embodiment, the first layer has a unit weight of at least about 20% by weight of the total unit weight of the fabric, such as a unit weight of at least about 25% by weight of the total unit weight of the fabric. In an embodiment, the first layer has a unit weight of at least about 50% by weight of the total unit weight of the fabric, or a unit weight of at least about 60% by weight of the total unit weight of the fabric. In an embodiment, the first layer has a unit weight in the range of about 20% by weight to about 80% by weight of the weight of the fabric, such as about 20% by weight to about 70% by weight of the weight of the fabric, or about 25% by weight to about 60% by weight of the weight of the fabric. The unit weight of the first layer of the fabric can be determined according to ISO 3374.

[0058] The second layer comprises second fibers oriented in a second direction, the second fibers being stabilizing fibers. In an embodiment, the second fibers comprise, consist essentially of, or consist of glass fibers (e.g., textured glass yarns). In an embodiment, the stabilizing fibers comprise, consist essentially of, or consist of glass fibers (e.g., textured glass yarns). In an embodiment, the second fibers comprise, consist essentially of, or consist of textured yarns (e.g., textured glass yarns). In an embodiment, the second layer comprises, consists essentially of, or consists of second fibers.

[0059] In an embodiment, the second fiber / stabilizing fiber can be any suitable glass reinforcing fiber, for example, made of E glass, E-CR glass (such as Advantex TMGlass), H glass, S glass, and AR glass type may be used. The glass fiber used as the second fiber may have a diameter in the range of about 5 μm to about 25 μm, for example, about 13 μm to about 24 μm.

[0060] In an embodiment, the second fiber / stabilizing fiber is a textured yarn, such as a textured yarn as described above (e.g., as described above with respect to Figure 4 In an embodiment, the second fiber / stabilizing fiber is a textured glass yarn.

[0061] In an embodiment, the carbon fiber and glass fiber hybrid fabric includes a first layer and a second layer, the first layer comprising carbon fibers as first fibers oriented in a first direction, and the second layer comprising texturized glass yarns as second fibers oriented in a second direction.

[0062] In an embodiment, "textured yarn" refers to a strand of fiber that includes a plurality of bulked segments (e.g., bulked segments formed when a strand of fiber is exposed to turbulent flow of compressed air). In an embodiment, a bulked segment of a texturized yarn (e.g., a texturized glass yarn) is a segment of the texturized yarn having a diameter that is at least 10% larger, e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger than the smallest diameter of the texturized yarn (e.g., the diameter of an unbulked segment of the texturized yarn is smaller than the smallest diameter of the bulked segment). The diameter of a segment of the texturized yarn may be measured perpendicular to the yarn. The minimum diameter of the texturized yarn may be defined as the minimum diameter of the texturized yarn for a given section of the texturized fiber, such as the minimum diameter of the texturized yarn in a 10 cm length of the texturized yarn, or the minimum diameter of the texturized yarn along the length of the texturized yarn in a hybrid fabric.

[0063] In an embodiment, the textured yarn (e.g., textured glass yarn) has a minimum diameter of less than about 5 mm, such as less than about 4 mm, less than about 3 mm, less than about 2 mm, or about 1 mm or less. In an embodiment, the textured yarn (e.g., textured glass yarn) has a minimum diameter in the range of about 0.1 mm to about 5 mm, such as about 0.2 mm to about 4 mm, about 0.3 mm to about 3 mm, about 0.5 mm to about 2 mm, about 0.5 mm to about 1.5 mm, or about 0.7 mm to about 1.2 mm, or about 0.8 mm to about 1 mm.

[0064] In an embodiment, the texturized yarn comprises a plurality of bulked segments, each bulked segment having a diameter that is at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than a minimum diameter of the texturized yarn. In an embodiment, the texturized yarn comprises a plurality of bulked segments, each bulked segment having a diameter that is in a range of 10% to 600%, 20% to 300%, or 20% to 250% larger than a minimum diameter of the texturized yarn. In an embodiment, the texturized yarn comprises a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than the smallest diameter of the texturized yarn, and the texturized yarn comprises 0.3 to 3 bulked segments per cm length. In an embodiment, the texturized yarn includes a plurality of bulked segments, each bulked segment having a diameter that is at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than the smallest diameter of the texturized yarn, and includes about 2 to about 30, or about 2 to about 25 bulked segments per 10 cm length of the texturized yarn. The number of bulked segments per 10 cm length of the texturized yarn can be determined by placing a strand of the texturized yarn (e.g., a strand of texturized glass yarn) in a straight line on a flat surface with no tension applied to the texturized yarn, and counting the number of bulked segments present in the 10 cm length of the texturized yarn, wherein the bulked segments are as defined herein.

[0065] In an embodiment, the texturized yarn comprises a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than a minimum diameter of the texturized glass yarn, wherein the bulked segments of the texturized glass yarn account for at least 10% of the length of the texturized yarn, e.g., at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50%.

[0066] In an embodiment, the texturized yarn (e.g., a texturized glass yarn) comprises at least about 2, such as at least about 3, or at least about 5 bulked segments (e.g., bulked segments as described herein) per 10 cm length of the texturized yarn. In an embodiment, the texturized yarn (e.g., a texturized glass yarn) comprises at most about 30, such as at most about 25, at most about 20, or at most about 15 bulked segments (e.g., bulked segments as described herein) per 10 cm length of the texturized yarn. In an embodiment, the texturized yarn (e.g., a texturized glass yarn) comprises from about 2 to about 30, such as from about 2 to about 25, from about 3 to about 20, or from about 5 to about 15 bulked segments (e.g., bulked segments as described herein) per 10 cm length of the texturized yarn. The number of bulked segments per 10 cm length of the texturized yarn can be determined by placing a strand of the texturized yarn (e.g., a strand of texturized glass yarn) in a straight line on a flat surface with no tension applied to the texturized yarn, and counting the number of bulked segments present in the 10 cm length of the texturized yarn, wherein bulked segments are as defined herein.

[0067] In an embodiment, the texturized yarn (e.g., a texturized glass yarn) includes a plurality of bulked segments (e.g., as described herein), with successive bulked segments spaced apart by a distance in the range of about 0.5 mm to about 80 mm, e.g., about 0.5 mm to about 50 mm, about 0.5 mm to about 10 mm, or about 2 mm to about 8 mm. The distance between successive bulked segments of the texturized yarn can be determined by placing a strand of the texturized yarn (e.g., a strand of the texturized glass yarn) in a straight line on a flat surface with no tension applied to the texturized yarn, and measuring the distance between the end of one bulked segment (e.g., where the diameter of the bulked segment decreases to less than 110% of the minimum diameter of the texturized glass yarn) and the beginning of the next bulked segment (e.g., where the diameter of the bulked segment increases to greater than 10% of the minimum diameter of the texturized glass yarn) using a measuring tape. In an embodiment, the plurality of bulked sections of the texturized yarn are regularly distributed along the texturized yarn, for example, the distances between consecutive bulked sections along the texturized yarn may be approximately the same (eg, within about ±10%, or within about ±5%).

[0068] In an embodiment, the texturized yarn (e.g., texturized glass yarn) includes a plurality of bulked segments, each bulked segment having a diameter in a range of 10% to 600%, 20% to 300%, or 20% to 250% greater than the minimum diameter of the texturized yarn (e.g., texturized glass yarn).

[0069] In an embodiment, the texturized yarn (e.g., texturized glass yarn) includes a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than the smallest diameter of the texturized yarn (e.g., texturized glass yarn), and the texturized yarn includes about 2 to about 25 (e.g., about 5 to about 15) bulked segments per 10 cm length.

[0070] In an embodiment, the texturized yarn (e.g., a texturized glass yarn) includes a plurality of bulked segments, each bulked segment having a diameter that is at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than a minimum diameter of the texturized yarn, and the texturized yarn includes about 2 to about 25 (e.g., about 5 to about 15) bulked segments per 10 cm length of the texturized yarn.

[0071] In an embodiment, the texturized yarn (e.g., a texturized glass yarn) comprises a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than the smallest diameter of the texturized yarn, and the texturized yarn comprises about 2 to about 25 (e.g., about 5 to about 15) bulked segments per 10 cm length of the texturized yarn, wherein consecutive bulked segments of the texturized yarn are spaced apart by a distance in the range of about 0.5 mm to about 80 mm, e.g., about 0.5 mm to about 50 mm, about 0.5 mm to about 10 mm, or about 2 mm to about 8 mm. In an embodiment, the bulked segments of the texturized yarn are regularly distributed along the texturized yarn.

[0072] In an embodiment, a texturized yarn (e.g., a texturized glass yarn) comprises a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than a minimum diameter of the texturized yarn, wherein the bulked segments of the texturized yarn account for at least 10% of the length of the texturized yarn, e.g., at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50%.

[0073] In an embodiment, the texturized yarn is a texturized glass yarn, ie, a strand of glass fibers including a plurality of bulked sections, such as those formed when a strand of glass fibers is exposed to turbulent flow of compressed air.

[0074] In an embodiment, the second fiber / stabilizing fiber is a textured glass yarn, such as a textured glass yarn as described above (e.g., as described above with respect to Figure 4 An example of a suitable texturized glass yarn is ECT9 T140 K252C (available from Vetrotex TM ). In an embodiment, the texturized glass yarn comprises glass fibers having a diameter in a range of about 5 μm to about 25 μm, such as about 9 μm to about 24 μm. In an embodiment, the texturized glass yarn comprises a plurality of bulked segments, each bulked segment having a diameter that is at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than the smallest diameter of the texturized glass yarn. In an embodiment, the texturized glass yarn comprises a plurality of bulked segments, each bulked segment having a diameter at least 10% larger (e.g., at least 15% larger, at least 20% larger, at least 30% larger, at least 40% larger, at least 50% larger, at least 70% larger, at least 80% larger, at least 100% larger, at least 150% larger, or at least 200% larger) than a minimum diameter of the texturized glass yarn, wherein the bulked segments of the texturized glass yarn account for at least 10% of the length of the texturized glass yarn, e.g., at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50%.

[0075] In embodiments, the texturized glass yarn has a linear mass density in a range of about 30 tex to about 500 tex, such as about 50 tex to about 300 tex, about 68 tex to about 280 tex, about 70 tex to about 300 tex, or about 70 tex to about 200 tex.

[0076] In an embodiment, the second fiber / stabilizing fiber, e.g., glass fiber (or glass fiber strand, e.g., crimped glass yarn) or crimped yarn oriented in a second direction, has a linear mass density in the range of about 30 tex to about 500 tex, e.g., about 50 tex to about 300 tex, about 68 tex to about 280 tex, about 70 tex to about 300 tex, or about 68 tex to about 140 tex.

[0077] In an embodiment, the second layer comprises a plurality of second fiber strands (e.g., textured glass yarn strands), the second layer having a second fiber strand count in the range of about 0.25 to about 5 strands per cm, or about 0.25 to about 2.5 strands per cm. In an embodiment, the second layer comprises a plurality of glass fiber strands (e.g., a plurality of glass fiber strands and each of the plurality of glass fiber strands has a linear mass density in the range of about 30 tex to about 500 tex, e.g., about 50 tex to about 300 tex, about 68 tex to about 280 tex, about 70 tex to about 300 tex, or about 68 tex to about 140 tex), the second layer having a glass fiber strand count in the range of about 0.25 to about 5 strands per cm, or about 0.25 to about 2.5 strands per cm. The number of glass fiber strands per cm is measured in a direction substantially perpendicular to the second direction, e.g., in the first direction.

[0078] In an embodiment, the second fiber / stabilizing fiber in the fabric, such as glass fiber (or glass fiber strand, such as crimped glass yarn) or crimped textured yarn oriented in the second direction, has a g / m 2 , for example less than about 75 g / m 2 , less than about 50g / m 2 , less than about 40g / m 2 , or less than about 30g / m 2 In an embodiment, the second fibers in the fabric, such as glass fibers (or glass fiber strands, such as crimped textured glass yarns) oriented in the second direction, have a weight per unit area of ​​at least about 5 g / m 2 , for example at least about 10 g / m 2 , or at least about 20g / m 2 In an embodiment, the second fibers in the fabric, such as glass fibers (or glass fiber strands, such as crimped textured glass yarns) oriented in the second direction, have a weight per unit area of ​​about 5 g / m 2 About 100g / m 2 , for example about 5g / m 2 About 75g / m 2 , about 10g / m 2 About 50g / m 2 , about 10g / m 2 About 40g / m 2 , about 10g / m 2 About 30g / m 2 , about 20g / m 2 About 30g / m 2 , or about 5g / m 2 About 30g / m 2The weight per unit area is within the range of.

[0079] In an embodiment, the second layer comprises a fourth fiber oriented in a fourth direction and / or a fifth fiber oriented in a fifth direction. In an embodiment, the fourth direction and / or the fifth direction are aligned with the second direction. In an embodiment, the fourth fiber and / or the fifth fiber (when present) are oriented in the second direction (i.e., the fourth direction and the fifth direction are the same as the second direction). The fourth fiber may include or consist of a fiber of a material other than glass, for example, the fourth fiber may include a carbon fiber. The fifth fiber may include or consist of a fiber of a material other than glass, for example, the fifth fiber may include a polymer fiber (e.g., a PET monofilament). In an embodiment, the fourth fiber includes, is substantially composed of, or is composed of a carbon fiber. In an embodiment, the fourth fiber is a carbon fiber. In an embodiment, the fifth fiber includes, is substantially composed of, or is composed of a polymer fiber (e.g., a PET monofilament). In an embodiment, the second layer comprises, is substantially composed of, or is composed of: a combination of a second fiber / stabilizing fiber and a fourth fiber and / or a fifth fiber. Examples of polymer fibers suitable for use as the fifth fiber include FILSTER 0.14mm, FILSTER 0.25mm, and FILSTER 0.35mm. In an embodiment, the fifth fiber comprises, consists essentially of, or consists of a polymer fiber having a diameter in a range of 0.05 mm to 0.5 mm.

[0080] In an embodiment, the second layer comprises, consists essentially of, or consists of second fibers / stabilizing fibers that are textured yarns (e.g., textured glass yarns) and fourth fibers that are carbon fibers. In an embodiment, the second layer comprises, consists essentially of, or consists of second fibers / stabilizing fibers that are textured yarns (e.g., textured glass yarns), fourth fibers that are carbon fibers, and fifth fibers that are polymeric fibers (e.g., polymer monofilaments, such as PET monofilaments).

[0081] In an embodiment, the second fibers / stabilizing fibers and the third fibers comprise glass fibers. In an embodiment, the second fibers and the third fibers comprise glass fibers, wherein the second glass fibers are different from the third glass fibers.

[0082] In an embodiment, the second fiber / stabilizing fiber accounts for less than about 50% by weight of the total weight of the fabric, such as less than about 40% by weight, less than about 35% by weight, less than about 30% by weight, or less than about 25% by weight of the total weight of the fabric. In an embodiment, the second fiber / stabilizing fiber accounts for about 5% to about 50% by weight of the total weight of the fabric, such as about 10% to about 40% by weight, or about 10% to about 30% by weight of the total weight of the fabric.

[0083] In an embodiment, the fourth fibers (e.g., carbon fibers oriented in a fourth direction) may account for at least about 15% by weight of the total weight of the fabric, such as at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, at least about 40% by weight, at least about 45% by weight, or at least about 50% by weight of the total weight of the fabric. In an embodiment, the fourth fibers (e.g., carbon fibers oriented in a fourth direction) account for about 0% by weight to about 80% by weight of the total weight of the fabric, such as about 15% by weight to about 70% by weight, about 15% by weight to about 60% by weight, about 20% by weight to about 75% by weight, about 25% by weight to about 75% by weight, about 25% by weight to about 70% by weight, about 25% by weight to about 60% by weight, about 30% by weight to about 75% by weight, about 30% by weight to about 70% by weight, about 30% by weight to about 60% by weight, about 35% by weight to about 75% by weight, about 35% by weight to about 70% by weight.

[0084] In an embodiment, the fifth fibers (e.g., polymer fibers oriented along a fifth direction) may account for up to about 30% by weight of the total weight of the fabric, such as up to about 20% by weight, or up to about 10% by weight of the total weight of the fabric. In an embodiment, the fifth fibers (e.g., polymer fibers oriented along a fifth direction) account for about 0% by weight to about 30% by weight of the total weight of the fabric, such as about 0.5% by weight to about 20% by weight, or about 1% by weight to about 10% by weight of the total weight of the fabric.

[0085] In an embodiment, the second layer (e.g., the second fibers and, if present, the fourth and / or fifth fibers) account for up to about 75% by weight of the total weight of the fabric, for example, up to about 70% by weight, up to about 60% by weight, up to about 50% by weight, up to about 40% by weight, or up to about 20% by weight of the total weight of the fabric. In an embodiment, the fibers oriented in the second direction (e.g., the second fibers and, if present, the fourth and / or fifth fibers) account for about 5% by weight to about 50% by weight of the total weight of the fabric, for example, about 10% by weight to about 40% by weight, or about 10% by weight to about 30% by weight of the total weight of the fabric. In an embodiment, the second layer (e.g., the second fibers and, if present, the fourth and / or fifth fibers) account for about 5% by weight to about 75% by weight of the total weight of the fabric, for example, about 10% by weight to about 70% by weight, or about 10% by weight to about 60% by weight of the total weight of the fabric.

[0086] In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 10% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 90% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 90% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 15% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 85% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 20% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 80% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 25% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 75% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 30% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 70% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 50% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 50% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 50% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: from about 60 wt % to about 100 wt % of second fibers (e.g., glass fibers and / or crimped textured yarns); from 0 wt % to about 40 wt % of fourth fibers (e.g., carbon fibers); and from 0 wt % to about 40 wt % of fifth fibers (e.g., polymer fibers), based on the total weight of the second layer.In an embodiment, the second layer comprises, consists essentially of, or consists of: about 70% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured yarns), based on the total weight of the second layer; 0% to about 30% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 30% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: about 15% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured yarns), based on the total weight of the second layer; 0% to about 85% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 50% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 15% to about 100% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 0% to about 85% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 30% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: based on the total weight of the second layer, about 15% to about 80% by weight of the second fibers (e.g., glass fibers and / or texturized yarns); 20% to about 85% by weight of the fourth fibers (e.g., carbon fibers); and 0% to about 50% by weight of the fifth fibers (e.g., polymer fibers). In an embodiment, the second layer comprises, consists essentially of, or consists of: from about 20 wt. % to about 70 wt. % of second fibers (e.g., glass fibers and / or crimped textured yarns); from 30 wt. % to about 80 wt. % of fourth fibers (e.g., carbon fibers); and from 0 wt. % to about 30 wt. % of fifth fibers (e.g., polymer fibers), based on the total weight of the second layer.

[0087] In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 50% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 50% by weight of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 10% to about 100% by weight of second fibers (e.g., glass fibers and / or crimped textured yarns), based on the total weight of the second layer; 0% to about 90% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 90% by weight of fifth fibers (e.g., polymer fibers). In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 60% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 40% by weight of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 30% to about 100% by weight of second fibers (e.g., glass fibers and / or crimped textured yarns), based on the total weight of the second layer; 0% to about 70% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of fifth fibers (e.g., polymer fibers). In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 70% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 30% by weight of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 50% to about 100% by weight of second fibers (e.g., glass fibers and / or crimped textured yarns), based on the total weight of the second layer; 0% to about 50% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 50% by weight of fifth fibers (e.g., polymer fibers). In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 50% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 50% by weight of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 15% to about 100% by weight of second fibers (e.g., glass fibers), based on the total weight of the second layer; 0% to about 85% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of fifth fibers (e.g., polymer fibers).In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 60 wt % to about 100 wt % of first fibers (e.g., carbon fibers) and 0 wt % to about 40 wt % of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 20 wt % to about 100 wt % of second fibers (e.g., glass fibers), based on the total weight of the second layer; 0 wt % to about 80 wt % of fourth fibers (e.g., carbon fibers); and 0 wt % to about 70 wt % of fifth fibers (e.g., polymer fibers). In an embodiment, the hybrid fabric includes: a first layer comprising, consisting essentially of, or consisting of: about 60% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 40% by weight of third fibers (e.g., glass fibers), based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 25% to about 100% by weight of second fibers (e.g., glass fibers), based on the total weight of the second layer; 0% to about 75% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 70% by weight of fifth fibers (e.g., polymer fibers). In an embodiment, the hybrid fabric comprises: a first layer comprising, consisting essentially of, or consisting of: about 60% to about 100% by weight of first fibers (e.g., carbon fibers) and 0% to about 40% by weight of third fibers (e.g., glass fibers) based on the total weight of the first layer; and a second layer comprising, consisting essentially of, or consisting of: about 15% to about 80% by weight of second fibers (e.g., glass fibers) based on the total weight of the second layer; 20% to about 85% by weight of fourth fibers (e.g., carbon fibers); and 0% to about 50% by weight of fifth fibers (e.g., polymer fibers). In each of these embodiments, the second fibers may be provided by a textured glass yarn as described herein. In each of these embodiments, the fabric may have a weight per unit area of ​​less than about 400 g / m. 2 , less than about 300g / m 2 , less than about 200g / m 2 , or less than about 150g / m 2 .

[0088] In an embodiment, the second layer has a unit weight of up to about 75% by weight of the total unit weight of the fabric, such as up to about 70% by weight of the total unit weight of the fabric, up to about 60% by weight of the total unit weight of the fabric, up to about 50% by weight of the total unit weight of the fabric, up to about 40% by weight, or up to about 30% by weight of the total unit weight of the fabric. In an embodiment, the second layer has a unit weight in the range of about 5% by weight to about 75% by weight of the weight of the fabric, such as about 10% by weight to about 70% by weight, about 20% by weight to about 70% by weight, about 25% by weight to about 70% by weight, about 5% by weight to about 50% by weight, about 5% by weight to about 40% by weight, about 10% by weight to about 30% by weight, about 20% by weight to about 40% by weight, about 20% by weight to about 30% by weight of the weight of the fabric. The unit weight of the second layer of the fabric can be determined according to ISO 3374.

[0089] In an embodiment, the stitching yarns comprise less than about 25% by weight of the total weight of the fabric, such as less than about 15% by weight, less than about 10% by weight, or less than about 8% by weight of the total weight of the fabric. In an embodiment, the stitching yarns comprise about 0.5% by weight to about 25% by weight of the total weight of the fabric, such as about 0.5% by weight to about 15% by weight, about 1% by weight to about 10% by weight, or about 2% by weight to about 8% by weight of the total weight of the fabric.

[0090] Any suitable stitching yarn may be employed. In an embodiment, the stitching yarn is a polyester yarn. In an embodiment, the stitching yarn has a linear mass density ranging from about 50 dtex to about 300 dtex.

[0091] In an embodiment, the stitching yarn passes through the fabric to form a stitching pattern, which can be selected from a tricot stitching pattern, a symmetrical double tricot stitching pattern, an asymmetrical double tricot stitching pattern, a symmetrical diamond stitching pattern, and an asymmetrical diamond stitching pattern. In an embodiment, the stitching yarn passes through the fabric to form a stitching pattern, which is a tricot stitching pattern.

[0092] In an embodiment, the stitching yarns define a stitch length ranging from about 2 mm to about 7 mm, such as about 3 mm.

[0093] The hybrid fabrics described herein may have a thickness of less than about 1000 g / m 2 , for example less than about 500 g / m 2 , less than about 400g / m 2 , less than about 300g / m 2 , less than about 200g / m 2 , or less than about 150g / m 2In an embodiment, the mixed fabric has a weight per unit area of ​​about 50 g / m 2 About 500g / m 2 , for example about 50g / m 2 About 400g / m 2 , about 50g / m 2 About 200g / m 2 , or about 100g / m 2 About 200g / m 2 The weight per unit area of ​​a fabric can be determined according to ISO 3374.

[0094] In the carbon fiber and glass fiber hybrid fabric described herein, at least one of the first layer and the second layer comprises glass fibers. In an embodiment, the glass fibers of the hybrid fabric are provided with at least one of the second fibers or the third fibers described herein. In an embodiment, the first layer comprises third fibers oriented in a third direction, the third fibers are glass fibers; and / or the stabilizing fibers are textured glass yarns.

[0095] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0096] a first layer comprising first fibers oriented in a first direction;

[0097] a second layer comprising second fibers oriented in a second direction;

[0098] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0099] wherein the second direction is within about 45 degrees to about 90 degrees of the first direction,

[0100] The first fiber is carbon fiber,

[0101] The second fiber is a stabilizing fiber,

[0102] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0103] The first fibers comprise at least about 15% by weight of the total weight of the fabric.

[0104] The second fibers comprise less than about 50% by weight of the total weight of the fabric.

[0105] Wherein: the first layer further comprises third fibers oriented along a third direction, the third fibers are glass fibers; and / or the stabilizing fibers are crimped textured glass yarns.

[0106] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0107] a first layer comprising first fibers oriented in a first direction;

[0108] a second layer comprising second fibers oriented in a second direction;

[0109] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0110] wherein the second direction is within about 45 degrees to about 90 degrees of the first direction,

[0111] The first fiber is carbon fiber,

[0112] The second fiber is the stabilizing fiber,

[0113] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0114] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0115] The second fibers comprise less than about 50 weight percent of the total weight of the fabric.

[0116] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0117] a first layer comprising first fibers oriented in a first direction;

[0118] a second layer comprising second fibers oriented in a second direction;

[0119] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 45 degrees to about 90 degrees of the first direction,

[0120] The first fiber is carbon fiber,

[0121] The second fiber is the stabilizing fiber,

[0122] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0123] The first fibers comprise at least about 25% by weight of the total weight of the fabric, and

[0124] The second fibers comprise less than about 50 weight percent of the total weight of the fabric.

[0125] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0126] a first layer comprising first fibers oriented in a first direction;

[0127] a second layer comprising second fibers oriented in a second direction;

[0128] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0129] The first fiber is carbon fiber,

[0130] The second fiber is a textured glass yarn,

[0131] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0132] The first fibers comprise at least about 15% by weight of the total weight of the fabric.

[0133] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0134] The first layer comprises at least about 25 weight percent of the total weight of the fabric.

[0135] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0136] a first layer comprising first fibers oriented in a first direction;

[0137] a second layer comprising second fibers oriented in a second direction;

[0138] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0139] The first fiber is carbon fiber,

[0140] The second fiber is a textured glass yarn,

[0141] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0142] The first fibers comprise at least about 25% by weight of the total weight of the fabric,

[0143] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0144] The first layer comprises at least about 50 weight percent of the total weight of the fabric.

[0145] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0146] a first layer comprising first fibers oriented in a first direction;

[0147] a second layer comprising second fibers oriented in a second direction;

[0148] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0149] The first fiber is carbon fiber,

[0150] The second fiber is a textured glass yarn,

[0151] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0152] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0153] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0154] The first layer comprises at least about 25 weight percent of the total weight of the fabric.

[0155] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0156] a first layer comprising first fibers oriented in a first direction;

[0157] a second layer comprising second fibers oriented in a second direction;

[0158] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0159] The first fiber is carbon fiber,

[0160] The second fiber is a textured glass yarn,

[0161] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0162] The first fibers comprise at least about 25% by weight of the total weight of the fabric,

[0163] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0164] The first layer comprises at least about 50 weight percent of the total weight of the fabric.

[0165] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0166] a first layer comprising first fibers oriented in a first direction;

[0167] a second layer comprising second fibers oriented in a second direction;

[0168] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0169] The first fiber is carbon fiber,

[0170] The second fiber is a textured glass yarn,

[0171] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0172] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0173] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0174] The first layer comprises at least about 25% by weight of the total weight of the fabric.

[0175] wherein the texturized glass yarn comprises a plurality of bulked sections, each bulked section having a diameter at least 10% greater than a minimum diameter of the texturized glass yarn, optionally wherein the bulked sections of the texturized glass yarn account for at least 10% of the length of the texturized glass yarn.

[0176] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0177] a first layer comprising first fibers oriented in a first direction;

[0178] a second layer comprising second fibers oriented in a second direction;

[0179] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0180] The first fiber is carbon fiber,

[0181] The second fiber is a crimped textured glass yarn,

[0182] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0183] The first fibers comprise at least about 25% by weight of the total weight of the fabric,

[0184] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0185] The first layer comprises at least about 50% by weight of the total weight of the fabric.

[0186] wherein the texturized glass yarn comprises a plurality of bulked sections, each bulked section having a diameter at least 10% greater than a minimum diameter of the texturized glass yarn, optionally wherein the bulked sections of the texturized glass yarn account for at least 10% of the length of the texturized glass yarn.

[0187] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0188] a first layer comprising first fibers oriented in a first direction and third fibers oriented in a third direction;

[0189] a second layer comprising second fibers oriented in a second direction;

[0190] a stitching yarn that holds the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0191] The first fiber is carbon fiber,

[0192] The second fiber is a textured glass yarn,

[0193] The third fiber is glass fiber,

[0194] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0195] The first fibers comprise at least about 25% by weight of the total weight of the fabric,

[0196] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0197] The first layer comprises at least about 50 weight percent of the total weight of the fabric.

[0198] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0199] A first layer comprising first fibers oriented in a first direction and fibers oriented in a third direction

[0200] tertiary fiber;

[0201] a second layer comprising second fibers oriented in a second direction;

[0202] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0203] wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0204] The first fiber is carbon fiber,

[0205] The second fiber is a textured glass yarn,

[0206] The third fiber is glass fiber,

[0207] The fabric has a weight per unit area of ​​less than about 500 g / m 2

[0208] The first fibers comprise at least about 40% by weight of the total weight of the fabric,

[0209] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0210] The first layer comprises at least about 60 weight percent of the total weight of the fabric.

[0211] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0212] A first layer comprising first fibers oriented in a first direction and fibers oriented in a third direction

[0213] tertiary fiber;

[0214] a second layer comprising second fibers oriented in a second direction;

[0215] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0216] wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0217] The first fiber is carbon fiber,

[0218] The second fiber is a textured glass yarn,

[0219] The third fiber is glass fiber,

[0220] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0221] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0222] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0223] The first layer comprises at least about 25% by weight of the total weight of the fabric.

[0224] wherein the texturized glass yarn comprises a plurality of enlarged segments, each enlarged segment having a diameter at least 10% greater than a minimum diameter of the texturized glass yarn, optionally wherein the enlarged segments of the texturized glass yarn account for at least 20% of the length of the texturized glass yarn.

[0225] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0226] A first layer comprising first fibers oriented in a first direction and fibers oriented in a third direction

[0227] tertiary fiber;

[0228] a second layer comprising second fibers oriented in a second direction;

[0229] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0230] wherein the second direction is within about 80 degrees to about 90 degrees of the first direction,

[0231] The first fiber is carbon fiber,

[0232] The second fiber is a textured glass yarn,

[0233] The third fiber is glass fiber,

[0234] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0235] The first fibers comprise at least about 40% by weight of the total weight of the fabric,

[0236] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0237] The first layer comprises at least about 60% by weight of the total weight of the fabric.

[0238] wherein the texturized glass yarn comprises a plurality of enlarged segments, each enlarged segment having a diameter at least 10% greater than a minimum diameter of the texturized glass yarn, optionally wherein the enlarged segments of the texturized glass yarn account for at least 20% of the length of the texturized glass yarn.

[0239] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0240] a first layer comprising first fibers oriented in a first direction;

[0241] A second layer includes second fibers oriented in a second direction and fourth fibers oriented in a fourth direction.

[0242] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0243] wherein the second direction is within about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction,

[0244] The first fiber is carbon fiber,

[0245] The second fiber is a textured glass yarn,

[0246] The fourth fiber is carbon fiber,

[0247] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0248] The first fibers comprise at least about 15% by weight of the total weight of the fabric.

[0249] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0250] The fourth fibers comprise at least about 10 weight percent of the total weight of the fabric.

[0251] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0252] a first layer comprising first fibers oriented in a first direction and third fibers oriented in a third direction;

[0253] A second layer includes second fibers oriented in a second direction and fourth fibers oriented in a fourth direction.

[0254] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0255] wherein the second direction is within about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction,

[0256] The first fiber is carbon fiber,

[0257] The second fiber is a textured glass yarn,

[0258] The third fiber is glass fiber,

[0259] The fourth fiber is carbon fiber,

[0260] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0261] The first fibers comprise at least about 15% by weight of the total weight of the fabric.

[0262] The second fibers comprise less than about 50 weight percent of the total weight of the fabric, and

[0263] The fourth fibers comprise at least about 10 weight percent of the total weight of the fabric.

[0264] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0265] a first layer comprising first fibers oriented in a first direction;

[0266] A second layer includes second fibers oriented in a second direction and fourth fibers oriented in a fourth direction.

[0267] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0268] wherein the second direction is within about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction,

[0269] The first fiber is carbon fiber,

[0270] The second fiber is a textured glass yarn,

[0271] The fourth fiber is carbon fiber,

[0272] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0273] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0274] The second fibers comprise less than about 30 weight percent of the total weight of the fabric, and

[0275] The fourth fibers comprise at least about 20 weight percent of the total weight of the fabric.

[0276] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises:

[0277] A first layer comprising first fibers oriented in a first direction and fibers oriented in a third direction

[0278] tertiary fiber;

[0279] A second layer comprising second fibers oriented in a second direction and fibers oriented in a fourth direction

[0280] The fourth fiber.

[0281] stitching yarns which hold the fibers of the first and second layers in their respective orientations,

[0282] wherein the second direction is within about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction,

[0283] The first fiber is carbon fiber,

[0284] The second fiber is a textured glass yarn,

[0285] The third fiber is glass fiber,

[0286] The fourth fiber is carbon fiber,

[0287] The fabric has a weight per unit area of ​​less than about 400 g / m 2

[0288] The first fibers comprise at least about 20% by weight of the total weight of the fabric,

[0289] The second fibers comprise less than about 30 weight percent of the total weight of the fabric, and

[0290] The fourth fibers comprise at least about 20 weight percent of the total weight of the fabric.

[0291] Typically, hybrid fabrics are resin-free, ie, none of the fibers forming the fabric are pre-impregnated with resin.

[0292] Figure 1 1 is a schematic diagram of a hybrid reinforcement fabric 100 composed of first fibers 102 (e.g., carbon fiber tows) and second fibers (e.g., glass fibers) 104. The first fibers 102 are oriented in a first direction (a 0° direction aligned with the length of the fabric), and the second fibers are oriented in a second direction ( Figure 1 90° direction shown in FIG.

[0293] Figure 2 Shows Figure 1 An enlarged view of section "A" of FIG. Figure 2 Stitching yarns 106 are shown forming a stitch pattern through the fabric 100 to hold the first fibers 102 and the second fibers 104 in their respective orientations.

[0294] The first fibers may be arranged in the first layer such that gaps exist between adjacent first fibers 102 (eg, gaps between adjacent carbon fiber tows).

[0295] In an embodiment, the stitching yarn forms a stitch pattern that includes stitches along at least one of the strands of first fibers 102, such as along each of a plurality of first fiber strands (eg, along each of a plurality of carbon fiber tows).

[0296] In an embodiment, the stitching yarn forms stitches in the interstices between adjacent strands of the first fibers 102 (eg, between adjacent carbon fiber tows).

[0297] In an embodiment, the first layer may include between about 0.25 and about 5 first fiber strands (e.g., carbon fiber tows) 102 per cm (as measured perpendicular to the first direction, for example as measured along the second direction), or about 0.25 to about 2.5 tows per cm.

[0298] In embodiments, the first layer may comprise between about 0.25 and about 5 third fiber strands (e.g., glass fiber strands) per cm (as measured perpendicular to the first direction, for example as measured along the second direction), or about 0.25 to about 2.5 strands per cm.

[0299] In embodiments, the second layer comprises between about 0.25 and about 5 second fiber strands (e.g., glass fiber strands) per cm (as measured perpendicular to the second direction, e.g., as measured along the first direction), or about 0.25 to about 2.5 strands per cm.

[0300] In an embodiment, the second layer comprises between about 0.25 and about 5 fourth fiber strands (e.g., carbon fiber tows) per cm (as measured perpendicular to the second direction, e.g., as measured along the first direction), or about 0.25 to about 2.5 strands per cm.

[0301] Figure 3c is a photograph of a hybrid reinforcement fabric 100 (as provided in Example 3 below), which includes a first layer containing first fibers 102 (e.g., carbon fiber tows) and third fibers 103 (e.g., glass fibers); and a second layer containing second fibers (e.g., glass fibers) 104 and fourth fibers (e.g., carbon fibers) 105. The first fibers 102 are oriented along a first direction (a 0° direction aligned with the length of the fabric), and the second fibers are oriented along a second direction substantially perpendicular to the first direction. The third fibers 103 are oriented along a third direction aligned with the first direction, and the fourth fibers 105 are oriented along a fourth direction aligned with the second direction.

[0302] The first fibers and the third fibers may be arranged in the first layer so that there are gaps between adjacent first fibers 102 and third fibers 103 (e.g., gaps between adjacent carbon fiber tows and gaps between adjacent glass fiber strands, and gaps between adjacent carbon fiber tows and glass fiber strands). The fibers of the second layer, such as the second fibers 104 and the fourth fibers 105, may be arranged so that there are gaps between adjacent fibers in the second layer (e.g., gaps between adjacent carbon fiber tows and gaps between adjacent glass fiber strands (e.g., crimped textured glass yarns), and gaps between adjacent carbon fiber tows and glass fiber strands (e.g., crimped textured glass yarns)).

[0303] In embodiments, the hybrid fabrics described herein may be impregnated with a resin and the resin cured to form a composite article.

[0304] Example

[0305] The following are examples of fabrics and related aspects described herein. Therefore, these examples should not be considered as limiting the present disclosure, but are only used to teach how to implement the methods of the present disclosure and obtain the products of the present disclosure.

[0306] Example 1

[0307] The hybrid fabric is produced by providing a first layer comprising carbon and glass fibres oriented in the 0° direction (ie along the length of the fabric), a second layer made of glass fibres oriented in the 90° direction (ie perpendicular to the length of the fabric).

[0308] The first layer is formed by providing strands of 12K carbon fiber, each strand having a linear density of about 800 tex (the filaments of the carbon fiber have a diameter of 7 μm and an epoxy compatible sizing agent) and 2 strands of 1200 tex glass fiber, the glass fiber being a direct roving (Advantex with an epoxy compatible sizing agent). TM E-CR glass fiber, the filaments of the glass fiber have a diameter of 17 μm) are fed, the strands of carbon fiber are aligned in the 0° direction and are equally spaced across the width of the fabric, and two glass fiber strands are placed at either end of the carbon fiber strands. The carbon fiber strands in the first layer are present at 0.98 strands per cm.

[0309] The second layer was formed by providing 68 tex glass fiber strands (E-glass with epoxy compatible sizing agent) oriented at 90° to the first fibers of the first layer, wherein the second layer contained 1.97 glass fiber strands per cm (measured perpendicular to the second direction, i.e., along the first direction). Stripes of fabric formed from the glass fiber strands of the second layer were cut on the machine in approximately 5 mm.

[0310] The first and second layers were stitched together using a polyester stitching yarn having a linear density of 7.6 tex and a tricot stitch pattern with a stitch length of 3 mm. Figure 2 As schematically shown in , the stitchbonded fabric is such that the stitching yarn 106 forms stitches along each of the carbon fiber strands (tows) 102 and also within each of the gaps between adjacent carbon fiber tows.

[0311] The total weight per unit area of ​​the fabric is 127g / m 2 .

[0312] Figure 3a A photograph of the fabric of Example 1 is shown. Figure 3a The photographs show that the fabric of Example 1 exhibits some shrinkage which results in an increase in the length of the streaks.

[0313] Example 2

[0314] The hybrid fabric was produced as described in Example 1, except that the second layer was formed by providing 140 tex crimped textured glass yarn (from Vetrotex) oriented at 90° to the first fibers of the first layer. TMThe second layer is formed of a crimped textured E-glass yarn ECT9 T140 K252C) wherein the distance between adjacent glass fiber strands of the second layer is about 5 mm. The crimped textured glass yarn used has a minimum diameter of 0.9 mm and 1.2 bulked sections per cm (each bulked section is defined as having a diameter d at least 10% greater than the minimum diameter of the yarn (i.e. greater than 1 mm) B The length of the yarn (measured perpendicular to the length of the yarn, e.g. Figure 4 ). The textured glass yarn used comprises 1.2 bulked sections per cm, and the bulked sections of the textured glass yarn account for more than 50% of the length of the textured glass yarn. The striations of the fabric formed by the glass fiber strands of the second layer are about 3 mm (smaller striations are possible due to improved product stability and reduced shrinkage). The fabric has a thickness of 0.45 mm. The improved stability of the hybrid fabric of Example 2 compared to the hybrid fabric of Example 1 can be seen from Figure 3a and Figure 3b It was observed that Figure 3a and 3b It is shown that the fabric of Example 2 has more uniform spacing of carbon tows and smaller striations compared to the fabric of Example 1 provided after stitchbonding due to the use of crimped textured glass yarns in Example 2.

[0315] The use of texturized glass fibers in the 90° direction (textured glass yarns) provides a lightweight product with excellent stability and handling resistance.

[0316] Figure 3b A photograph of the fabric of Example 2 is shown.

[0317] Example 3

[0318] The hybrid fabric is produced by providing a first layer containing carbon fibers (first fibers) and glass fibers (third fibers) oriented in a 0° direction (i.e. along the length of the fabric) and a second layer made of crimped textured glass yarns (second fibers), carbon fibers (fourth fibers) and PET monofilaments (fifth fibers) oriented in a 90° direction (i.e. perpendicular to the length of the fabric).

[0319] The first layer is formed by providing strands of 12K carbon fiber, each strand of carbon fiber having a linear density of about 800 tex (the filaments of the carbon fiber having a diameter of 7 μm and an epoxy compatible sizing agent), and strands of 68 tex glass fiber, the strands of the glass fiber being made of direct roving (Advantex with an epoxy compatible sizing agent). TME-CR glass fiber, the filaments of the glass fiber had a diameter of 9 μm) were fed, the strands of carbon fiber and glass fiber were aligned in the 0° direction and evenly spaced across the fabric width, with 0.25 strands of carbon fiber per cm and 0.74 strands of glass fiber per cm.

[0320] The second layer is formed by providing 140 tex crimped textured glass yarn (from Vetrotex) oriented at 90° to the first fibers of the first layer. TM The woven fabric is formed of a woven E-glass yarn ECT9 T140 K252C) having about 0.87 strands of woven glass yarn per cm, with the strands of woven glass yarn being equally spaced over the length of the fabric. The woven glass yarn used has a minimum diameter of 0.9 mm and 12 bulked sections per 10 cm (each bulked section being defined as having a diameter d at least 10% greater than the minimum diameter of the yarn (i.e. greater than 1 mm) B The length of the yarn (measured perpendicular to the length of the yarn, e.g. Figure 4 ). The textured glass yarn used includes 12 bulked sections per 10 cm, and the bulked sections of the textured glass yarn occupy more than 50% of the length of the textured glass yarn. The second layer also contains strands of 12K carbon fiber aligned with the textured glass yarn, each carbon fiber strand having a linear density of about 800 tex (the carbon fiber filaments have a diameter of 7 μm and an epoxy resin compatible sizing agent), and 0.43 strands of carbon fiber per cm of the length of the fabric; and PET monofilaments aligned with the textured yarn, which have a diameter of 15 μm, a linear density of 24.3 tex, and 0.87 PET monofilaments per cm of the length of the fabric. The carbon fibers, textured glass yarns, and PET monofilaments are evenly spaced apart over the length of the fabric.

[0321] The first and second layers were stitched together using a polyester stitching yarn having a linear density of 7.6 tex and a tricot stitch pattern with a stitch length of 3 mm. Figure 2 As schematically shown in , the stitchbonded fabric is such that the stitching yarn 106 forms stitches along each of the carbon fiber strands (tows) 102 and also within each of the gaps between adjacent carbon fiber tows.

[0322] The total weight per unit area of ​​the fabric is 85g / m 2 .

[0323] The fabric formed from the glass fiber strands of the second layer has striations less than 5 mm (smaller striations are possible due to improved product stability and reduced shrinkage).

[0324] Figure 3c A photograph of the fabric of Example 3 is shown.

[0325] Table 1 below provides a summary of the fabrics produced according to Examples 1 to 3.

[0326] Table 1

[0327]

[0328] The weight per unit area of ​​the different components and fabrics was determined according to ISO 3374.

[0329] It has also been found that the hybrid fabrics of the embodiments are easily infused with resin at an acceptable infusion rate without requiring the carbon fibers (eg, carbon fiber tows) used to form the hybrid fabric to be spread or pre-impregnated with resin.

[0330] The present inventors have surprisingly found that by providing a hybrid fabric comprising carbon fibers in a first direction and texturized yarns in a second direction, the stability and handling resistance of a lightweight hybrid fabric is improved compared to a hybrid fabric comprising standard fibers (e.g. standard glass fibers) in the second direction instead of texturized yarns.

[0331] Conventionally, a skilled artisan aiming to provide a non-crimp fabric would select fiber positions in order to optimize fiber alignment, which would be expected to optimize the mechanical properties of the non-crimp fabric. Therefore, the use of textured yarns in non-crimp fabrics (such as the hybrid fabrics described herein) goes against the skilled artisan's understanding of how non-crimp fabrics should be produced (the fibers in the textured yarns are not all aligned (see, e.g., Figure 4 ), this misalignment of the fibers in the textured yarn allows for the desired bulk of the textured yarn). Even more surprisingly, the use of the textured yarn in the hybrid fabrics described herein actually improves the stability and handling resistance of the hybrid fabric.

[0332] The examples provided herein demonstrate that the use of texturized yarns as described herein allows for the provision of very lightweight carbon fiber and glass fiber hybrid fabrics, which may contain carbon fibers oriented in a single direction or carbon fibers oriented in different directions, by improving the stability of the fabric.

[0333] The features disclosed in the foregoing description or in the following claims or in the accompanying drawings, expressed in their specific form or in terms of means for performing the disclosed functions or methods or processes for obtaining the disclosed results, may, where appropriate, be used alone or in any combination of these features to realize the invention in its various different forms.

[0334] Although the present invention has been described in conjunction with the above exemplary embodiments, many equivalent modifications and variations will be apparent to those skilled in the art when this disclosure is given. Therefore, the exemplary embodiments of the present invention set forth above are considered to be illustrative rather than restrictive. Various changes may be made to the described embodiments without departing from the spirit and scope of the present invention.

[0335] For the avoidance of any doubt, any theoretical explanations provided herein are intended to enhance the reader's understanding. The inventors do not wish to be bound by any of these theoretical explanations.

[0336] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0337] Throughout this specification, including the claims that follow, unless the context requires otherwise, the words "comprise" and "comprising" and variations such as "have" and "containing", will be understood to imply the inclusion of stated integers or steps or groups of integers or steps but not the exclusion of any other integers or steps or groups of integers or steps.

[0338] It must be noted that, as used in the specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly indicates otherwise. Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation by using the antecedent "about", it should be understood that the particular value forms another embodiment. The term "about" in relation to a numerical value is optional and means, for example, + / - 10%.

Claims

1. A carbon fiber and glass fiber hybrid fabric, the fabric include: a first layer comprising first fibers oriented in a first direction; a second layer comprising second fibers oriented in a second direction; stitching yarns that hold the fibers of the first layer and the second layer in their respective orientations, wherein the second direction is within about 45 degrees to about 90 degrees of the first direction, the first fibers include carbon fibers, The second fiber is a stabilizing fiber, The fabric has a weight per unit area of ​​less than about 500 g / m 2 , The first fibers comprise at least about 15% by weight of the fabric, and The second fibers comprise less than about 50% by weight of the fabric.

2. The fabric of claim 1, wherein the weight per unit area of ​​the fabric is less than about 200 g / m 2 .

3. The fabric of claim 1 or 2, wherein the stabilizing fiber is a textured yarn.

4. The fabric of claim 3, wherein the textured yarn is a textured glass yarn.

5. The fabric of claim 3 or 4, wherein the textured yarn has a minimum diameter of less than about 4 mm, or about 1 mm or less.

6. The fabric of any one of claims 3 to 5, wherein the texturized yarn comprises a plurality of bulked sections, each bulked section having a diameter at least 10% greater than a minimum diameter of the texturized yarn.

7. The fabric of claim 6, wherein the bulked section of the texturized yarn comprises at least 10% of the length of the texturized yarn.

8. The fabric of claim 6 or claim 7, wherein the texturized yarn comprises from about 2 to about 30 bulked segments per 10 cm length of the texturized yarn.

9. The fabric of any one of claims 3 to 8, wherein the texturized yarns oriented in the second direction comprise from about 5% to about 30% by weight of the fabric.

10. The fabric according to any one of the preceding claims, wherein the first layer comprises third fibers oriented in a third direction, the third fibers being glass fibers.

11. The fabric of any one of the preceding claims, wherein the first layer comprises between about 0.25 and about 5 first fiber strands per cm.

12. The fabric of any one of the preceding claims, wherein the stitching yarn forms stitches along a plurality of the first fiber strands.

13. The fabric of any one of the preceding claims, wherein the second layer comprises second fiber strands, and the second layer comprises between about 0.25 and about 5 second fiber strands per cm.

14. A fabric according to any one of the preceding claims, wherein the first layer comprises third fibers oriented in a third direction, the third fibers being glass fibers; and / or the stabilizing fibers are texturized glass yarns.

15. A fabric according to any one of the preceding claims, the first layer comprising first fibers oriented in a first direction and third fibers oriented in a third direction, and the second layer comprising second fibers oriented in a second direction and fourth fibers oriented in a fourth direction, in: The first fibers comprise from about 15% to about 80% by weight of the total weight of the fabric; The second fibers comprise from about 5% to about 50% by weight of the total weight of the fabric; The third fibers comprise from about 0 weight % to about 50 weight % of the total weight of the fabric; and The fourth fibers comprise from about 0 wt % to about 80 wt % of the total weight of the fabric.

16. The fabric of any of the preceding claims, wherein the first layer has a basis weight in the range of about 20 wt. % to about 80 wt. % based on the total weight of the fabric, and the second layer has a basis weight in the range of about 5 wt. % to about 75 wt. % of the total basis weight of the fabric.

17. A method for producing a carbon fiber and glass fiber hybrid fabric, the method include: providing a first layer comprising first fibers oriented in a first direction, the first fibers comprising carbon fibers; providing a second layer comprising second fibers oriented in a second direction, the second fibers comprising stabilizing fibers, the second layer being disposed on the first layer, the second direction being within about 45 degrees to about 90 degrees of the first direction; The first layer and the second layer are stitched together using a stitching yarn to form a 2 The unit area weight of the mixed fabric, wherein the first fibers oriented in the first direction comprise at least about 15 weight percent of the total weight of the fabric, and the second fibers oriented in the second direction comprise at most about 50 weight percent of the total weight of the fabric.

18. A composite product comprising a resin and the hybrid fabric according to any one of claims 1 to 16.

19. The textured yarn is used to provide a yarn having a weight of less than about 500 g / m 2 Use of carbon fiber and glass fiber hybrid fabric with a unit area weight.

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