Stabilized fabric

Abstract

Described herein is a fabric comprising: a first fiber oriented in a first direction; a second fiber oriented in a second direction; and a stitch-bonding yarn that maintains the first fiber and the second fiber in their respective orientations, the second direction being different from the first direction, where the first fiber comprises glass fibers and / or carbon fibers, and the second fiber is a crimp-textured yarn.

Description

Technical Field

[0001] The present invention relates to fabrics comprising glass and / or carbon fibres, in particular for use in combination with reinforcement elements in structural components such as wind turbine blades or related components such as spar caps. In particular, the present invention relates to wrinkle-free fabrics comprising glass and / or carbon fibres and texturised yarns. The present invention also relates to the use of texturised yarns for stabilising wrinkle-free fabrics. Background Art

[0002] It is known to use glass fibers and / or carbon fibers to form reinforcing fabrics to reinforce structural components such as wind turbine blades or related components (eg spar caps).

[0003] Structural components (reinforced structural components) including reinforcing fabrics are typically formed by stacking layers of reinforcing fabric in a mold, filling the mold with resin, and curing the resin to form the component. This method can be time consuming. Attempts have been made to improve the production efficiency of reinforced structural components, including pre-cutting reinforcing fabrics and forming stacked layers of pre-cut reinforcing fabrics before assembling the reinforced structural components. However, difficulties associated with the handleability and stability of the reinforcing fabrics have been found, particularly when transporting stacked layers of pre-cut reinforcing fabrics. Such difficulties associated with the handleability and stability of the reinforcing fabrics may result in deformation of the fabric, which may then require additional effort to correct the fabric size and reorient the fabric layers. In addition to increasing layup time, problems associated with the handleability and stability of the reinforcing fabrics may increase the loss of the fabric or result in a deleterious effect on the mechanical properties of the structural component.

[0004] As the search for alternative energy sources continues, the use of wind energy and wind turbines has received increasing attention. As interest in harnessing wind energy to generate more energy has grown, technological advances in the field have allowed for increased sizes of wind turbine blades. Increasing the size of wind turbine blades has also increased the time required to produce wind turbine blades.

[0005] It would be desirable to provide a reinforcement fabric that is dimensionally stable and also resistant to handling, to allow for improved production efficiency of wind turbine blades or related components. Summary of the invention

[0006] In most general terms, the present invention provides a wrinkle-free fabric comprising glass fibers and / or carbon fibers in combination with textured yarns.

[0007] The inventors have found that the present invention allows the provision of an easy to handle and dimensionally stable fabric useful in the production of wind turbine blades or related components. The inventors have also found that providing such a fabric improves the efficiency of the production of wind turbine blades or related components.

[0008] In a first aspect, the present invention provides a fabric comprising:

[0009] first fibers oriented in a first direction;

[0010] second fibers oriented in a second direction; and

[0011] a stitching yarn that holds the first fibers and the second fibers in their respective orientations, the second orientation being different from the first orientation,

[0012] The first fibers include glass fibers and / or carbon fibers, and the second fibers are textured yarns.

[0013] In a second aspect, the present invention provides a method of providing a fabric, the method comprising:

[0014] providing a first structural layer comprising first fibers oriented in a first direction, the first fibers comprising glass fibers and / or carbon fibers;

[0015] providing a first stabilizing layer comprising second fibers oriented in a second direction, the second fibers being textured yarns, the second direction being different from the first direction; and

[0016] The first structural layer and the first stabilizing layer are stitched together using a stitching yarn to form a fabric.

[0017] In a third aspect, the present invention provides the use of a textured yarn, such as a textured glass yarn, for improving the stability of a non-wrinkle fabric comprising glass fibers and / or carbon fibers.

[0018] In a fourth aspect, the present invention provides a composite article comprising a fabric as described herein.

[0019] 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

[0020] Embodiments and experiments illustrating the principles of the present invention will now be discussed with reference to the accompanying drawings, in which:

[0021] Figure 1 is a schematic diagram of a cross section through a texturized yarn;

[0022] Figure 2 is a schematic diagram showing a fabric according to an embodiment of the present invention;

[0023] Figure 3 is a schematic diagram showing the production of a fabric according to an embodiment of the present invention; and

[0024] Figure 4is a graph showing the results of a No-Twist-Out Test performed on the fabrics described herein. DETAILED DESCRIPTION

[0025] 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.

[0026] Fabrics described herein may include glass fibers. The term "glass fibers" 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 fabrics described herein may be provided as glass fiber strands (or tows). The glass fibers described herein may have a sizing agent on their surface, such as a sizing agent applied to the glass fibers during their formation. The sizing agent may include components that promote the formation of glass fibers and / or their use in a matrix resin, such as a film former, a lubricant, a coupling agent (to promote compatibility between glass fibers and a resin for forming a composite product comprising fabrics described herein), etc. In some embodiments, the glass fibers include a polyester compatible sizing agent or an epoxy compatible sizing agent.

[0027] 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.

[0028] 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.

[0029] Any suitable glass reinforcing fiber can be used as the glass fiber described herein, for example, as the first fiber and / or the fourth fiber, for example, E glass, E-CR glass (such as Advantex available from Owens Corning) can be used. TM Glass fibers made of (A), C-glass, H-glass, S-glass and AR glass types.

[0030] In an embodiment, the glass fibers referred to herein (e.g., the first and / or third and / or fourth fibers that may comprise, consist essentially of, or consist of glass fibers) have a linear mass density in the range of about 50 tex to about 5000 tex, e.g., about 200 tex to about 4800 tex, about 300 tex to about 2500 tex, about 300 tex to about 2400 tex, or about 600 tex to about 1200 tex.

[0031] 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 1 A schematic diagram of a cross section through a "textured yarn" (eg, a textured glass yarn) is shown.

[0032] 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 1 A schematic diagram of a cross section through a "textured glass yarn" is shown in FIG.

[0033] Figure 1 A textured yarn, such as textured glass yarn 104a, is shown, which includes an enlarged section B, such as having a diameter d B The expanded section B of the crimped textured yarn (eg, crimped textured glass yarn) is formed when a bundle of continuous filaments (eg, a bundle of continuous glass filaments, such as a strand of glass filaments) passes through the turbulent flow of compressed air. Figure 1 The texturized yarn shown in FIG. 1 (eg, texturized glass yarn 104a) shows an enlarged section B having a diameter dB, which is substantially parallel to a section having a diameter d S The unexpanded sections S are interspersed together. Diameter d S The diameter dB may correspond to the minimum diameter of a texturized yarn (e.g., a texturized glass yarn). The diameter dB may be a diameter that is at least 10% greater than the minimum diameter of a texturized yarn (e.g., a texturized glass yarn). Thus, in embodiments, a "textured yarn" (e.g., a texturized glass yarn) refers to a strand of fiber (e.g., a strand of glass fiber) that includes a plurality of expanded sections (e.g., expanded sections formed when a strand of fiber is exposed to turbulent flow of compressed air). The diameter d B or SIt can be determined by placing a strand of texturized yarn (e.g., 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, by measuring the width of the texturized yarn perpendicular to the length of the texturized yarn, using, for example, a measuring ruler. The minimum diameter can be taken as the minimum diameter of a given length of texturized yarn (e.g., texturized glass yarn), such as the minimum diameter of a 10 cm length of texturized yarn (e.g., texturized glass yarn), or the minimum diameter of the texturized yarn (e.g., texturized glass yarn) along the length of the texturized yarn (e.g., texturized glass yarn) in a fabric.

[0034] Fabrics described herein may include carbon fibers. The term "carbon fiber" is used herein to refer to a plurality of continuous carbon filaments (the term "continuous" used herein refers to a length that is many times its diameter, for example, at least about 5000 times its diameter, for example, at least about 10 000 times its diameter of fiber / filament). The carbon fibers used in fabrics described herein may be provided as carbon fiber tows (or strands), which are bundles of continuous carbon filaments. Carbon fibers described herein may have a sizing agent on their surface, for example, carbon fibers have a sizing agent applied to the carbon fibers during fiber formation. Sizing agents may include components that promote the formation of carbon fibers and / or their use in matrix resins, such as film formers, lubricants, coupling agents (to promote compatibility between carbon fibers and resins used to form composite products comprising fabrics described herein), etc. In some embodiments, carbon fibers include polyester compatible sizing agents or epoxy compatible sizing agents.

[0035] In embodiments, the carbon fibers, when present, have a linear mass density in the range of about 100 tex to about 5000 tex, e.g., 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, about 400 tex to about 4800 tex, about 600 tex to about 4800 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.

[0036] In an embodiment, the carbon fiber (when present) is provided by a carbon fiber tow (carbon fiber strand). In an embodiment, the size of the carbon fiber tow ranges from 6K to 50K, such as 6K to 24K or 6K to 12K. For example, the first fiber can 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 consists of #×1,000 individual carbon filaments, i.e., a carbon fiber tow of size 6K consists of approximately 6000 carbon fiber filaments / fibers.

[0037] The present invention provides a fabric comprising first fibers oriented in a first direction and second fibers oriented in a second direction. The fabric is a non-crease fabric, and the first fibers and the second fibers are held in their respective orientations by stitching yarns (rather than weaving the first fibers and the second fibers together, i.e., the non-crease fabric is a non-woven fabric).

[0038] In an embodiment, the second direction is within about 0 degrees to about 90 degrees of the first direction, for example, the second direction is within about 10 degrees to about 90 degrees of the first direction, within about 15 degrees to about 90 degrees of the first direction, or within about 25 degrees to about 90 degrees of the first direction. For example, the second direction may be within about 30 degrees to about 90 degrees of the first direction, or within about 45 degrees to about 90 degrees of the first direction.

[0039] In an embodiment, the fabric has a thickness of about 200 g / m 2 About 2500g / m 2 In the range of, for example, about 300g / m 2 About 2000g / m 2 , about 400g / m 2 About 2000g / m 2 , about 400g / m 2 About 1500g / m 2 , about 500g / m 2 About 1500g / m 2 , about 500g / m 2 About 1300g / m 2 , or about 750g / m 2 About 2500g / m 2 The weight per unit area of ​​a fabric can be determined according to ISO 3374.

[0040] In an embodiment, the first fibers oriented in the first direction include glass fibers and / or carbon fibers. In an embodiment, the first fibers oriented in the first direction include glass fibers. In an embodiment, the first fibers oriented in the first direction include carbon fibers. In an embodiment, the first fibers include, consist essentially of, or consist of glass fibers. In an embodiment, the first fibers are glass fibers. In an embodiment, the first fibers include, consist essentially of, or consist of glass fibers and / or carbon fibers.

[0041] The fabric comprises first fibers oriented in a first direction, the first fibers comprising glass fibers and / or carbon fibers.

[0042] The fabric comprises second fibers oriented in a second direction, the second fibers being textured yarns, such as textured glass yarns.

[0043] In an embodiment, the fabric comprises third fibers oriented in a third direction and / or fourth fibers oriented in a fourth direction.

[0044] In an embodiment, the fabric comprises:

[0045] a first structural layer comprising first fibers oriented in a first direction;

[0046] a first stabilizing layer comprising second fibers oriented in a second direction; and

[0047] A stitching yarn holds first fibers and second fibers in their respective orientations, the second direction being different from the first direction.

[0048] In an embodiment, the fabric comprises:

[0049] a first structural layer comprising first fibers oriented in a first direction;

[0050] a first stabilizing layer comprising second fibers oriented in a second direction;

[0051] a second stabilizing layer and / or a second structural layer, the second stabilizing layer comprising third fibers oriented in a third direction, the second structural layer comprising fourth fibers oriented in a fourth direction; and

[0052] A stitching yarn holds the first fibers, the second fibers, the third fibers, and / or the fourth fibers in their respective orientations, the second direction being different from the first direction.

[0053] In an embodiment, the fabric comprises:

[0054] a first structural layer comprising first fibers oriented in a first direction;

[0055] a first stabilizing layer comprising second fibers oriented in a second direction; and

[0056] a second stabilizing layer comprising third fibers oriented in a third direction; and

[0057] A stitching yarn holds the first fibers, the second fibers, and the third fibers in their respective orientations, the second direction being different from the first direction, and optionally the third direction being different from the first direction and the second direction.

[0058] In an embodiment, the fabric comprises:

[0059] a first structural layer comprising first fibers oriented in a first direction;

[0060] a first stabilizing layer comprising second fibers oriented in a second direction;

[0061] a second structural layer comprising fourth fibers oriented in a fourth direction; and

[0062] A stitching yarn holds the first fibers, the second fibers, and the fourth fibers in their respective orientations, the second direction being different from the first direction, and optionally the fourth direction being different from the second direction.

[0063] In an embodiment, the fabric comprises:

[0064] a first structural layer comprising first fibers oriented in a first direction;

[0065] a first stabilizing layer comprising second fibers oriented in a second direction;

[0066] a second stabilizing layer comprising third fibers oriented in a third direction;

[0067] a second structural layer comprising fourth fibers oriented in a fourth direction; and

[0068] A stitching yarn holds the first fibers, the second fibers, the third fibers, and the fourth fibers in their respective orientations, the second direction being different from the first direction, and optionally, the second direction and the third direction being different from the first direction and the fourth direction.

[0069] In embodiments, the fabric includes a first structural layer comprising, consisting essentially of, or consisting of first fibers oriented in a first direction.

[0070] In embodiments, the fabric includes a first stabilizing layer comprising, consisting essentially of, or consisting of second fibers oriented in the second direction (ie, texturized yarns oriented in the second direction).

[0071] In embodiments, the fabric includes a second stabilizing layer comprising, consisting essentially of, or consisting of third fibers oriented in a third direction.

[0072] In embodiments, the fabric comprises a second structural layer comprising, consisting essentially of, or consisting of fourth fibers oriented along a fourth direction.

[0073] In an embodiment, the fabric comprises a first structural layer, a first stabilizing layer, a second stabilizing layer, and a second structural layer. In an embodiment, at least one of the first stabilizing layer and the second stabilizing layer is disposed between the first structural layer and the second structural layer. In an embodiment, the first stabilizing layer and the second stabilizing layer are disposed between the first structural layer and the second structural layer. In an embodiment, the first stabilizing layer is disposed between the first structural layer and the second structural layer, and the second structural layer is disposed on the second stabilizing layer. In an embodiment, the second stabilizing layer is disposed between the first structural layer and the second structural layer, and the second structural layer is disposed on the first stabilizing layer.

[0074] In an embodiment, the second direction is different from the first direction and the fourth direction. In an embodiment, the second direction is different from the first direction and the fourth direction, and the first direction and the fourth direction differ by at least 45°. In an embodiment, the second direction is the same as or different from the third direction. In an embodiment, the third direction is different from the first direction. In an embodiment, the third direction is different from the first direction and the fourth direction. In an embodiment, the third direction is different from the first direction and the fourth direction, and the first direction and the fourth direction differ by at least 45°. In an embodiment, the first direction, the second direction, the third direction and the fourth direction are all different from each other.

[0075] In an embodiment, the fabric comprises:

[0076] a first structural layer comprising first fibers oriented in a first direction;

[0077] a first stabilizing layer comprising second fibers oriented in a second direction;

[0078] a second stabilizing layer comprising third fibers oriented in a third direction;

[0079] a second structural layer comprising fourth fibers oriented in a fourth direction; and

[0080] a stitching yarn that holds the first fibers, the second fibers, the third fibers, and the fourth fibers in their respective orientations,

[0081] The second direction and the third direction are different from the first direction and the fourth direction, optionally the second direction and the third direction are different and / or the first direction and the fourth direction are different.

[0082] The fabrics described herein have a fabric length defined by the production direction of the fabric. In an embodiment, the fabric length (through the production direction of the fabric) is aligned with the stitching direction of the stitching yarns. The fabric length can be described as the "0° direction of the fabric".

[0083] In an embodiment, at least one of the second direction and the third direction is substantially perpendicular to the fabric length, ie perpendicular to the 0° direction of the fabric.In an embodiment, the second direction is substantially perpendicular to the fabric length, ie perpendicular to the 0° direction of the fabric.

[0084] In an embodiment, the fabric is a biaxial fabric comprising a first structural layer and a second structural layer, wherein the first direction is different from the fourth direction. In an embodiment, the fabric comprises a first structural layer and a second structural layer, the first direction is in a range of greater than 0° to about 90° relative to the 0° direction of the fabric, and the fourth direction is in a range of about 0° to about -90° relative to the 0° direction of the fabric. In an embodiment, the fabric comprises a first structural layer and a second structural layer, the first direction is in a range of about 10° to less than about 90° relative to the 0° direction of the fabric, and the fourth direction is in a range of about -10° to less than about -90° relative to the 0° direction of the fabric. In an embodiment, the fabric comprises a first structural layer and a second structural layer, the first direction is in a range of about 45° to about 89° relative to the 0° direction of the fabric, and the fourth direction is in a range of about -45° to about -89° relative to the 0° direction of the fabric.

[0085] In an embodiment, the fabric comprises:

[0086] a first structural layer comprising first fibers oriented in a first direction;

[0087] a first stabilizing layer comprising second fibers oriented in a second direction;

[0088] a second stabilizing layer comprising third fibers oriented in a third direction;

[0089] a second structural layer comprising fourth fibers oriented in a fourth direction; and

[0090] a stitching yarn that holds the first fibers, the second fibers, the third fibers, and the fourth fibers in their respective orientations,

[0091] wherein the first direction is within about 45° to less than about 90° (e.g., about 45° to about 89°) of the 0° direction of the fabric, the fourth direction is within about -45° to less than about -90° (e.g., about -45° to about -89°) of the 0° direction of the fabric, the second direction is substantially perpendicular to the 0° direction of the fabric and the third direction is substantially aligned with the 0° direction of the fabric.

[0092] The phrase "substantially perpendicular to the 0° direction of the fabric" may be used herein to refer to a direction within a range of about + / -88° to about 90° relative to the 0° direction of the fabric, for example, a direction within a range of about + / -89° to about 90° relative to the 0° direction of the fabric.

[0093] The phrase "substantially aligned with the 0° direction of the fabric" may be used herein to refer to a direction within a range of about -1° to about 1° relative to the 0° direction of the fabric, or aligned with the 0° direction of the fabric.

[0094] In embodiments, the first fibers and / or the fourth fibers comprise, consist essentially of, or consist of glass fibers and / or carbon fibers.

[0095] In an embodiment, the first fibers and / or the fourth fibers include, consist essentially of, or consist of glass fibers, such as glass fibers having a linear mass density in a range of, for example, about 200 tex to about 4800 tex, about 300 tex to about 2500 tex, about 300 tex to about 2400 tex, or about 600 tex to about 1200 tex.

[0096] In an embodiment, the second fiber is a textured yarn, such as a textured glass yarn, such as a textured yarn as described above (e.g., as described above with respect to Figure 1 In an embodiment, the textured glass yarn has a linear mass density in the 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, about 70 tex to about 200 tex, or about 50 tex to about 140 tex.

[0097] In an embodiment, "textured yarn" refers to a strand of 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). In an embodiment, a bulked section of a texturized yarn is a section 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 section of the texturized yarn is smaller than the smallest diameter of the bulked section). The diameter of a section of the texturized yarn may be measured perpendicular to the length of 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 fabric.

[0098] 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.

[0099] In an embodiment, the texturized yarn (e.g., a 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 yarn. In an embodiment, the texturized yarn (e.g., a texturized glass 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 the smallest diameter of the texturized yarn. In an embodiment, the texturized yarn (e.g., a 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, and including 2 to 30 (e.g., 2 to 25, 3 to 30, or 5 to 15) bulked segments per 10 cm length of the texturized yarn. In an embodiment, the texturized yarn (e.g., a 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, and including about 2 to about 30, e.g., about 3 to about 30, about 2 to about 25, or about 5 to about 15 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 bulked segments are as defined herein.

[0100] 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 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%.

[0101] 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 30, 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.

[0102] 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%, within about ±5%).

[0103] 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).

[0104] 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 30 (e.g., about 2 to about 25, about 5 to about 15) bulked segments per 10 cm length.

[0105] 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 30 (e.g., about 2 to about 25, about 5 to about 15) bulked segments per 10 cm length of the texturized yarn.

[0106] 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 30 (e.g., about 2 to about 25, 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.

[0107] 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%.

[0108] 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.

[0109] The second fiber is a textured glass yarn, such as the textured glass yarn described above (e.g., as described above with respect to Figure 1 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%. In an embodiment, for example, the 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 glass yarn, and the texturized glass yarn includes about 2 to about 30 (e.g., about 2 to about 25, about 5 to about 15) bulked segments per 10 cm length of the texturized yarn, wherein consecutive bulked segments of the texturized glass 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.

[0110] In an embodiment, the fabric comprises a second stabilizing layer comprising third fibers oriented in a third direction. In an embodiment, the third fibers comprise, consist essentially of, or consist of glass fibers, such as glass fibers having a linear mass density in the range of about, for example, about 50 tex to about 2400 tex, about 50 tex to about 1200 tex, about 50 tex to about 600 tex, about 50 tex to about 200 tex, or about 50 tex to about 140 tex.

[0111] In an embodiment, the third fiber comprises, consists essentially of, or consists of glass fiber. In an embodiment, the third fiber comprises, consists essentially of, or consists of glass fiber, such as glass fiber having a linear mass density in the range of about, for example, about 50 tex to about 2400 tex, about 50 tex to about 1200 tex, about 50 tex to about 600 tex, or about 50 tex to about 140 tex. In an embodiment, the third fiber is a textured yarn, such as a textured glass yarn. In an embodiment, the textured glass yarn has a linear mass density in the range of about 50 tex to about 200 tex, or about 50 tex to about 140 tex.

[0112] In an embodiment, the first fibers comprise at least about 25% by weight of the total weight of the fabric. In an embodiment, the first fibers comprise about 25% to about 95% by weight of the total weight of the fabric, such as about 25% to about 75% by weight, or about 25% to about 70% by weight of the total weight of the fabric.

[0113] In an embodiment, the first structural layer accounts for at least about 25% by weight of the total weight of the fabric. In an embodiment, the first structural layer accounts for about 25% to about 95% by weight of the total weight of the fabric, such as about 25% to about 75% by weight, or about 25% to about 70% by weight of the total weight of the fabric.

[0114] In an embodiment, the fabric includes a second structural layer, and the second structural layer accounts for at least about 25 weight % of the total weight of the fabric. In an embodiment, the second structural layer accounts for about 25 weight % to about 75 weight % of the total weight of the fabric, or about 25 weight % to about 70 weight %.

[0115] In an embodiment, the textured yarn (e.g., textured glass yarn) comprises up to about 25% by weight of the total weight of the fabric, such as up to about 20% by weight of the total weight of the fabric, up to about 15% by weight of the total weight of the fabric, up to about 10% by weight of the total weight of the fabric, up to about 8% by weight of the total weight of the fabric, or up to about 5% by weight of the total weight of the fabric. In an embodiment, the textured yarn (e.g., textured glass yarn) comprises from about 0.5% by weight to about 25% by weight of the total weight of the fabric, such as from about 0.5% by weight to about 15% by weight of the total weight of the fabric, from about 0.5% by weight to about 10% by weight of the total weight of the fabric, from about 0.5% by weight to about 8% by weight of the total weight of the fabric, or from about 1% by weight to about 5% by weight of the total weight of the fabric.

[0116] In an embodiment, the second fibers account for up to about 25% by weight of the total weight of the fabric, such as up to about 20% by weight of the total weight of the fabric, up to about 15% by weight of the total weight of the fabric, or up to about 10% by weight of the total weight of the fabric, up to about 8% by weight of the total weight of the fabric, or up to about 5% by weight of the total weight of the fabric. In an embodiment, the second fibers account for about 0.5% to about 25% by weight of the total weight of the fabric, such as about 0.5% to about 15% by weight of the total weight of the fabric, about 0.5% to about 10% by weight of the total weight of the fabric, about 0.5% to about 8% by weight of the total weight of the fabric, or about 1% to about 5% by weight of the total weight of the fabric.

[0117] In an embodiment, the first stabilization layer comprises up to about 25% by weight of the total weight of the fabric, such as up to about 20% by weight of the total weight of the fabric, up to about 15% by weight of the total weight of the fabric, or up to about 10% by weight of the total weight of the fabric. In an embodiment, the first stabilization layer comprises from about 0.5% to about 25% by weight of the total weight of the fabric, such as from about 0.5% to about 15% by weight of the total weight of the fabric, from about 0.5% to about 10% by weight of the total weight of the fabric, from about 0.5% to about 8% by weight of the total weight of the fabric, or from about 1% to about 5% by weight of the total weight of the fabric.

[0118] In an embodiment, the second stabilizing layer comprises up to about 25% by weight of the total weight of the fabric, such as up to about 20% by weight of the total weight of the fabric, up to about 15% by weight of the total weight of the fabric, or up to about 10% by weight of the total weight of the fabric. In an embodiment, the second stabilizing layer comprises from about 0.5% to about 25% by weight of the total weight of the fabric, such as from about 0.5% to about 15% by weight of the total weight of the fabric, from about 0.5% to about 10% by weight of the total weight of the fabric, from about 0.5% to about 8% by weight of the total weight of the fabric, or from about 1% to about 5% by weight of the total weight of the fabric.

[0119] In an embodiment, the glass fibers (e.g., including texturized glass yarns) comprise at least about 50 wt %, such as at least about 60 wt %, at least about 70 wt %, at least about 80 wt %, at least about 90 wt %, at least about 95 wt %, or at least about 98 wt %, of the total weight of the fabric.

[0120] In an embodiment, the stitching yarns comprise less than about 10% by weight of the fabric, or less than about 8% by weight of the fabric. In an embodiment, the stitching yarns comprise from about 0.1% by weight to about 10% by weight of the fabric, such as from about 1% by weight to about 10% by weight of the fabric, or from about 2% by weight to about 8% by weight.

[0121] 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.

[0122] 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.

[0123] In an embodiment, the stitching yarns define a stitch length ranging from about 2 mm to about 7 mm, such as about 3 mm.

[0124] Typically, the fabric is resin-free, ie, none of the fibers forming the fabric have been pre-impregnated with resin.

[0125] Figure 2 is a schematic diagram of a fabric 100 composed of first fibers 102 (e.g., fiberglass strands) and second fibers (e.g., textured glass yarns) 104. The first fibers 102 are oriented in a first direction (a 45° direction, which is 45° from the 0° direction of the fabric), and the second fibers are oriented in a second direction (a 90° direction, which is substantially perpendicular to the length of the fabric ( Figure 2 0° direction shown in FIG.

[0126] Figure 31 is a schematic diagram of a fabric 100, which is composed of a first structural layer 110, a first stabilizing layer 120, a second stabilizing layer 130, and a second structural layer 140, wherein the first structural layer is formed of first fibers oriented in a first direction (45° direction, which is 45° to the 0° direction of the fabric), the first stabilizing layer is formed of second fibers oriented in a second direction (90° direction, which is substantially perpendicular to the 0° direction of the fabric), the second stabilizing layer is formed of third fibers oriented in a third direction (0° direction, which is aligned with the length of the fabric), and the second structural layer is formed of fourth fibers oriented in a fourth direction (-45° direction, which is -45° to the length direction of the fabric). Figure 3 In the illustrated embodiment, the first stabilization layer 120 and the second stabilization layer 130 are disposed between the first structural layer 110 and the second structural layer 140. As described herein, alternative configurations are possible.

[0127] In embodiments, the fabrics described herein may be impregnated with a resin and the resin cured to form a composite article.

[0128] Example

[0129] 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.

[0130] Comparative Example 1

[0131] The biaxial fabric is produced by providing a first structural layer made of glass fibers oriented in a 45° direction, a first stabilizing layer made of glass fibers oriented in a 0° direction (i.e. along the length of the fabric), a second stabilizing layer made of glass fibers oriented in a 90° direction (i.e. perpendicular to the length of the fabric) and a second structural layer made of glass fibers oriented in a -45° direction.

[0132] The first structural layer is provided by providing a direct roving (Advantex with epoxy compatible sizing agent TM The E-CR glass fiber is formed by feeding strands of 1200 tex glass fiber (the filaments of the glass fiber have a diameter of 17 μm), the strands of the glass fiber are aligned along a 45° direction, wherein the first structural layer contains 2.91 glass fiber strands per centimeter (measured perpendicular to the first direction).

[0133] The first stabilizing layer was formed by providing strands of 68 tex glass fiber (E-glass with an epoxy compatible sizing, the glass fiber filaments having a diameter of <19 μm) aligned in a 0° direction, wherein the first stabilizing layer contained 0.30 glass fiber strands per centimeter.

[0134] The second stabilizing layer was formed by providing strands of 68 tex glass fibers (E-glass with an epoxy compatible sizing, the glass fiber filaments having a diameter of <19 μm) oriented 90° to the fibers of the first stabilizing layer, wherein the second stabilizing layer contained 0.30 glass fiber strands per centimeter.

[0135] The second structural layer is provided by providing a direct roving (Advantex with epoxy compatible sizing agent TM The E-CR glass fiber is formed by feeding strands of 1200 tex glass fiber (the filaments of the glass fiber have a diameter of 17 μm), the strands of the glass fiber are aligned in a -45° direction, and the second structural layer contains 2.91 glass fiber strands per centimeter.

[0136] The fabric formed from the glass fiber strands is cut on the machine in stripes <10 mm.

[0137] The fabric layers are arranged so that the first stabilizing layer and the second stabilizing layer (layer 2 and layer 3 in Table 1) are arranged between the first structural layer and the second structural layer (layer 1 and layer 4 in Table 1), and are sewn together using polyester stitching yarn with a linear density of 7.6 tex and a chain stitching pattern with a stitch length of 2.6 mm.

[0138] The total unit area mass of the fabric is 998g / m 2 .

[0139] Example 2

[0140] A biaxial fabric is produced by providing a first structural layer made of glass fibers oriented in a 45° direction, a first stabilizing layer made of texturized glass yarns oriented in a 90° direction (i.e. perpendicular to the length of the fabric), a second stabilizing layer made of glass fibers oriented in a 0° direction (i.e. along the length of the fabric), and a second structural layer made of glass fibers oriented in a -45° direction.

[0141] The first structural layer is provided by providing a direct roving (Advantex with epoxy compatible sizing agent TM The E-CR glass fiber is formed by feeding strands of 1200 tex glass fiber (the filaments of the glass fiber have a diameter of 17 μm), the strands of the glass fiber are aligned along a 45° direction, wherein the first structural layer contains 2.91 glass fiber strands per centimeter (measured perpendicular to the first direction).

[0142] The first stabilizing layer is provided by providing 140 tex crimped textured glass yarn (from Vetrotex) oriented at 90° to the 0° direction of the fabric. TMThe first stabilizing layer is formed of a textured E-glass yarn ECT9 T140 K252C with an epoxy resin compatible sizing agent, the first stabilizing layer containing 0.30 glass fiber strands (textured glass yarn) per centimeter. The textured glass yarn used has a minimum diameter of 0.9 mm and has 12 expansion sections per 10 cm (each expansion section is defined as a section with a diameter d B (measured perpendicular to the length of the yarn, e.g. Figure 1 The yarn is at least 10% larger than the minimum diameter of the yarn (ie, larger than 1 mm). The textured glass yarn used contains 12 bulked sections per 10 cm, and the bulked sections of the textured glass yarn account for more than 50% of the length of the textured glass yarn.

[0143] The second stabilizing layer was formed by providing strands of 68 tex glass fiber (E-glass with an epoxy compatible sizing, the glass fiber filaments having a diameter of <19 μm) aligned in a 0° direction, wherein the second stabilizing layer contained 0.30 glass fiber strands per centimeter.

[0144] The second structural layer is provided by providing a direct roving (Advantex with epoxy compatible sizing agent TM The E-CR glass fiber is formed by feeding strands of 1200 tex glass fiber (the filaments of the glass fiber have a diameter of 17 μm), the strands of the glass fiber are aligned in a -45° direction, and the second structural layer contains 2.91 glass fiber strands per centimeter.

[0145] The fabric layers are arranged so that the first stabilizing layer and the second stabilizing layer (layer 2 and layer 3 in Table 1) are arranged between the first structural layer and the second structural layer (layer 1 and layer 4 in Table 1), and are sewn together using polyester stitching yarn with a linear density of 7.6 tex and a chain stitching pattern with a stitch length of 2.6 mm.

[0146] The total unit area mass of the fabric is 1000g / m 2 .

[0147] Example 3

[0148] A biaxial fabric was produced as described in Example 2, except that the order of the first stabilizing layer and the second structural layer was swapped so that the fabric layers were ordered so that the second stabilizing layer (layer 2 in Table 1) was disposed between the first structural layer and the second structural layer (layers 1 and 3 in Table 1), and the second structural layer (layer 3 in Table 1) was disposed on the first stabilizing layer (layer 4 in Table 1).

[0149] Example 4

[0150] The biaxial fabric was produced as described in Example 2, except that the first stabilizing layer was formed by providing a 140 tex crimped textured glass yarn (from Vetrotex) with 0.16 glass fiber strands per cm oriented at 90° to the fibers of the first stabilizing layer. TM The crimped and deformed E-glass yarn ECT9 T140 K252C) is formed.

[0151] The total unit area mass of the fabric is 998g / m 2 .

[0152] The fabrics of Comparative Example 1 and Examples 2-4 are summarized in the following Table 1. The references to Layers 1-4 in the table indicate the order of layers employed in each example (in numerical order from top to bottom), with Layer 1 being the uppermost layer and Layer 4 being the bottom layer.

[0153] Table 1

[0154]

[0155]

[0156] The weight per unit area of ​​the different components and fabrics was determined according to ISO 3374.

[0157] Fabric stability

[0158] The stability of various biaxial fabrics was tested using several fabric rolling and unrolling strategies.

[0159] The sample fabrics were unrolled and 2-meter-long samples were cut from each of the fabrics. The 2-meter samples were then rerolled on a cardboard tube with an outer diameter of 95 mm. To test the degree of deformation, the width of the sample was measured at several designated points (at 5 cm, 50 cm, 100 cm, 150 cm, and 195 cm) before and after rerolling.

[0160] Figure 4 is a graph showing the results of a no-tumble unfolding test performed on four different samples (Examples 1-4). These results were obtained by taking 3 test samples from each roll and subjecting them to the test method. The average width increase for each measurement point was then obtained. It can be observed that the fabrics of Examples 2-4 all show an increase in stability compared to the fabric of Comparative Example 1. It can be concluded that the use of texturized yarns provides a significant improvement in the dimensional stability of the fabric.

[0161] These tests demonstrate the ability of texturized yarns to improve the dimensional stability and handleability of non-wrinkle fabrics, particularly biaxial non-wrinkle fabrics.It should be noted that the inventors have observed similar improvements in unidirectional fabrics containing texturized yarns as described herein.

[0162] Conventionally, a skilled artisan aiming to provide a non-crimp fabric would select fibers and fiber positions in order to optimize fiber alignment, which would be expected to optimize the mechanical properties of the non-crimp fabric. Thus, the use of textured yarns in non-crimp fabrics such as the fabrics described herein goes against the skilled artisan's understanding of how non-crimp fabrics should be produced (fibers in textured yarns are not all aligned (see, e.g., Figure 1 ), this misalignment of the fibers in the textured yarn allows for the desired bulk of the textured yarn). Even more surprisingly, the use of textured yarns in the fabrics described herein actually improves the dimensional stability and handling resistance of the fabrics.

[0163] Impact on penetration performance

[0164] To ensure that the use of texturized yarns did not adversely affect the different fabric properties, the soak-through properties were also investigated.

[0165] Single layer cured thickness (CPT)

[0166] The CPT test measures the absorption of resin by a fabric. The focus of this test is to measure the thickness of the resulting saturated board and the glass weight fraction of the board. For this test, 20 layers of fabric with a size of 60×60 cm are completely saturated with resin.

[0167] Two different fabrics (Comparative Example 1 and Example 2) were evaluated using the CPT test using epoxy resin. The results shown in Table 2 indicate that resin absorption was not significantly altered by the presence of the texturized yarn. In addition, it was observed that the fabric containing the texturized glass yarn exhibited excellent soak-through time.

[0168] Table 2

[0169] Penetration thickness (mm) Glass weight fraction (%) Comparative Example 1 0.725 73 Example 2 0.731 73

[0170] In-Plane Penetration Rate Test (IPIT)

[0171] The IP IT test measures the distance covered by the resin over time. The flow front (distance) of the resin is recorded after 2, 4, 6, 8, 10, 12, 16, 20, 26, 32, 38, 44, 50, 55 and 60 minutes. The distance that the resin has traveled through the fabric is called the penetration length. The measured length relative to the penetration time is used as a measure of the penetration rate of the fabric. The IP IT test can be used to compare the penetration rates of different fabrics as long as the other test parameters are substantially the same.

[0172] Two different fabrics, Comparative Example 1 and Example 2, were evaluated using the IPIT test using epoxy resin in a 90° orientation direction (along the length of the texturized yarn). The results of the IPIT test were similar to the CPT test, indicating that the fabrics described herein exhibited excellent soak-through performance.

Claims

1. A fabric, comprising: first fibers oriented in a first direction; second fibers oriented in a second direction; and a stitching yarn that holds the first fibers and the second fibers in their respective orientations, the second orientation being different from the first orientation, The first fibers include glass fibers and / or carbon fibers, and the second fibers are textured yarns.

2. The fabric of claim 1, wherein the textured yarn comprises from about 0.5% to about 10% by weight of the fabric.

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

4. The fabric of any one of the preceding claims, wherein the texturized yarn has a minimum diameter of less than about 4 mm.

5. The fabric of any one of the preceding claims, 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 glass yarn.

6. The fabric of claim 5, wherein the bulked section of the texturized yarn comprises at least 10% of the length of the texturized glass yarn.

7. The fabric of claim 5 or claim 6, wherein the texturized yarn comprises from about 2 to about 30 bulked segments per 10 cm length of the texturized glass yarn.

8. The fabric of any one of claims 5 to 7, wherein the texturized yarn comprises a plurality of bulked sections, consecutive bulked sections of the texturized yarn being spaced apart by a distance in the range of about 0.5 mm to about 80 mm.

9. The fabric of any one of the preceding claims, wherein the second direction is greater than 0 degrees to about 90 degrees in the first direction.

10. The fabric according to any one of the preceding claims, wherein the fabric has a weight per unit area of ​​about 400 g / m 2 About 2500g / m 2 .

11. The fabric of any one of the preceding claims, wherein glass fibers comprise at least about 50 weight percent of the total weight of the fabric.

12. A fabric according to any one of the preceding claims, comprising: a first structural layer comprising first fibers oriented in the first direction; a first stabilization layer comprising second fibers oriented in the second direction; as well as A second stabilizing layer and / or a second structural layer, the second stabilizing layer comprising third fibers oriented along a third direction, the second structural layer comprising fourth fibers oriented along a fourth direction.

13. The fabric of claim 12, comprising the second structural layer, wherein the first stabilization layer is disposed between the first structural layer and the second structural layer, the first direction and the fourth direction being different from the second direction.

14. The fabric of claim 12, comprising the second structural layer, wherein the second structural layer is disposed between the first structural layer and the first stabilization layer, the first direction and the fourth direction being different from the second direction.

15. The fabric of any one of claims 12 to 14, wherein the first direction is within about 45° to about 89° of the 0° direction of the fabric, the fourth direction is within about -45° to about -89° of the 0° direction of the fabric, the second direction is substantially perpendicular to the 0° direction of the fabric, and the third direction is substantially aligned with the 0° direction of the fabric.

16. A method of providing a fabric, the method comprising: providing a first layer comprising first fibers oriented in a first direction, the first fibers comprising glass fibers and / or carbon fibers; providing a second layer comprising second fibers oriented in a second direction, the second fibers being textured yarns, the second direction being different from the first direction; as well as The first layer and the second layer are stitched together using a stitching yarn to form the fabric.

17. Use of a textured yarn for improving the stability of a non-wrinkle fabric comprising glass and / or carbon fibers.

18. A composite article comprising the fabric according to any one of claims 1 to 15.

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