Hybrid Fabric

Abstract

In this specification, about 500 g / m 2 A hybrid woven carbon fiber and fiberglass fabric having a total areal weight of less than 1000 mm is described.

Description

[Technical field]

[0001] The present invention relates to a hybrid fabric comprising carbon and glass fibers, particularly a hybrid fabric useful for combining reinforcing elements in structural components such as wind turbine blades or related components such as spar caps. [Background technology]

[0002] Carbon fiber reinforced materials are electrically conductive and exhibit good mechanical properties, including stiffness and tensile strength, at low density, making them useful for strengthening structural components such as wind turbine blades or related components.

[0003] It is 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 often formed by placing a carbon pultruded plank into a mold, filling the mold with resin, and curing the resin to form the part.

[0004] Traditionally, wind turbine blades have been made from non-conductive materials such as fiberglass reinforced polymers / plastics. However, incorporating conductive reinforcing parts, such as carbon components, into wind turbine blades to minimize damage to the blades during lightning strikes creates new challenges.

[0005] Carbon fiber reinforced materials, such as pultruded carbon fiber planks used in the manufacture of wind turbine blades or related components, can be bonded together using a hybrid fabric comprising carbon fiber and glass fiber, which can be more easily infused with resin than carbon reinforced materials, such as pultruded carbon fiber planks, and can provide a conductive layer between the pultruded carbon fiber planks.

[0006] It is desirable to provide a hybrid fabric that is lightweight, dimensionally stable, and resistant to handling to enable improved efficiency in the manufacture of wind turbine blades or related components. Summary of the Invention

[0007] Most commonly, the present invention provides a fiberglass fiberglass having a fiber thickness of about 1000 g / m 2 Less than about 500 g / m 2 The hybrid woven fabric may include a first layer including first fibers including carbon fibers oriented in a first direction and a second layer including second fibers being stabilizing fibers oriented in a second direction, the first fibers and second fibers being maintained in their respective orientations by stitching, and the woven fabric has an areal weight of less than about 1000 g / m. 2 Less than about 500 g / m 2 is less than.

[0008] The inventors have determined that the present invention provides a low total areal weight (i.e., less than about 1000 g / m 2 Less than about 500 g / m 2 The inventors have found that the provision of a hybrid fabric allows for the provision of an easy to handle, dimensionally stable hybrid fabric having a fiber tensile strength of less than 1000 MPa (less than 1000 MPa), which is useful in the manufacture of wind turbine blades or related components, in particular wind turbine blades or related components comprising carbon fiber pultruded planks. The inventors have also found that the provision of such a hybrid fabric improves the efficiency of the manufacture of wind turbine blades or related components.

[0009] In a first aspect, the present invention provides a woven carbon fiber and glass fiber hybrid fabric comprising: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 45 degrees to about 90 degrees of the first direction, the first fibers include carbon fibers; the second fiber comprises a stabilizing fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 15% by weight of the fabric; A hybrid woven fabric is provided, in which the second fibers constitute less than about 50% by weight of the fabric.

[0010] In a second aspect, the present invention provides a method for producing a woven carbon fiber and glass fiber hybrid fabric, comprising the steps of: 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 a range of about 45 degrees to about 90 degrees of the first direction; Approximately 500g / m 2 and sewing the first layer and the second layer together using a sewing thread to form a hybrid woven fabric having an areal weight of less than The method provides that 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.

[0011] In a third aspect, the present invention provides a composite article comprising the hybrid fabric described herein.

[0012] 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.

[0013] In a fifth aspect, the present invention provides a spunbonded ... 2 The present invention provides a use of textured yarn to provide a hybrid woven carbon fiber and glass fiber fabric having an areal weight of less than 100 g / m.

[0014] The present invention includes combinations of the aspects and preferred features described herein, except where such combinations are expressly not permitted or explicitly avoided. [Brief description of the drawings]

[0015] BRIEF DESCRIPTION OF THE DRAWINGS Embodiments and experiments illustrating the principles of the present invention are described with reference to the accompanying drawings. [Figure 1] FIG. 1 is a schematic diagram illustrating a woven fabric according to one embodiment of the present invention. [Diagram 2] FIG. 2 is an enlarged view of a portion A shown in FIG. [Figure 3a] 1 is a photograph of a fabric formed according to Example 1. [Figure 3b] 1 is a photograph of a fabric formed according to Example 2. [Figure 3c] 1 is a photograph of a fabric formed according to Example 3. [Figure 4] FIG. 2 is a schematic diagram of a cross section of a textured yarn. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Aspects and embodiments of the present invention will now be described with reference to the accompanying drawings. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned herein are incorporated by reference.

[0017] As used herein, the term "glass fiber" is used to refer to a plurality of continuous glass filaments (the term "continuous" as used herein is used to refer to a fiber / filament whose length is many times longer than its diameter, e.g., at least about 5000 times longer than its diameter, e.g., at least about 10000 times longer than its diameter). The glass fibers used in the woven 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 fiber and / or the third fiber) may have a sizing agent on their surface, e.g., the second fiber and / or the third fiber may have a sizing agent applied to the glass fibers during the formation of the fibers. The sizing agent may include components that facilitate the formation of the glass fibers and / or their use in matrix resins, such as film formers, lubricants, coupling agents (to promote compatibility between the glass fibers and resins used to form composite articles including the hybrid woven fabrics described herein). In some embodiments, the glass fibers of the first fiber and / or the third fiber include a polyester-compatible sizing or an epoxy-compatible sizing.

[0018] As used herein, the term "fiberglass strand" or "fiberglass tow" refers to a bundle of continuous glass filaments. In embodiments, a fiberglass strand or tow is a bundle of glass filaments without any twists.

[0019] In an embodiment, the fiberglass strands or fiberglass tows are provided from fiberglass direct rovings, which are made of bundles of continuous, untwisted (i.e., substantially parallel, or parallel) glass filaments that are combined into a single strand (as the glass filaments are formed) and wound onto bobbins.

[0020] The term "textured yarn" refers to a fiber, e.g., a strand of fiberglass, that comprises, consists essentially of, or consists of bundles of continuous filaments (e.g., unbonded bundles of continuous filaments) that have been textured in a turbulent stream of compressed air. A schematic diagram of a cross-section of a "textured yarn", e.g., a textured glass yarn, is shown in FIG.

[0021] The term "textured glass yarn" refers to a strand of glass fiber that includes, consists essentially of, or consists of bundles of continuous glass filaments (e.g., unbonded bundles of continuous glass filaments) that have been textured in a turbulent stream of compressed air. The glass filaments that form the textured glass yarn may be made from E-glass, E-CR-glass (such as Advantex™ glass), H-glass, S-glass, or AR-glass types. An example of a suitable textured glass yarn is ECT9 T140 K252C (available from Vetrotex™). A schematic diagram of a cross-section of a "textured glass yarn" is shown in FIG. 4.

[0022] FIG. 4 shows a bulky portion B, for example, with a diameter d B 4 shows a textured yarn, e.g., textured glass yarn 104a, including a lofted portion B having a diameter d. The lofted portion B of the textured yarn is formed when a bundle of continuous filaments, e.g., glass filaments (strands of filaments, e.g., strands of glass filaments), passes through a turbulent stream of compressed air. The textured yarn, e.g., textured glass yarn 104a shown in FIG. 4 includes a lofted portion B having a diameter d. S with a diameter d B The bulky portion B has a diameter d S may correspond to the minimum diameter of the textured yarn, e.g., textured glass yarn. B may be at least 10% greater than the minimum diameter of the textured yarn. Thus, in embodiments, a "textured yarn" (e.g., textured glass yarn) refers to a strand of fiber (e.g., a strand of fiberglass) that includes a plurality of lofts, e.g., the lofts are formed when the strand of fiber is exposed to a turbulent flow of compressed air. B Or d Scan be determined by placing a strand of textured yarn (e.g., a strand of textured glass yarn) in a straight line on a flat surface without tension on the textured yarn and measuring the diameter of the bulky or non-bulky portion, for example, by measuring the width of the textured yarn perpendicular to the length of the textured yarn, respectively, using a measuring ruler. The minimum diameter can be interpreted as the smallest diameter of a given length of textured yarn (e.g., textured glass yarn), for example, the smallest diameter in a 10 cm length of textured yarn (e.g., textured glass yarn), or the smallest diameter of the textured yarn (e.g., textured glass yarn) along the length of the textured yarn (e.g., textured glass yarn) in a hybrid woven fabric.

[0023] As used herein, the term "carbon fiber" refers to a plurality of continuous carbon filaments (the term "continuous" as used herein is used to refer to a fiber / filament whose length is many times longer than its diameter, e.g., at least about 5000 times longer than its diameter, e.g., at least about 10000 times longer than its diameter). The carbon fibers used in the woven 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, e.g., the first fiber and / or the fourth fiber may have a sizing agent applied to the carbon fibers during the formation of the fibers. The sizing agent may include components that facilitate the formation of the carbon fibers and / or their use in matrix resins, such as film formers, lubricants, coupling agents (to promote compatibility between the carbon fibers and resins used to form composite articles including the hybrid woven fabrics described herein). In some embodiments, the carbon fibers of the first fibers and / or the fourth fibers include a polyester-compatible sizing or an epoxy-compatible sizing.

[0024] The present invention provides a carbon fiber and glass fiber hybrid fabric comprising a first layer including a first fiber oriented in a first direction and a second layer including a second fiber oriented in a second direction. The hybrid fabric is a non-crimp fabric, and the first and second fibers are maintained in their respective orientations by stitching (the first and second fibers are not woven together, i.e., the non-crimp fabric is a non-woven fabric). The second direction is within about 45 degrees to about 90 degrees of the first direction, for example, the second direction may be within about 60 degrees to about 90 degrees of the first direction, within about 70 degrees to about 90 degrees of the first direction, within about 80 degrees to about 90 degrees of the first direction, within about 85 degrees to about 90 degrees of the first direction, within about 88 degrees to about 90 degrees of the first direction, or within about 90 degrees of the first direction. In an embodiment, the second direction is substantially perpendicular to the first direction.

[0025] 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 the 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.

[0026] In an embodiment, the first layer comprises, consists essentially of, or consists of a first fiber and a third fiber, the first fiber being oriented in a first direction and the third fiber being oriented in a third direction. The third fiber may comprise glass fiber. In an embodiment, the third fiber comprises, consists essentially of, or consists of glass fiber. In an embodiment, the third fiber is glass fiber. In an embodiment, the first layer comprises, consists essentially of, or consists of carbon fiber (first fiber) and glass fiber (third fiber). In an embodiment, the first direction and the third direction are the same direction (i.e., the third direction may be aligned with the first direction).

[0027] In an embodiment, the first fibers, e.g., carbon fibers oriented in a first direction, have a thickness 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, 400 tex to about 4800 tex, about 600 tex to about The linear mass density is 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.

[0028] In an embodiment, the first fibers, eg, carbon fibers oriented in a first direction, have a diameter in the range of about 5 to about 15 μm, eg, about 5 μm to about 11 μm.

[0029] In an embodiment, the first layer includes a plurality of first fiber strands. In an embodiment, the first fiber strands are carbon fiber tows. In an embodiment, the carbon fiber tows have a size ranging from 6K to 50K, e.g., 6K to 24K, or 6K to 12K. For example, the first fiber may be sourced from one or more carbon fiber tows having a size ranging from 6K to 50K, e.g., 6K to 24K, or 6K to 12K. The #K designation means that the carbon tow is composed of #×1,000 individual carbon filaments, i.e., a carbon fiber tow having a size of 6K is made of approximately 6000 carbon fiber filaments / fibers.

[0030] In an embodiment, the first layer includes a plurality of first fiber strands, the first layer having a first fiber strand count in a range of about 0.25 to about 5 tows / cm, or about 0.25 to about 2.5 tows / cm. In an embodiment, the first layer includes a plurality of carbon fiber tows (e.g., a plurality of carbon fiber tows, each of the plurality of carbon fiber tows having a size in a range of 6K to 50K, e.g., 6K to 24K, or 6K to 12K), the first layer having a carbon fiber tow count in a range of about 0.25 to about 5 tows / cm, or about 0.25 to about 2.5 tows / 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.

[0031] 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 the 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.

[0032] Any suitable glass reinforcing fibers can be used as the third fibers, such as fibers made from E-glass, E-CR glass (such as Advantex™ glass), H-glass, S-glass, and AR glass types. The glass fibers used as the third fibers can have diameters ranging from about 7 to about 25 μm, such as from about 9 μm to about 17 μm.

[0033] The first fibers (e.g., carbon fibers oriented in a first direction) may comprise at least about 15% by weight of the total weight of the woven fabric, e.g., 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 woven fabric. In an embodiment, the first fibers (e.g., carbon fibers oriented in a first direction) may comprise from about 15% by weight to about 80% by weight of the total weight of the woven fabric, e.g., from about 15% by weight to about 70% by weight, from about 15% by weight to about 60% by weight, from about 20% by weight to about 75% by weight, from about 25% by weight to about 75% by weight, from about 25% by weight to about 70% by weight, from about 25% by weight to about 60% by weight, from about 30% by weight to about 75% by weight. %, about 30% to about 70% by weight, about 30% to about 60% by weight, about 35% to about 75% by weight, about 35% to about 70% by weight, about 35% to about 60% by weight, about 40% to about 75% by weight, about 40% to about 70% by weight, about 40% to about 60% by weight, about 50% to about 75% by weight, about 50% to about 70% by weight, about 50% to about 60% by weight. In an embodiment, the first fibers (e.g., carbon fibers oriented in a first direction) may comprise about 15% to about 80% by weight of the fabric, e.g., about 15% to about 70% by weight of the fabric, about 15% to about 60% by weight of the fabric, about 20% to about 75% by weight of the fabric, about 20% to about 70% by weight of the fabric, or about 20% to about 60% by weight of the fabric.

[0034] The third fibers (e.g., glass fibers oriented in a third direction) may comprise up to about 70% by weight of the total weight of the woven fabric, e.g., up to about 50% by weight, up to about 40% by weight, up to about 30% by weight, up to about 20% by weight of the total weight of the woven fabric. In an embodiment, the third fibers (e.g., glass fibers oriented in a first direction) comprise from about 0% to about 70% by weight of the total weight of the woven fabric, e.g., from about 2% to about 50% by weight, from about 5% to about 30% by weight, or from about 2% to about 20% by weight.

[0035] In an embodiment, the fibers of the first layer (e.g., the first fibers oriented in a first direction and, if present, the third fibers oriented in a third direction) comprise up to about 90% by weight of the total weight of the woven fabric, e.g., up to about 85% by weight of the woven fabric, or up to about 80% by weight of the woven fabric. In an embodiment, the fibers of the first layer (e.g., the first fibers and, if present, the third fibers) comprise from about 20% to about 90% by weight of the total weight of the woven fabric, e.g., from about 25% to about 85% by weight, or from about 25% to about 80% by weight of the total weight of the woven fabric.

[0036] In an embodiment, the first fibers in the woven fabric, e.g., carbon fibers (or carbon fiber tows) oriented in a first direction, have a weight of about 200 g / m 2 Less than, for example, about 150 g / m 2 Less than 100g / m 2 Less than 90g / m 2 Less than or about 80 g / 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 an areal weight of at least about 10 g / m 2 , e.g., at least about 20 g / m 2 , at least about 30 g / m 2 , at least about 40 g / m 2 , at least about 50 g / m 2 , at least about 60 g / m 2 , at least about 70 g / m 2 , or at least about 75 g / 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 an areal weight of about 10 g / m 2 ~about 200g / m 2 For example, about 20 g / 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 / m2 ~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 10 g / m 2 ~about 50g / m 2 The area weight ranges from 0.01 to 0.01 mm.

[0037] 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).

[0038] In an embodiment, the first layer has an area weight of at least about 20% by weight of the total area weight of the textile fabric, for example, at least about 25% by weight of the total area weight of the textile fabric. In an embodiment, the first layer has an area weight of at least about 50% by weight of the total area weight of the textile fabric, or at least about 60% by weight of the total area weight of the textile fabric. In an embodiment, the first layer has an area weight ranging from about 20% to about 80% by weight of the textile fabric, for example, from about 20% to about 70% by weight of the textile fabric, or from about 25% to about 60% by weight of the textile fabric. The area weight of the first layer of the textile fabric may be determined according to ISO 3374.

[0039] The second layer comprises second fibers oriented in a second direction, the second fibers being stabilized 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 stabilized 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, consist essentially of, or consist of the second fibers.

[0040] In embodiments, the second fibers / stabilizing fibers may be any suitable glass reinforcing fibers, for example, fibers made from E-glass, E-CR glass (such as Advantex™ glass), H-glass, S-glass, and AR glass types may be used. The glass fibers used as the second fibers may have a diameter ranging from about 5 to about 25 μm, for example, from about 13 μm to about 24 μm.

[0041] In an embodiment, the second fiber / stabilizing fiber is a textured yarn, such as a textured yarn as described above (e.g., a textured yarn as described above in connection with Figure 4). In an embodiment, the second fiber / stabilizing fiber is a textured glass yarn.

[0042] In an embodiment, a carbon fiber and fiberglass hybrid fabric includes a first layer including carbon fibers as first fibers oriented in a first direction and a second layer including textured glass yarns as second fibers oriented in a second direction.

[0043] In an embodiment, a "textured yarn" refers to a strand of fiber that includes a plurality of bulky portions, for example, the bulky portions are formed when the strand of fiber is exposed to a turbulent stream of compressed air. In an embodiment, the bulky portion of a textured yarn (e.g., textured glass yarn) is a portion of the textured yarn that has a diameter that is at least 10% larger than the minimum diameter of the textured yarn, for example, 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 (e.g., having a non-bulky portion of the textured yarn that has a diameter less than the minimum diameter of the bulky portion). The diameter of the portion of the textured yarn may be measured perpendicular to the yarn. The minimum diameter of the textured yarn may be defined as the minimum diameter of the textured yarn for a given portion of the textured fiber, for example, the minimum diameter of the textured yarn in a 10 cm length of the textured yarn, or the minimum diameter of the textured yarn along the length of the textured yarn in a hybrid woven fabric.

[0044] In an embodiment, the textured yarn (e.g., textured glass yarn) has a minimum diameter of less than about 5 mm, e.g., 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, e.g., 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.

[0045] In an embodiment, the textured yarn includes a plurality of bulky portions, each of which has a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the minimum diameter of the textured yarn. In an embodiment, the textured yarn includes a plurality of bulky portions, each of which has a diameter in the range of 10% to 600%, 20% to 300%, or 20% to 250% greater than the minimum diameter of the textured yarn. In an embodiment, the textured yarn comprises a plurality of bulky portions, each bulky portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured yarn, and comprises 0.3 to 3 bulky portions per cm of textured yarn length. In an embodiment, the textured yarn comprises a plurality of bulky portions, each bulky portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured yarn, and comprises about 2-30, or about 2-25, bulky portions per 10 cm length of the textured yarn. The number of bulky portions per 10 cm length of the textured yarn can be determined by placing a strand of the textured yarn (e.g., a strand of textured glass yarn) in a straight line on a flat surface without tension on the yarn and counting the number of bulky portions present in a 10 cm length of the textured yarn, where bulky portions are as defined herein.

[0046] In an embodiment, the textured yarn includes a plurality of lofted portions, each having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured glass yarn, and the lofted portions of the textured glass yarn make up at least 10% of the length of the textured 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%.

[0047] In an embodiment, the textured yarn (e.g., textured glass yarn) comprises at least about 2, e.g., at least about 3 or at least about 5 bulky portions (e.g., bulky portions described herein) per 10 cm length of the textured yarn. In an embodiment, the textured yarn (e.g., textured glass yarn) comprises up to about 30, e.g., up to about 25, up to about 20, or up to about 15 bulky portions (e.g., bulky portions described herein) per 10 cm length of the textured yarn. In an embodiment, the textured yarn (e.g., textured glass yarn) comprises from about 2 to about 30, e.g., from about 2 to about 25, from about 3 to about 20, or from about 5 to about 15 bulky portions (e.g., bulky portions described herein) per 10 cm length of the textured yarn. The number of bulky segments per 10 cm length of textured yarn can be determined by placing a strand of textured yarn (e.g., a strand of textured glass yarn) in a straight line on a flat surface without tension on the yarn and counting the number of bulky segments present in a 10 cm length of textured yarn, where bulky segments are as defined herein.

[0048] In an embodiment, a textured yarn (e.g., textured glass yarn) includes a plurality of bulky portions (e.g., bulky portions described herein), where successive bulky portions are spaced apart by a distance ranging from about 0.5 to about 80 mm, e.g., from about 0.5 to about 50 mm, from about 0.5 to about 10 mm, or from about 2 to about 8 mm. The distance between successive bulky portions of a textured yarn can be determined by placing a strand of textured yarn (e.g., a strand of textured glass yarn) in a straight line on a flat surface without tension on the textured yarn, and using a measuring ruler to measure the distance between the end of one bulky portion (e.g., where the diameter of the bulky portion decreases to less than 110% of the minimum diameter of the textured glass yarn) and the beginning of the next bulky portion (e.g., where the diameter of the bulky portion increases by more than 10% above the minimum diameter of the textured glass yarn). In embodiments, the multiple loft portions of the textured yarn are regularly distributed along the textured yarn, e.g., the distance between successive loft portions along the textured yarn may be approximately the same (e.g., within about ±10%, or within about ±5%).

[0049] In an embodiment, the textured yarn (e.g., textured glass yarn) includes a plurality of bulky portions, each of which has a diameter in the range of 10% to 600%, 20% to 300%, or 20% to 250% greater than the minimum diameter of the textured yarn (e.g., textured glass yarn).

[0050] In an embodiment, the textured yarn (e.g., textured glass yarn) includes a plurality of loft portions, each loft portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured yarn (e.g., textured glass yarn), and includes about 2 to about 25 (e.g., about 5 to about 15) loft portions per 10 cm of the textured yarn length.

[0051] In an embodiment, the textured yarn (e.g., textured glass yarn) includes a plurality of loft portions, each loft portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured yarn, and the textured yarn includes from about 2 to about 25 (e.g., from about 5 to about 15) loft portions per 10 cm of the textured yarn length.

[0052] In an embodiment, the textured yarn (e.g., textured glass yarn) comprises a plurality of bulky portions, each of which has a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the minimum diameter of the textured yarn, the textured yarn comprises about 2 to about 25 (e.g., about 5 to about 15) bulky portions per 10 cm of the textured yarn length, and successive bulky portions of the textured yarn are spaced apart by a distance ranging from about 0.5 to about 80 mm, e.g., from about 0.5 to about 50 mm, from about 0.5 to about 10 mm, or from about 2 mm to about 8 mm. In an embodiment, the bulky portions of the textured yarn are regularly distributed along the textured yarn.

[0053] In an embodiment, the textured yarn (e.g., textured glass yarn) includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the minimum diameter of the textured yarn, and the lofted portions of the textured yarn make up at least 10% of the length of the textured 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%.

[0054] In an embodiment, the textured yarn is a textured glass yarn, i.e., a strand of fiberglass that includes a plurality of lofts, for example, the lofts being formed when the strand of fiberglass is exposed to a turbulent flow of compressed air.

[0055] In an embodiment, the second fiber / stabilizing fiber is a textured glass yarn, such as a textured glass yarn as described above (e.g., textured glass yarn as described above in connection with FIG. 4). An example of a suitable textured glass yarn is ECT9 T140 K252C (available from Vetrotex™). In an embodiment, the textured glass yarn comprises glass fibers having a diameter ranging from about 5 to about 25 μm, e.g., from about 9 μm to about 24 μm. In an embodiment, the textured glass yarn comprises a plurality of bulky portions, each bulky portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the smallest diameter of the textured glass yarn. In an embodiment, the textured glass yarn includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater (e.g., at least 15% greater, at least 20% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 70% greater, at least 80% greater, at least 100% greater, at least 150% greater, or at least 200% greater) than the minimum diameter of the textured glass yarn, and the lofted portions of the textured glass yarn make up at least 10%, e.g., at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% of the length of the textured glass yarn.

[0056] In embodiments, the textured glass yarn 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 70 tex to about 200 tex.

[0057] In an embodiment, the second fiber / stabilizing fiber, such as a glass fiber (or glass fiber strand, e.g., textured glass yarn) or textured 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.

[0058] In an embodiment, the second layer includes 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 tows / cm, or about 0.25 to about 2.5 tows / cm. In an embodiment, the second layer includes a plurality of glass fiber strands (e.g., a plurality of glass fiber strands, each of the plurality of glass fiber strands having 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 / cm, or about 0.25 to about 2.5 strands / cm. The number of glass fiber strands per cm is measured in a direction substantially perpendicular to the second direction, for example, measured in the first direction.

[0059] In an embodiment, the second fiber / stabilizing fiber in the woven fabric, e.g., glass fiber (or glass fiber strand, e.g., textured glass yarn) or textured yarn oriented in the second direction, has a weight of about 100 g / m 2 Less than about 75 g / m 2 Less than 50g / m 2 Less than 40g / m 2 Less than or about 30 g / m 2 In an embodiment, the second fibers in the fabric, e.g., glass fibers (or glass fiber strands, e.g., textured glass yarns) oriented in the second direction, have an areal weight of at least about 5 g / m 2 , e.g., at least about 10 g / m 2 , or at least about 20 g / m2 In an embodiment, the second fibers of the fabric, e.g., glass fibers (or glass fiber strands, e.g., textured glass yarns) oriented in the second direction, have an areal weight of about 5 g / m 2 ~about 100g / m 2 , for example, about 5 g / 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 5 g / m 2 ~about 30g / m 2 The area weight ranges from 0.01 to 0.01 mm.

[0060] 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 (if 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 comprise or consist of a fiber of a material other than glass, for example, the fourth fiber may comprise carbon fiber. The fifth fiber may comprise or consist of a fiber of a material other than glass, for example, the fifth fiber may comprise a polymer fiber (e.g., PET monofilament). In an embodiment, the fourth fiber comprises, consists essentially of, or consists of carbon fiber. In an embodiment, the fourth fiber is carbon fiber. In an embodiment, the fifth fiber comprises, consists essentially of, and / or consists of a polymer fiber (e.g., PET monofilament). In an embodiment, the second layer comprises, consists essentially of, or consists of the second fiber / stabilizing fiber in combination with the fourth fiber and / or the fifth fiber. Examples of polymeric 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 polymeric fibers having a diameter in the range of 0.05mm to 0.5mm.

[0061] In an embodiment, the second layer comprises, consists essentially of, or consists of a second fiber / stabilizing fiber that is a textured yarn (e.g., textured glass yarn), and a fourth fiber that is a carbon fiber. In an embodiment, the second layer comprises, consists essentially of, or consists of a second fiber / stabilizing fiber that is a textured yarn (e.g., textured glass yarn), a fourth fiber that is a carbon fiber, and a fifth fiber that is a polymer fiber (e.g., a polymer monofilament such as a PET monofilament).

[0062] In an embodiment, the second / stabilizing fibers and the third fibers comprise glass fibers. In an embodiment, the second fibers and the third fibers comprise glass fibers, and the second glass fibers are different from the third glass fibers.

[0063] In embodiments, the second fibers / stabilizing fibers comprise less than about 50% by weight of the total weight of the woven fabric, e.g., less than about 40%, less than about 35%, less than about 30%, or less than about 25% by weight of the total weight of the woven fabric. In embodiments, the second fibers / stabilizing fibers comprise between about 5% and about 50% by weight of the total weight of the woven fabric, e.g., between about 10% and about 40%, or between about 10% and about 30% by weight of the total weight of the woven fabric.

[0064] In embodiments, the fourth fibers (e.g., carbon fibers oriented in a fourth direction) may comprise at least about 15% by weight of the total weight of the fabric, e.g., 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) constitute about 0% to about 80% by weight of the total weight of the woven fabric, e.g., about 15% to about 70% by weight, about 15% to about 60% by weight, about 20% to about 75% by weight, about 25% to about 75% by weight, about 25% to about 70% by weight, about 25% to about 60% by weight, about 30% to about 75% by weight, about 30% to about 70% by weight, about 30% to about 60% by weight, about 35% to about 75% by weight, or about 35% to about 70% by weight.

[0065] In an embodiment, the fifth fibers (e.g., polymeric fibers oriented in a fifth direction) may comprise up to about 30% by weight of the total weight of the woven fabric, e.g., up to about 20% by weight of the total weight of the woven fabric, or up to about 10% by weight of the total weight of the woven fabric. In an embodiment, the fifth fibers (e.g., polymeric fibers oriented in a fifth direction) comprise from about 0% to about 30% by weight of the total weight of the woven fabric, e.g., from about 0.5% to about 20% by weight, from about 1% to about 10% by weight of the total weight of the woven fabric.

[0066] In embodiments, the second layer (e.g., the second fibers, and if present, the fourth and / or fifth fibers) constitute up to about 75% by weight of the total weight of the woven fabric, e.g., up to about 70%, up to about 60%, up to about 50%, up to about 40%, or up to about 20% by weight of the total weight of the woven fabric. In embodiments, the fibers oriented in the second direction (e.g., the second fibers, and if present, the fourth and / or fifth fibers) constitute from about 5% to about 50% by weight of the total weight of the woven fabric, e.g., from about 10% to about 40% by weight, or from about 10% to about 30% by weight of the total weight of the woven fabric. In embodiments, the second layer (e.g., the second fibers and, if present, the fourth fibers and / or the fifth fibers) comprises from about 5% to about 75% by weight of the total weight of the fabric, e.g., from about 10% to about 70% by weight, or from about 10% to about 60% by weight of the total weight of the fabric.

[0067] In an embodiment, the second layer comprises, consists essentially of, or consists of about 10% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured 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., polymeric fibers) based on the total weight of the second layer. 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), 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., polymeric fibers) based on the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 20% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured 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., polymeric fibers) of the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 25% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured 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., polymeric fibers) of the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 30% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured 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., polymeric fibers) of the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 50% to about 100% by weight of the second fibers (e.g., glass fibers and / or textured 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., polymeric fibers) of the total weight of the second layer.In an embodiment, the second layer comprises, consists essentially of, or consists of about 60% to about 100% by weight of the second fiber (e.g., glass fiber and / or textured yarn), 0% to about 40% by weight of the fourth fiber (e.g., carbon fiber), and 0% to about 40% by weight of the fifth fiber (e.g., polymer fiber) 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 fiber (e.g., glass fiber and / or textured yarn), 0% to about 30% by weight of the fourth fiber (e.g., carbon fiber), and 0% to about 30% by weight of the fifth fiber (e.g., polymer fiber) based on the total weight of the second layer. 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), 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., polymeric fibers) based on the total weight of the second layer. 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), 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., polymeric fibers) based on the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 15% to about 80% by weight of second fibers (e.g., glass fibers and / or textured yarns), 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., polymeric fibers) based on the total weight of the second layer. In an embodiment, the second layer comprises, consists essentially of, or consists of about 20% to about 70% by weight of second fibers (e.g., glass fibers and / or textured yarns), 30% to about 80% by weight of fourth fibers (e.g., carbon fibers), and 0% to about 30% by weight of fifth fibers (e.g., polymeric fibers) based on the total weight of the second layer.

[0068] In an embodiment, the hybrid woven fabric comprises a first layer comprising, consisting essentially of, or consisting of about 50% to about 100% by weight of a first fiber (e.g., carbon fiber) and 0% to about 50% by weight of a third fiber (e.g., glass fiber) based on the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 10% to about 100% by weight of a second fiber (e.g., glass fiber and / or textured yarn); and 0% to about 90% by weight of a fourth fiber (e.g., carbon fiber) and 0% to about 90% by weight of a fifth fiber (e.g., polymeric fiber) based on the total weight of the second layer. In an embodiment, the hybrid woven fabric comprises a first layer comprising, consisting essentially of, or consisting of about 60% to about 100% by weight of a first fiber (e.g., carbon fiber) and 0% to about 40% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 30% to about 100% by weight of a second fiber (e.g., glass fiber and / or textured yarn); 0% to about 70% by weight of a fourth fiber (e.g., carbon fiber); and 0% to about 70% by weight of a fifth fiber (e.g., polymeric fiber) of the total weight of the second layer. In an embodiment, the hybrid woven fabric comprises a first layer comprising, consisting essentially of, or consisting of about 70% to about 100% by weight of a first fiber (e.g., carbon fiber) and 0% to about 30% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 50% to about 100% by weight of a second fiber (e.g., glass fiber and / or textured yarn); 0% to about 50% by weight of a fourth fiber (e.g., carbon fiber); and 0% to about 50% by weight of a fifth fiber (e.g., polymeric fiber) of the total weight of the second layer.In an embodiment, the hybrid fabric comprises a first layer comprising, consisting essentially of, or consisting of about 50% to about 100% by weight of a first fiber (e.g., carbon fiber) and 0% to about 50% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 15% to about 100% by weight of a second fiber (e.g., glass fiber); 0% to about 85% by weight of a fourth fiber (e.g., carbon fiber); and 0% to about 70% by weight of a fifth fiber (e.g., polymeric fiber) of the total weight of the second layer. 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 a first fiber (e.g., carbon fiber) and 0% to about 40% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 20% to about 100% by weight of a second fiber (e.g., glass fiber); 0% to about 80% by weight of a fourth fiber (e.g., carbon fiber); and 0% to about 70% by weight of a fifth fiber (e.g., polymeric fiber) of the total weight of the second layer. 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 a first fiber (e.g., carbon fiber) and 0% to about 40% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer; a second layer comprising, consisting essentially of, or consisting of about 25% to about 100% by weight of a second fiber (e.g., glass fiber); 0% to about 75% by weight of a fourth fiber (e.g., carbon fiber); and 0% to about 70% by weight of a fifth fiber (e.g., polymeric fiber) of the total weight of the second layer.In an embodiment, the hybrid woven fabric comprises a first layer comprising, consisting essentially of, or consisting of about 60% to about 100% by weight of a first fiber (e.g., carbon fiber) and 0% to about 40% by weight of a third fiber (e.g., glass fiber) of the total weight of the first layer, a second layer comprising, consisting essentially of, or consisting of about 15% to about 80% by weight of a second fiber (e.g., glass fiber), 20% to about 85% by weight of a fourth fiber (e.g., carbon fiber), and 0% to about 50% by weight of a fifth fiber (e.g., polymer fiber) of the total weight of the second layer. In each of these embodiments, the second fiber may be provided by a textured glass yarn as described herein. In each of these embodiments, the areal weight of the woven fabric is about 400 g / m. 2 Less than 300g / m 2 Less than 200g / m 2 Less than or about 150 g / m 2 It may be less than.

[0069] In an embodiment, the second layer has an areal weight of up to about 75% by weight of the total area weight of the woven fabric, for example, up to about 70% by weight of the total area weight of the woven fabric, up to about 60% by weight of the total area weight of the woven fabric, up to about 50% by weight of the total area weight of the woven fabric, up to about 40% by weight of the total area weight of the woven fabric, or up to about 30% by weight of the total area weight of the woven fabric. In an embodiment, the second layer has an areal weight ranging from about 5% to about 75% by weight of the woven fabric, for example, from about 10% to about 70% by weight of the woven fabric, from about 20% to about 70% by weight of the woven fabric, from about 25% to about 70% by weight of the woven fabric, from about 5% to about 50% by weight of the woven fabric, from about 5% to about 40% by weight of the woven fabric, from about 10% to about 30% by weight of the woven fabric, from about 20% to about 40% by weight of the woven fabric, or from about 20% to about 30% by weight of the woven fabric. The areal weight of the second layer of the woven fabric may be determined according to ISO 3374.

[0070] In embodiments, the suture comprises less than about 25% by weight of the total weight of the woven fabric, e.g., less than about 15%, less than about 10%, or less than about 8% by weight of the total weight of the woven fabric. In embodiments, the suture comprises from about 0.5% to about 25% by weight of the total weight of the woven fabric, e.g., from about 0.5% to about 15%, from about 1% to about 10%, or from about 2% to about 8% by weight of the total weight of the woven fabric.

[0071] Any suitable suture may be employed. In embodiments, the suture is a polyester thread. In embodiments, the suture has a linear mass density in the range of about 50 decitex to about 300 decitex.

[0072] In an embodiment, the sutures form a stitching pattern through the fabric, and the stitching pattern may be selected from a tricot stitching pattern, a symmetric double tricot stitching pattern, an asymmetric double tricot stitching pattern, a symmetric diamond stitching pattern, and an asymmetric diamond stitching pattern. In an embodiment, the sutures form a stitching pattern through the fabric, and the stitching pattern is a tricot stitching pattern.

[0073] In an embodiment, the suture defines a suture length, the suture length being within the range of about 2 mm to about 7 mm, for example about 3 mm.

[0074] The hybrid fabrics described herein have a fiberglass fiber thickness of about 1000 g / m 2 Less than about 500 g / m 2 Less than 400g / m 2 Less than 300g / m 2 Less than 200g / m 2 Less than or about 150 g / m 2 In an embodiment, the hybrid woven fabric may have an areal weight of less than about 50 g / m 2 ~about 500g / m 2 , for example, about 50 g / m 2 ~about 400g / m 2 , about 50g / m 2 ~about 200g / m 2 , about 100g / m 2 ~about 200g / m 2 The area weight of the fabric may be determined according to ISO 3374.

[0075] In the carbon fiber and glass fiber hybrid fabrics 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.

[0076] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 45 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a stabilizing fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 15% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer further comprises third fibers oriented in a third direction, the third fibers being glass fibers, and / or the stabilizing fibers being textured glass yarns.

[0077] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 45 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a stabilizing fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; The second fibers comprise at least about 50% by weight of the total weight of the fabric.

[0078] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 45 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a stabilizing fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 25% by weight of the total weight of the fabric; The second fibers comprise at least about 50% by weight of the total weight of the fabric.

[0079] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 15% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 25% by weight of the total weight of the fabric.

[0080] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 25% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 50% by weight of the total weight of the fabric.

[0081] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 25% by weight of the total weight of the fabric.

[0082] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 25% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 50% by weight of the total weight of the fabric.

[0083] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; the first layer comprises at least about 25% by weight of the total weight of the fabric; The textured glass yarn includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater than the smallest diameter of the textured glass yarn, and optionally, the lofted portions of the textured glass yarn constitute at least 10% of the length of the textured glass yarn.

[0084] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 25% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; the first layer comprises at least about 50% by weight of the total weight of the fabric; The textured glass yarn includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater than the smallest diameter of the textured glass yarn, and optionally, the lofted portions of the textured glass yarn constitute at least 10% of the length of the textured glass yarn.

[0085] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 25% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 50% by weight of the total weight of the fabric.

[0086] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; The area weight of the fabric is approximately 500 g / m 2 is less than the first fibers constitute at least about 40% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The first layer comprises at least about 60% by weight of the total weight of the fabric.

[0087] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; the first layer comprises at least about 25% by weight of the total weight of the fabric; The textured glass yarn includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater than the smallest diameter of the textured glass yarn, and optionally, the lofted portions of the textured glass yarn constitute at least 20% of the length of the textured glass yarn.

[0088] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; The second direction is within a range of about 80 degrees to about 90 degrees of the first direction, the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 40% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; the first layer comprises at least about 60% by weight of the total weight of the fabric; The textured glass yarn includes a plurality of lofted portions, each lofted portion having a diameter at least 10% greater than the smallest diameter of the textured glass yarn, and optionally, the lofted portions of the textured glass yarn constitute at least 20% of the length of the textured glass yarn.

[0089] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction and fourth fibers oriented in a fourth direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; the second direction is within a range of about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction; the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the fourth fiber is a carbon fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 15% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The fourth fiber comprises at least about 10% by weight of the total weight of the fabric.

[0090] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction and fourth fibers oriented in a fourth direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; the second direction is within a range of about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction; the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; the fourth fiber is a carbon fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 15% by weight of the total weight of the fabric; the second fibers constitute at least about 50% by weight of the total weight of the woven fabric; The fourth fiber comprises at least about 10% by weight of the total weight of the fabric.

[0091] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction; a second layer including second fibers oriented in a second direction and fourth fibers oriented in a fourth direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; the second direction is within a range of about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction; the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the fourth fiber is a carbon fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; the second fibers constitute at least about 30% by weight of the total weight of the woven fabric; The fourth fiber comprises at least about 20% by weight of the total weight of the fabric.

[0092] In an embodiment, the carbon fiber and glass fiber hybrid fabric comprises: a first layer including first fibers oriented in a first direction and third fibers oriented in a third direction; a second layer including second fibers oriented in a second direction and fourth fibers oriented in a fourth direction; a suture that maintains the fibers of the first layer and the second layer in their respective orientations; the second direction is within a range of about 45 degrees to about 90 degrees (optionally about 80 degrees to about 90 degrees) of the first direction; the first fiber is a carbon fiber; The second fiber is a textured glass yarn; the third fiber is a glass fiber; the fourth fiber is a carbon fiber; The area weight of the fabric is approximately 400 g / m 2 is less than the first fibers constitute at least about 20% by weight of the total weight of the fabric; the second fibers constitute at least about 30% by weight of the total weight of the woven fabric; The fourth fiber comprises at least about 20% by weight of the total weight of the fabric.

[0093] Generally, hybrid fabrics are resin-free, i.e., none of the fibers forming the fabric are pre-impregnated with resin.

[0094] 1 is a schematic diagram of a hybrid reinforced 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 (the 0° direction aligned with the length of the fabric) and the second fibers are oriented in a second direction substantially perpendicular to the first direction (the 90° direction shown in FIG. 1).

[0095] Figure 2 shows an enlarged view of section "A" of Figure 1. Figure 2 shows sutures 106 forming a stitching pattern through the fabric 100 to maintain the first fibers 102 and the second fibers 104 in their respective orientations.

[0096] The first fibers may be arranged in the first layer such that there are gaps 102 between adjacent first fibers (eg, gaps between adjacent carbon fiber tows).

[0097] In an embodiment, the suture forms a stitching pattern that includes stitching along at least one of the strands of the first fiber 102, for example, along each of a plurality of first fiber strands (e.g., along each of a plurality of carbon fiber tows).

[0098] In an embodiment, the suture forms a suture in the gap between adjacent strands of the first fiber 102, for example, between adjacent carbon fiber tows.

[0099] In an embodiment, the first layer may include about 0.25 to about 5 first fiber strands (e.g., carbon fiber tows) 102 per cm (measured perpendicular to the first direction, e.g., measured along the second direction), or about 0.25 to about 2.5 tows per cm.

[0100] In an embodiment, the first layer may include about 0.25 to about 5 third fiber strands (e.g., fiberglass strands) per cm (measured perpendicular to the first direction, e.g., measured along the second direction), or about 0.25 to about 2.5 tows per cm.

[0101] In an embodiment, the second layer includes about 0.25 to about 5 second fiber strands (e.g., glass fiber strands) per cm (measured perpendicular to the second direction, e.g., measured along the first direction), or about 0.25 to about 2.5 strands per cm.

[0102] In an embodiment, the second layer includes about 0.25 to about 5 fourth fiber strands (e.g., carbon fiber tows) per cm (measured perpendicular to the second direction, e.g., measured along the first direction), or about 0.25 to about 2.5 strands per cm.

[0103] 3c is a photograph of a hybrid reinforced fabric 100 (as provided in Example 3 below) including a first layer including first fibers 102 (e.g., carbon fiber tows) and third fibers 103 (e.g., glass fibers), and a second layer including second fibers (e.g., glass fibers) 104 and fourth fibers (e.g., carbon fibers) 105. The first fibers 102 are oriented in a first direction (0° direction aligned with the length of the fabric), and the second fibers are oriented in a second direction substantially perpendicular to the first direction. The third fibers 103 are oriented in a third direction aligned with the first direction, and the fourth fibers 105 are oriented in a fourth direction aligned with the second direction.

[0104] The first fibers and the third fibers may be arranged in the first layer such that there are gaps between adjacent first fibers 102 and third fibers 103 (e.g., gaps between adjacent carbon fiber tows and 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 such that there are gaps between adjacent fibers of the second layer (e.g., gaps between adjacent carbon fiber tows and adjacent glass fiber strands (e.g., textured glass yarns), and gaps between adjacent carbon fiber tows and glass fiber strands (e.g., textured glass yarns).

[0105] In embodiments, the hybrid fabrics described herein may be impregnated with a resin, and the resin may be cured to form a composite article. EXAMPLES

[0106] The following illustrate examples of the textiles and related aspects described herein, and therefore should not be construed as limiting the disclosure, but merely to teach how to carry out the methods and obtain the products of the disclosure.

[0107] Example 1 A hybrid fabric was produced by providing a first layer comprising carbon and glass fibers oriented in a 0° direction (i.e., along the length of the fabric) and a second layer made from glass fibers oriented in a 90° direction (i.e., perpendicular to the length of the fabric).

[0108] The first layer was formed by providing a strand of 12K carbon fiber (carbon fiber filament with 7 μm diameter and epoxy resin compatible sizing) with each carbon fiber strand having a linear density of about 800 tex, and two strands of 1200 tex glass fiber provided directly from a roving (Advantex™ E-CR glass fiber, glass fiber filament with 17 μm diameter with epoxy resin compatible sizing), the carbon fiber strands were aligned in a 0° direction and equally spaced across the fabric width, and two glass fiber strands were located on either end of the carbon fiber strand. The carbon fiber strands of the first layer were present at 0.98 strands per cm.

[0109] The second layer was formed by providing 68 tex fiberglass strands (E-glass with an epoxy resin compatible sizing) oriented at 90° to the first fibers of the first layer, the second layer containing 1.97 fiberglass strands per cm (measured perpendicular to the second direction, i.e. along the first direction). The woven fringe formed by the fiberglass strands of the second layer was machine cut to approximately 5 mm.

[0110] The first and second layers were sewn together using a polyester suture having a linear density of 7.6 tex employing a tricot stitch pattern with a stitch length of 3 mm. The fabric was sewn such that the suture 106 formed a stitch along each of the carbon fiber strands (tows) 102 and within each of the gaps between adjacent carbon fiber tows, as shown diagrammatically in FIG.

[0111] The total area weight of the fabric is 127 g / m 2 It was.

[0112] Figure 3a shows a photograph of the fabric of Example 1. The photograph in Figure 3a shows that the fabric of Example 1 exhibited some shrinkage, which caused an increase in fringe length.

[0113] Example 2 A hybrid fabric was produced as described in Example 1, except that the second layer was formed by placing approximately 5 mm of a 140 tex textured glass yarn (Textured E-glass yarn ECT9 T140 K252C from Vetrotex™) oriented 90° to the first fiber of the first layer between adjacent glass fiber strands of the second layer. The textured glass yarn used had a minimum diameter of 0.9 mm and had 1.2 lofts per cm (each loft was at least 10% larger (i.e., greater than 1 mm) than the minimum diameter of the yarn (e.g., measured perpendicular to the length of the yarn, as shown in Figure 4). B (Determined as the length of the yarn having a bulge of 1.2 pieces per cm). The textured glass yarn used contained 1.2 bulges per cm, and the bulge of the textured glass yarn constituted more than 50% of the length of the textured glass yarn. The fringe of the fabric formed by the glass fiber strands of the second layer was about 3 mm (smaller fringes are possible due to improved product stability and reduced shrinkage). The thickness of the fabric was 0.45 mm. The improved stability of the hybrid fabric of Example 2 compared to the hybrid fabric of Example 1 can be observed from Figures 3a and 3b, which show a more uniform spacing of the carbon tows in the fabric of Example 2 provided after stitching due to the use of the textured glass yarn in Example 2, with smaller fringes, compared to the fabric of Example 1.

[0114] The use of textured glass fibres (textured glass yarns) in a 90° orientation provided a lightweight product with excellent stability and resistance to handling.

[0115] FIG. 3b shows a photograph of the fabric of Example 2.

[0116] Example 3 A hybrid fabric was produced by providing a first layer comprising 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 from 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).

[0117] The first layer was formed by providing 12K carbon fiber strands (carbon fiber filaments with 7 μm diameter and epoxy resin compatible sizing) with each carbon fiber strand having a linear density of approximately 800 tex, and 68 tex glass fiber strands provided directly from a roving (Advantex™ E-CR glass fiber, glass fiber filaments with 9 μm diameter with epoxy resin compatible sizing), with the carbon fiber and glass fiber strands aligned in the 0° direction and spaced uniformly across the fabric width at 0.25 carbon fiber strands per cm and 0.74 glass fiber strands per cm.

[0118] The second layer was formed by providing 140 Tex textured glass yarns (textured E-glass yarn ECT9 T140 K252C from Vetrotex™) oriented at 90° to the first fibers of the first layer with approximately 0.87 strands of textured glass yarn per cm, the strands of textured glass yarn being equally spaced along the length of the fabric. The textured glass yarn used had a minimum diameter of 0.9 mm and had 12 bulky sections per 10 cm (each bulky section having a diameter d at least 10% larger (i.e., greater than 1 mm) than the minimum diameter of the yarn (measured perpendicular to the length of the yarn, e.g., as shown in Figure 4). BThe bulkiness of the textured glass yarn was determined as the length of the yarn having a linear density of about 800 tex (the carbon fiber filaments had a diameter of 7 μm and an epoxy resin compatible sizing agent) over the length of the fabric. The second layer also included 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 had a diameter of 7 μm and an epoxy resin compatible sizing agent) with 0.43 carbon fiber strands per cm over the length of the fabric, and PET monofilaments aligned with the textured yarn, had a diameter of 15 μm, a linear density of 24.3 tex, and had 0.87 PET monofilaments per cm over the length of the fabric. The carbon fiber, textured glass yarn, and PET monofilaments were uniformly spaced over the length of the fabric.

[0119] The first and second layers were sewn together using a polyester suture having a linear density of 7.6 tex employing a tricot stitch pattern with a stitch length of 3 mm. The fabric was sewn such that the suture 106 formed a stitch along each of the carbon fiber strands (tows) 102 and within each of the gaps between adjacent carbon fiber tows, as shown diagrammatically in FIG.

[0120] The total area weight of the fabric is 85 g / m 2 It was.

[0121] The woven fringe formed by the second layer of fiberglass strands was less than 5 mm (smaller fringes were possible due to improved product stability and reduced shrinkage).

[0122] FIG. 3c shows a photograph of the fabric of Example 3.

[0123] Table 1 below provides a summary of the fabrics produced according to Examples 1-3.

[0124] [Table 1]

[0125] The area weights of the different components and fabrics were determined according to ISO 3374.

[0126] The example hybrid fabrics have also been found to be easily infused at acceptable infusion rates without the need for the carbon fibers (e.g., carbon fiber tows) used to form the hybrid fabric to be spread or pre-impregnated with resin.

[0127] The inventors have surprisingly found that by providing a hybrid fabric comprising carbon fibers in a first direction and textured yarns in a second direction, the stability and resistance to handling of the lightweight hybrid fabric is improved as compared to a hybrid fabric comprising standard fibers (e.g., standard glass fibers) in the second direction as opposed to textured yarns.

[0128] Traditionally, those skilled in the art who wish to provide a non-crimped fabric will select fibers and fiber positions to optimize fiber alignment that is expected to optimize the mechanical properties of the non-crimped fabric. Thus, the use of textured yarn in a non-crimped fabric, such as the hybrid fabric described herein, goes against the understanding of those skilled in the art of how a non-crimped fabric should be produced (the fibers in the textured yarn are not all aligned (see, for example, FIG. 4), and this non-alignment of the fibers in the textured yarn allows for the necessary bulk of the textured yarn). Even more surprisingly, the use of textured yarn in the hybrid fabric described herein actually improves the stability and resistance to handling of the hybrid fabric.

[0129] The examples provided herein demonstrate that using textured yarns as described herein allows for the provision of very lightweight carbon fiber and fiberglass hybrid fabrics by improving the stability of fabrics that may contain unidirectionally oriented carbon fibers or differently oriented carbon fibers.

[0130] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, may be expressed in their specific form, or in terms of means for performing a disclosed function, or a method or process for obtaining a disclosed result, as appropriate, and may be utilized individually or in any combination of such features to realize the invention in its various forms.

[0131] While the present invention has been described in conjunction with the exemplary embodiments set forth above, many equivalent modifications and variations will become apparent to those skilled in the art upon receipt of this disclosure. Accordingly, the exemplary embodiments of the present invention set forth above are considered to be illustrative and not limiting. Various modifications to the described embodiments may be made without departing from the spirit and scope of the present invention.

[0132] For the avoidance of doubt, any theoretical explanations provided herein are provided for the purpose of enhancing the understanding of the reader, and the inventors do not wish to be bound by any of these theoretical explanations.

[0133] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0134] Throughout this specification, including the claims which follow, unless the context indicates otherwise, the terms "comprise" and "include", as well as variations such as "comprises", "comprising" and "including", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0135] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates 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 values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. The term "about" in reference to numerical values ​​is optional and may mean, for example, + / - 10%.

Claims

1. It is a hybrid fabric of carbon fiber and glass fiber, A first layer comprising first fibers oriented in a first direction, A second layer comprising second fibers oriented in a second direction, The present invention includes sutures that maintain the fibers of the first and second layers in their respective orientations, The second direction is within a range of approximately 45 degrees to approximately 90 degrees of the first direction. The first fiber contains carbon fiber, The second fiber is a stabilizing fiber, The area weight of the aforementioned fabric is approximately 500 g / m². 2 It is less than, The first fiber constitutes at least about 15% by weight of the fabric, The second fiber constitutes less than approximately 50% by weight of the fabric, resulting in a hybrid fabric.

2. The area weight of the aforementioned fabric is approximately 200 g / m². 2 The textile according to claim 1, which is less than [amount missing].

3. The woven fabric according to claim 1, wherein the stabilizing fiber is a processed yarn.

4. The fabric according to claim 3, wherein the processed yarn is processed glass yarn.

5. The woven fabric according to claim 3, wherein the processed yarn has a minimum diameter of less than approximately 4 mm or less than approximately 1 mm.

6. The fabric according to claim 3, wherein the processed yarn includes a plurality of bulky portions, each bulky portion having a diameter at least 10% larger than the minimum diameter of the processed yarn.

7. The woven fabric according to claim 6, wherein the bulky portion of the processed yarn constitutes at least 10% of the length of the processed yarn.

8. The woven fabric according to claim 6, wherein the processed yarn includes approximately 2 to approximately 30 bulky portions per 10 cm of processed yarn.

9. The fabric according to claim 3, wherein the processed yarn oriented in the second direction constitutes about 5% to about 30% by weight of the fabric.

10. The fabric according to claim 1, wherein the first layer comprises a third fiber oriented in a third direction, and the third fiber is a glass fiber.

11. The fabric according to claim 1, wherein the first layer comprises about 0.25 to about 5 first fiber strands per centimeter.

12. The fabric according to claim 1, wherein the suture thread forms a suture along a plurality of first fiber strands.

13. The fabric according to claim 1, wherein the second layer comprises a second fiber strand, and the second layer comprises about 0.25 to about 5 second fiber strands per centimeter.

14. The fabric according to claim 1, wherein the first layer comprises a third fiber oriented in a third direction, the third fiber being a glass fiber, and / or the stabilizing fiber being a processed glass yarn.

15. The first layer comprises a first fiber oriented in a first direction and a third fiber oriented in a third direction, and the second layer comprises a second fiber oriented in a second direction and a fourth fiber oriented in a fourth direction. The first fiber constitutes approximately 15% to approximately 80% by weight of the total weight of the fabric. The second fiber constitutes approximately 5% to 50% by weight of the total weight of the fabric. The third fiber constitutes approximately 0% to approximately 50% by weight of the total weight of the fabric. The fabric according to claim 1, wherein the fourth fiber constitutes about 0% to about 80% by weight of the total weight of the fabric.

16. The textile according to claim 1, wherein the first layer has an area weight in the range of about 20% to about 80% by weight of the total weight of the textile, and the second layer has an area weight in the range of about 5% to about 75% by weight of the total area weight of the textile.

17. A method for producing a hybrid fabric of carbon fiber and glass fiber, To provide a first layer containing first fibers, wherein the first fibers are oriented in a first direction, and the first fibers include carbon fibers. To provide a second layer comprising second fibers oriented in a second direction, wherein the second fibers include stabilizing fibers, the second layer is arranged on the first layer, and the second direction is within the range of about 45 degrees to about 90 degrees of the first direction. Approximately 500g / m 2 To form the hybrid fabric having an area weight of less than , the first layer and the second layer are sewn together using sutures, A method wherein the first fibers oriented in the first direction constitute at least about 15% by weight of the total weight of the fabric, and the second fibers oriented in the second direction constitute up to about 50% by weight of the total weight of the fabric.

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

19. Approximately 500g / m 2 The use of processed yarn to provide a hybrid fabric of carbon fiber and glass fiber having an area weight of less than 1.

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