Fiber Structure with Interlayer Binding Yarns to Suppress End Fraying
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Solution Overview
Problem
Existing fiber structures face the challenge of yarn fraying from the ends, which is typically addressed by adding a fusing step to the weaving process, increasing the manufacturing complexity.
Innovation Solution
A fiber structure design with interlayer binding yarns that interlace with first yarns at the ends, forming a tighter bond to prevent fraying without requiring additional manufacturing steps, and utilizing a matrix material impregnation to potentially melt these binding yarns for further reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermofusible yarns are added at the ends of the fiber structure to suppress fraying, then fraying of the second yarns is prevented, but the number of manufacturing steps increases due to the additional fusing step
Solution Approach 1:
The patent combines the fraying suppression function with the existing interlayer binding yarns used in the weaving process. The interlayer binding yarns are made of thermofusible material and are already present in the fiber structure during weaving, so they serve dual purposes: binding layers together and preventing fraying at the ends, eliminating the need for separate thermofusible yarns and fusing step
Solution Approach 2:
The interlayer binding yarns are designed to perform multiple functions simultaneously: (1) binding multiple fiber layers together in the stacking direction, and (2) suppressing fraying of second yarns at the ends of the fiber structure. This multi-functionality resolves the contradiction by using existing components for additional protective purposes
2Ease of manufacture
If interlayer binding yarns are used to bind fiber layers, then manufacturing steps are reduced, but fraying suppression at the ends may be insufficient without additional thermofusible yarns
Solution Approach 1:
The patent applies different configurations of interlayer binding yarns in different regions of the fiber structure. In the central region, standard spacing is used, while in the end regions, the spacing between interlayer binding yarns is reduced to provide enhanced fraying suppression exactly where it is most needed, without adding thermofusible yarns elsewhere
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively suppresses yarn fraying at the ends while maintaining manufacturing efficiency by integrating interlayer binding yarns that share paths with central yarns, enhancing structural integrity without additional processing steps or tools.
Implementation Method 1
multiple interlayer binding yarns binding the multiple fiber layers in the stacking direction. Each of the interlayer binding yarns is adjacent to one of the second yarns in the first direction, has a yarn main axis extending in the second direction, and is engaged with the first yarns of the first yarn layers located at the opposite ends of the fiber structure in the stacking direction
Implementation Method 2
utilizing a matrix material impregnation to potentially melt these binding yarns for further reinforcement
Data Source
AI summary
A fiber structure includes multiple fiber layers and multiple interlayer binding yarns. The fiber layers include multiple first yarn layers and one or more second yarn layers. Each of the first yarn layers includes multiple first yarns each having a yarn main axis extending in a first direction. Each of the second yarn layers includes an end second yarn located at an end of the central region. The interlayer binding yarns located in an end region include two of the interlayer binding yarns that pass through mutually different paths in a cross section of the fiber structure orthogonal to the first direction, so as to interlace with the first yarns. A pitch in the first direction between the interlayer binding yarns in the end region is smaller than a pitch in the first direction between the interlayer binding yarns in the central region.