Flexible Carbon Fiber Fabric That Prevents Unthreading
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Solution Overview
Problem
Existing carbon fiber fabrics are too rigid and prone to unthreading when deformed, making them unsuitable for clothing and leather goods that require flexible and sewable materials.
Innovation Solution
A flexible carbon fiber fabric is developed by applying a protective layer and a polyurethane or acrylic film, allowing the outer fibers to adhere while inner fibers remain free to slide, maintaining fiber arrangement and preventing unthreading, with edges sewn to form a hem for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber fabric is impregnated with polymeric resins to obtain rigid materials, then strength and structural stability are improved, but flexibility and sewability deteriorate
Solution Approach 1:
The patent applies different treatments to different parts of the fabric structure: the surface receives a protective coating for strength, while the inner layers remain untreated to maintain flexibility. This local differentiation allows the fabric to exhibit both rigidity where needed and flexibility where required for sewing and draping.
Solution Approach 2:
The fabric is divided into multiple layers with distinct functions: outer layers provide structural strength and protection, while inner layers maintain flexibility and comfort. This segmentation allows each layer to optimize its specific function without compromising the overall fabric performance.
2Ease of operation
If carbon fiber fabric is left raw to maintain flexibility, then ease of sewing is improved, but the fabric tends to unthread and cannot maintain fiber arrangement when deformed
Solution Approach 1:
The fabric undergoes preliminary treatments during manufacturing, including surface coating and heat setting, which pre-establish the fiber arrangement stability before the fabric is used. This preliminary action prevents unthreading and maintains fiber positioning even when the fabric is later deformed during sewing and wear.
Solution Approach 2:
The patent modifies physical parameters of the fabric through controlled heating and coating processes. These parameter changes alter the surface properties and inter-fiber bonding to prevent unthreading while preserving the overall flexibility and sewability of the fabric.
3Strength
If a protective layer is applied to the fabric surface, then resistance to surface wear and handling during manufacture are improved, but flexibility may be reduced
Solution Approach 1:
The protective coating is applied selectively to the surface layers of the fabric, providing wear resistance and handling protection where needed, while leaving the inner layers untreated to maintain flexibility and comfort against the skin.
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 fabric achieves high resistance and flexibility, preventing unthreading and maintaining texture integrity even after deformation, suitable for clothing, leather goods, and automotive applications.
Implementation Method 1
These known fabrics are impregnated with polymeric resins
Implementation Method 2
the particular polyurethane or acrylic film adheres only to the most superficial fibers of the fabric of carbon fiber
Implementation Method 3
The resins are cured to obtain rigid materials
Data Source
Figure 1~2
AI summary
Woven carbon fiber, in which a polyurethane film or acrylic (4) is joined to at least one side of this fabric (1). The present invention also relates to a process for the manufacture of such fabric, as well as a product of clothing or leather goods comprising this fabric.