Multi-Layer Carbon Fabric to Block Molten Metal Penetration
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Solution Overview
Problem
Existing high-temperature and fire-resistant materials, such as welding blankets, often fail to effectively prevent molten metal spatter and fire flames from penetrating due to open inter-yarn apertures, and they lack flexibility and drapeability compared to single-layer sheet materials.
Innovation Solution
A unified multi-layer woven or knitted fabric made of intimately blended staple carbon and non-carbon fibers, such as wool, with layers interlaced to close inter-yarn apertures and enhanced by needle punching to create a napped surface, preventing penetration of molten metal and fire flames, and allowing for three-dimensional shaping without adhesives or chemical bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If single-layer sheet materials or needle-punched nonwoven fabrics are used, then fire resistance is provided, but inter-yarn apertures remain open allowing molten metal and fire flames to penetrate
Solution Approach 1:
The patent transitions from single-layer to multi-layer fabric construction, adding the dimensional aspect of layering to block penetration paths. Multiple layers create overlapping barriers that prevent molten metal and flames from penetrating through, effectively addressing the harmful factors while maintaining reliability.
Solution Approach 2:
The patent employs composite fabric structures combining different fiber types (carbon fibers, wool, cotton, polyester) in multi-layer constructions. This composite approach creates materials with enhanced protective properties, where each layer contributes specific characteristics to block harmful factors while maintaining structural integrity.
2Object-affected harmful factors
If multi-layer woven fabrics with closed apertures are used, then penetration protection is improved, but flexibility and drapeability are reduced
Solution Approach 1:
The patent modifies physical parameters of the fabric including yarn twist, weave density, and layer construction to achieve optimal balance. By adjusting these parameters, the fabric maintains closed apertures for protection while preserving flexibility and drapeability through controlled yarn selection and weaving patterns.
Solution Approach 2:
The patent applies different fiber compositions and weave patterns to specific layers or regions of the fabric. This local quality approach allows certain areas to provide enhanced protection while other areas maintain flexibility, achieving both penetration blockage and ease of operation in different zones of the same fabric.
Data Source
AI summary
A method of making a high-temperature and fire-resistant fabric is described in which staple carbon fiber yarns are woven into a unified multi-layer woven fabric. The warp ends and filling picks of the unified multi-layer woven structure are positioned such that they prevent penetration of fire flames, welding sparks and molten metal spatter from penetrating through the unified multi-layer fabric.