DE20100915U1 - Inexpensive production of spatial components from fibers, threads or yarns using spacer knits - Google Patents

Description

Inexpensive production of rattan weaving fibres, _threads or yarns by means of abstract knitting. * Chisels,

Components that are designed as spatial structures with a top and bottom surface and special spacers are known, for example, in the form of sandwich constructions or spacer fabrics.

Sandwich constructions usually consist of a core made of webs arranged in a grid (generally honeycombs made of paper or metal foil) which is glued to a lower and an upper cover (generally metal sheets or foils, mats made of glass or carbon fibre).

Several work steps are always required to produce sandwich constructions of this type, which means that they are very expensive to produce. It is possible to adjust the properties of the top and bottom surfaces to vary depending on the location, but this involves a lot of effort; with the honeycomb core, this measure is not possible for technical and economic reasons. In addition, sandwich constructions are rigid and are therefore not suitable for applications where flexibility is important.

Spacer fabrics consist of three elements: surface, undersurface and the firmly integrated connecting threads that keep the first two at a distance. They are manufactured on expensive machines. The production of spacer fabrics requires extensive preparatory work, as the yarns have to be applied to large-format special yarn carriers (warp beams). This makes the process inflexible and it is difficult to react to changing requirements. For the reasons outlined above, this process is essentially only used for large production quantities.

The invention is based on the object of producing components in small quantities using a cost-effective process, in which the distance between the upper _and lower surfaces is defined and maintained by spacers, and in which the three elements mentioned (spacers, upper and lower surfaces) can optionally have different or identical physical properties.

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len can be constant or varying depending on the location. The manufacturing costs are of particular importance here.

The invention solves the problem by producing and using spacer knits. The use of circular knitting machines is provided as a particularly inexpensive method for this.

Circular knitting machines are inexpensive to manufacture, purchase and operate. In addition, the yarns (fibers) can be processed directly from the spools on which they are delivered. This means that there are no additional costs for rewinding and for providing the necessary machines, and no additional time is required. The actual production can therefore be flexibly adapted to current requirements without any loss of time or delay. This is why this process is also ideal for producing small quantities.

Spacer knits (see Fig. 1 and 2) consist of an upper surface (see item 1) and a lower surface (see item 2) which are kept apart by firmly bound connecting threads (see item 3). The resulting product is manufactured in just one single operation. Depending on the requirements of the area of application or the end product, an appropriate distance can be predetermined by the machine settings.

The product leaving the circular knitting machine is a tube (see Fig. 1) of any length (so-called "endless product") and can already represent the end product in this original production form, or it can be folded up in whole or in part to form a double-layered surface or shell. If required, a flat material (see Fig. 2) can be produced by (complete or partial) slitting at the side, which then has twice the width. Any shape can be produced by contour cutting before or after slitting. Both the base material (tube, flat material after slitting) and the cut-outs or sections can be used; j»"'"::"":'j \ "· \'\ '-': ': ^: ". : : *:

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Due to the manufacturing process, the individual threads are spatially aligned differently and intertwined with each other several times. This creates a stable bond that is not affected (dissolved) by bending or rolling / winding the end product. The original shape is resumed once the load is removed, so an elastic reaction to the forces acting on it occurs. These properties refer not only to tensile and compressive forces in the direction of the top / bottom surface (i.e. in the direction of the spacers), but also to tensile and compressive forces in the plane of the product or in any intermediate direction.

An additional, significant strengthening of this bond can be achieved by gluing the loops. This is particularly advantageous when the top and/or bottom surface is resinified with the spacer threads. Materials can be selected that are flexible after setting at room temperature. When using materials that harden after setting, suitable shaping before hardening can ensure that the end product takes on and retains a predetermined shape.

The application- or use-specific properties of the end product can be controlled and determined by using different fibers, threads or yarns, each with special characteristics (e.g. natural fibers, synthetics, ceramic, glass or carbon fibers, metallic cables or electrically conductive wires, heating wires). These different starting materials can be used in the entirety of the end product or in individual areas. These areas can be limited to parts of the "spacer" elements or the "top or bottom surface" or can be arranged in several of these elements in any distribution. These can be continuous tracks (strips) in the longitudinal or transverse direction or isolated, locally predetermined cells.

The advantage of the process described here lies primarily in the low-cost production with rafccü. tunstelibärfeniPäCamfetelTl uhdänMet: VäölzaW vön'fniteinander combinable

materials (yarns, threads, fibres, wires, cables).

A special shape is required, for example, if the product is to be used as a piece of clothing. This is not possible with sandwich constructions, as these are not suitable for applications that require a high degree of flexibility due to the rigidity inherent in the process. However, spacer knits are ideal for this type of use due to the large number of freely movable links and loops. This can preferably be sports or work clothing, where, in addition to easy shape adjustment, the possibility of using special materials in particularly important places is an advantage. For example: the areas closest to the body (underside) can be made of breathable material; the webs can be particularly stiff or elastic; the size of the spacing can ensure particularly good ventilation or particularly good shielding from external forces or temperatures; the side facing away from the body (surface) can have open or closed pores; it can be resistant to chemicals, physical influences (heat, mechanical forces) or abrasion. Possible areas of application include goalkeeper or firefighter clothing, bulletproof vests, gloves and winter boots.

By using electrically conductive raw materials (wires, cables) exclusively or partially, a product can be created that, for example, shields against electromagnetic waves. It can thus keep out interference radiation in order to either protect devices or organisms from external influences or to prevent impulses from escaping. Protective clothing of the type described here can be used particularly where people are exposed to a strong electromagnetic field ("electrosmog"). This can be the case, for example, for maintenance personnel at mobile phone transmitters or radar systems if these systems are not switched off for the duration of inspection, maintenance or repairs.

By using the sys-tems, heating can be

This makes it possible to produce a protective suit or undersuit that simultaneously ensures a body-friendly atmosphere (ventilation, perspiration, mobility), dampens or distributes external forces and can be heated in certain areas. This is useful when used in winter or arctic conditions or when a diver is working underwater.

Damage or violent destruction of the product can be detected if the product is designed accordingly by monitoring the integrity of electrically conductive fibres (wires, cables) in a spacer fabric manufactured in this way by means of a suitable control device.

The endless material produced on the circular knitting machine can be cut to any length. When building interiors, this can be used to create cladding elements that seamlessly span the full width or height of a wall or even go beyond it. The product can be bent and thus cover the edges of a room. By incorporating electrically conductive fibers (wires, cables), these cladding elements can protect against incoming and outgoing radiation (eavesdropping security, Faraday cage principle). They can have current flowing through them and thus act as heating elements, or a heating or cooling medium can flow in the space between the upper and lower layers. At the same time, they can be used to detect damage by connecting suitable devices.

Due to the low-cost manufacturing method, the continuous material is suitable for the production of roll-up partition walls like blinds, for example in multi-purpose gymnasiums. The low weight is an advantage for the design of the overall construction.

Because the threads are intertwined several times, it is ensured that the entire connection does not come apart even after cutting. The free thread ends created by a mechanical cutting process, however, sometimes look unsightly and disruptive; they can often be glued, welded or

fused. This can be done in a separate step by applying heat, or by choosing a suitable cutting process, e.g. laser cutting. The edge area can be additionally strengthened in this way.

Another example of the use of these components is their use as luggage racks in vehicles, primarily in aircraft. A particular advantage here is that the tubular blanks produced on the circular knitting machine can be made in any diameter, so that they can be produced in all required dimensions. Before the resin hardens, they can be shaped into any desired cross-sectional shape. Because of the structure with spacers, cables can be laid between the upper and lower layers, and fastening or operating elements can be installed before or after the resin or adhesive hardens. The cutouts for the openings can be used as covers for the luggage compartment lid.

Claims (19)

1. Spatial component made of natural fibers, synthetics, ceramic, glass or carbon fibers, metallic lines or electrically conductive wires or mixtures thereof, characterized in that it consists of an upper and a lower surface which are kept at a distance by connecting threads incorporated therein and that it is manufactured on a circular knitting machine and that the loops of the spacer threads are glued or resinified to the upper and/or lower layer. 2. Spatial component made of natural fibers, synthetics, ceramic, glass or carbon fibers, metallic lines or electrically conductive wires or mixtures thereof, characterized in that it consists of an upper and a lower surface which are kept at a distance by connecting threads incorporated therein and that it is manufactured on a circular knitting machine and that the upper and/or lower layer is laminated, coated, covered or bonded. 3. Component according to claim 1, characterized in that it is glued or resinified with a material which is flexible at room temperature. 4. Component according to claim 1, characterized in that it is glued or resinified with a material which is rigid at room temperature. 5. Component according to claim 1 or 2, characterized in that it is contoured before or after resinification, bonding, laminating or coating by partial or continuous trimming at the edge or in the inner region. 6. Component according to claim 3, characterized in that the cutouts resulting from contouring and/or the remaining remainder are reused. 7. Component according to at least one of the above claims, characterized in that the free ends of the fibers or threads arising at the cut edges are secured or bound by gluing, welding or fusing. 8. Component according to at least one of the above claims, characterized in that it shields electromagnetic waves by the incorporation of wires or lines. 9. Component according to at least one of the above claims, characterized in that heating wires are incorporated in it. 10. Component according to at least one of the above claims, characterized in that a heating or cooling medium flows in the space between the upper and lower layers. 11. Component according to at least one of the above claims, characterized in that it serves as a shield for devices or organisms which should not be exposed to external electromagnetic waves. 12. Component according to at least one of the above claims, characterized in that it serves as a shield for devices from which electromagnetic waves should not penetrate to the outside. 13. A component which is processed as a cladding for ceilings or walls of buildings or parts of buildings, characterized in that it contains at least one element which was manufactured according to at least one of the preceding claims. 14. Component which is processed as a rollable, foldable or movable wall, characterized in that it contains at least one element which was manufactured according to at least one of the preceding claims. 15. Component which is processed as a fully or partially heated garment, characterized in that it contains at least one element which was manufactured according to at least one of the preceding claims. 16. Component which is processed in whole or in part as a covering for protection against mechanical effects, characterized in that it contains at least one element which was manufactured according to at least one of the preceding claims. 17. Component which is processed in whole or in part as a covering for protection against thermal effects, characterized in that it contains at least one element which was manufactured according to at least one of the preceding claims. 18. Component that is processed as protective clothing for persons exposed to electromagnetic waves (electrosmog), characterized in that it contains at least one element that was manufactured according to at least one of the preceding claims. 19. Component that is processed as a luggage rack in vehicles, primarily in aircraft, characterized in that it contains at least one element that was manufactured according to at least one of the preceding claims.