GB2249050A - Reinforcing fabric for plastics - Google Patents
Reinforcing fabric for plastics Download PDFInfo
- Publication number
- GB2249050A GB2249050A GB9021729A GB9021729A GB2249050A GB 2249050 A GB2249050 A GB 2249050A GB 9021729 A GB9021729 A GB 9021729A GB 9021729 A GB9021729 A GB 9021729A GB 2249050 A GB2249050 A GB 2249050A
- Authority
- GB
- United Kingdom
- Prior art keywords
- layer
- lateral side
- yarns
- rovings
- layers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 133
- 230000003014 reinforcing effect Effects 0.000 title claims abstract description 83
- 239000004033 plastic Substances 0.000 title claims abstract description 17
- 229920003023 plastic Polymers 0.000 title claims abstract description 17
- 239000012779 reinforcing material Substances 0.000 claims abstract description 16
- 239000012260 resinous material Substances 0.000 claims description 15
- 239000002990 reinforced plastic Substances 0.000 claims description 11
- 229920001169 thermoplastic Polymers 0.000 claims description 10
- 239000004416 thermosoftening plastic Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 239000004760 aramid Substances 0.000 claims description 4
- 229920003235 aromatic polyamide Polymers 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 230000002787 reinforcement Effects 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 241001061257 Emmelichthyidae Species 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/304—In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
- D04H3/004—Glass yarns or filaments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/009—Condensation or reaction polymers
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
- B29K2105/101—Oriented
- B29K2105/108—Oriented arranged in parallel planes and crossing at substantial angles
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Laminated Bodies (AREA)
Abstract
A reinforcing fabric (1, 2) for plastics comprises a plurality of superimposed layers (3, 4, 5, 6), each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material (7) laid side-by-side, the rovings or yarns in at least two of the layers being stitched together and each layer (3, 4, 5, 6) having at least one lateral side edge which terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer. <IMAGE>
Description
REINFORCING FABRIC FOR PLASTICS, METHOD OF PRODUCING SAME AND
METHOD OF PRODUCING REINFORCED PLASTICS ARTICLES
This invention relates to a reinforcing fabric for plastics, a method of producing a reinforcing fabric for plastics and a method of producing reinforced plastics articles.
Multi-axial reinforcing fabrics for plastics are known which comprise a plurality of superimposed layers, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two of the layers extending in different directions and said layers being stitched together. Such known reinforcing fabrics have considerable advantages over other reinforcing materials commonly used in plastics technology, such as chopped strand mat or woven reinforcing materials, in that they provide improve strength characteristics and are more readily formable to complex shapes, e.g. to follow the contours of a mould.They suffer from the disadvantage, however, that when two lengths of the reinforcing fabric are laid side-byside, e.g. in a mould, in order to preserve the continuity of the reinforcement it is necessary to overlap the adjacent margins of the two lengths of reinforcing fabric and this doubles the thickness of the reinforcement in the region of the overlap, which is unacceptable for many reinforced plastics articles such as the hulls of some marine craft or some structural parts for aircraft.
The present invention has as its object to provide a reinforcing fabric for plastics which enables two lengths of reinforcing fabric to be overlapped with only a minimal increase in thickness in the region of the overlap, as well as a method of producing the reinforcing fabric and an improved method of producing reinforced plastics articles.
The present invention provides a reinforcing fabric for plastics, the fabric comprising a plurality of super-imposed layers, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-byside, the rovings or yarns in at least two of the layers extending in different directions, said layers being stitched together and each layer having at least one lateral side edge which terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer.
According to a first embodiment of a reinforcing fabric according to the present invention, at least one layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer. An outer layer of the fabric may have one lateral side edge which terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge coterminous with the corresponding lateral side edge of the adjacent layer. The rovings or yarns in said outer layer preferably extend longitudinally of the fabric.Preferably, with the exception of said outer layer, each layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the corresponding lateral side edge of said adjacent layer, whereby the lateral side margins of the fabric are stepped in opposite directions.
According to a second embodiment of a reinforcing fabric according to the present invention, both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the fabric are stepped.
Preferably the rovings or yarns in the other outer layer extend longitudinally of the fabric.
A reinforcing fabric according to the present invention may be a multi-axial fabric and may have, for example, at least a first layer the rovings or yarns of which extend at 0o with respect to the longitudinal direction of the fabric, at least a second layer the rovings or yarns of which extend at 450 to the rovings or yarns of said first layer and at least a third layer the rovings or yarns of which extend at 900 to the rovings or yarns of the first layer. Advantageously, the reinforcing fabric has at least a fourth layer the rovings or yarns of which extend at 450 to the rovings or yarns of said first layer and at 900 to the rovings or yarns of said second layer.
A reinforcing fabric according to the invention may have first and second layers, first stitching connecting the rovings or yarns in each of said first and second layers to one another and connecting said first and second layers together, at least one further layer second stitching connecting the rovings or yarns in said at least one further layer to one another, and third stitching connecting said at least one further layer to said first and second layers.
Preferably, the lateral side edges of said layers each terminate short of or extend beyond the lateral side edges of an adjacent layer by substantially the same amount.
The rovings or yarns in each of said layers may be of any material suitable for reinforcing plastics, such as glass fibre,
Aramid fibre or carbon fibre or mixtures thereof.
If desired, rovings or yarns of thermoplastics resinous material may be interspersed with said rovings or yarns of reinforcing material in at least one of said layers and/or at least one sheet or strip of thermo-plastics resinous material may be inserted between at least two of said layers, whereby to provide a fabric which is formable under heat and pressure.
The invention also provides a method of producing a reinforcing fabric for plastics, the method comprising the steps of:
(a) producing a plurality of layers each consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two layers extending in different directions;
(b) superimposing said layers one upon another so that at least one lateral side edge of each layer terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer, and
(c) stitching together said layers.
The method may comprising superimposing said layers one upon another so that at least one layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer. Said layers may be superimposed one upon another so that one lateral side edge of an outer layer terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge is coterminous with the corresponding lateral side edge of the adjacent layer. Preferably said outer layer is produced so that the rovings or yarns thereof will extend longitudinally of the fabric.With the exception of said outer layer, said layers may be superimposed one upon another so that each layer has one lateral side edge terminating short of the corresponding side edge of an adjacent layer and the other lateral side edge extending beyond the corresponding lateral side edge of said adjacent layer, whereby the lateral side margins of the fabric are stepped in opposite directions.
According to another embodiment of the invention, the method comprising superimposing said layers one upon another so that both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the fabric are stepped. Preferably, the other outer layer is produced so that the rovings or yarns thereof extend longitudinally of the fabric.
The method may comprise producing and/or super-imposing said layers so that the rovings or yarns of at least a first layer extend at Oo with respect to the longitudinal direction of the fabric, the rovings or yarns of at least a second layer extend at 450 to the rovings or yarns of said first layer, and the rovings or yarns of at least a third layer extend at 900 to the rovings or yarns of said first layer. At least a fourth layer may be produced and/or superimposed so that the rovings or yarns thereof extend at 450 to the rovings or yarns of the first layer and at 900 to the rovings or yarns of said second layer.
The method of the present invention may comprise the steps of:
(i) producing first and second superimposed layers,
(ii) stitching the superimposed first and second layers to stitch together the rovings or yarns in each layer and the layers themselves,
(iii) producing at least one further layer,
(iv) stitching together the rovings or yarns in said at least one further layer,
(v) superimposing said first and second layer with said at least one further layer, and
(vi) stitching together the superimposed layers.
Said layers may be superimposed with the lateral edges thereof terminating short of or extending beyond the lateral side edges of an adjacent layer by substantially the same amount.
The rovings or yarns in each of said layers may be of any material suitable for reinforcing plastics, such as glass fibre,
Aramid fibre or carbon fibre or mixtures thereof.
The method of the invention may further comprise interspersing rovings or yarns of thermoplastics resinous material rovings or yarns of reinforcing material in at least one of said layers at least one sheet or strip of thermoplastics material between at least two of said layers before said layers are stitched together, whereby to produce a reinforcing fabric.
The invention further provides a method of forming a reinforced plastics article comprising the steps of:
(a) obtaining a reinforcing fabric comprising a plurality of superimposed layers, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two of the layers extending in different directions, said layers being stitched together and each layer having at least one lateral side edge which terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer,
(b) laying at least two lengths of said fabric side-by-side in overlaying relation so that a lateral side margin of at least one layer of one of said lengths overlaps the adjacent lateral side margin of the corresponding layer of the other of said lengths,
(c) impregnating the fabric with synthetic resinous material, and
(d) curing or setting the synthetic resinous material.
The rovings or yarns in an outer layer of said fabric may extend longitudinally of the fabric the said outer layers of the at least two lengths of fabric may be arranged side-by-side without overlap.
Preferably, the adjacent lateral side margins of the at least two lengths of fabric are stepped in opposite directions to that they interfit when overlapped.
According an embodiment of the method of forming a reinforced plastics article according to the present invention, the method comprises the steps of:
(i) obtaining a first length of reinforcing fabric wherein both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and wherein both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the first length of fabric are stepped,
(ii) obtaining second and third lengths of reinforcing fabric wherein, with the exception of an outer layer one lateral side edge of which terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge of which is coterminous with the corresponding lateral side edge of the adjacent layer, each layer of each of said second and third lengths has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer, whereby the opposite side margins of each of the second and third lengths are stepped in opposite directions, and
(iii) overlapping the second and third lengths of reinforcing fabric with the first length of reinforcing fabric on opposite sides thereof so that the overlapping margins interfit.
The first length of reinforcing fabric in the just described embodiment, which accords with the reinforcing fabric according to the second embodiment hereinbefore described, provides a useful junction fabric between said second and third lengths of reinforcing fabric, which accord with the first embodiment of reinforcing fabric hereinbefore described. This junction fabric is useful in that it enables work to proceed on either side thereof using lengths of reinforcing fabric according to the first above described embodiment or enables work to be recommenced, e.g. at the beginning of a new working day or shift, if work was previously terminated with the article incomplete so that the resinous material with which previously laid reinforcing fabric has been impregnated has cured or set.
Preferably, in the method of forming a reinforced plastics article according to the present invention, the rovings or yarns in the corresponding layers of the at least two lengths of reinforcing fabric extend in the same direction. This has the advantage that when the two lengths of reinforcing fabric are overlapped so that the lateral side margins of the corresponding layers of each of said lengths overlap, the rovings or yarns in the overlapped corresponding layers will be able to inter-mingle or intersperse to a degree, e.g. under heat and pressure, to further minimise the thickness of the overlap between the two lengths of reinforcing fabric.
Said at least two lengths of reinforcing fabric may be laid side-by-side in overlapping relationship in a mould to produce said article. The synthetic resinous material may be cured or set under heat and/or pressure.
The invention will be more particularly described with reference to the accompanying drawings, in which:
Figure 1 is a diagrammatic illustration of two lengths of a reinforcing fabric according to a first embodiment of the present invention laid side-by-side in overlapping relation, and
Figure 2 is a diagrammatic elevation of a length of reinforcing fabric according to a second embodiment of the present invention laid side-by-side in overlapping relation with two lengths of reinforcing fabric according to the first embodiment of the invention.
Referring to Figure 1 of the drawings it will be seen that there is diagrammatically illustrated two lengths 1, 2 of reinforcing fabric laid side-by-side in overlapping relation.
Each of the lengths 1, 2 of reinforcing fabric comprises four layers, 3, 4, 5 and 6, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material 7 laid side-by-side. Although only shown for the length of reinforcing fabric 1, the rovings or yarns 7 of the layers 3 and 4 of each length of reinforcing fabric 1, 2 are stitched to one another and the layers 3, 4 are stitched together by first stitching 8. The rovings or yarns in the layer 5 are stitched together by stitching 9 and the rovings or yarns in the layer 6 are stitched together by stitching 10. Finally, the layers 3, 4, 5 and 6 are stitched together by stitching 11. The layer 3 of each length of reinforcing material 1, 2 terminates short of the layer 4 at one lateral side edge thereof and is coterminous with the layer 4 at the other lateral side edge thereof.Layer 4 terminates short of the layer 5 at one lateral side edge thereof and extends beyond the layer 5 at the other lateral side edge thereof. In similar manner, the layer 5 terminates short of the layer 6 at one lateral side edge thereof and extends beyond the layer 6 at the other lateral side edge thereof. In this way the lateral side edges of each of the lengths of reinforcing fabric 1, 2 are stepped in opposite directions as shown.In the illustrated embodiment, the rovings or yarns 7 in the layer 3 of each length of reinforcing fabric 1, 2 extend at 00 with respect to the longitudinal direction of the fabric, the rovings or yarns in the layer 4 extend at 450 to the rovings or yarns in the layer 3, the rovings or yarns in the layer 5 extend at 900 to the rovings or yarns in the layer 3 and the rovings or yarns in the layer 6 extend at 450 with respect to the rovings or yarns in the layer 3 and at 900 with respect to the rovings or yarns in the layer 4.
In use, the lengths of reinforcing fabric 1, 2 are overlapped so that the layer 6 of the length of fabric 1 overlaps the layer 6a of the length of fabric 2, the layer 5 of the length of fabric 1 overlaps the layer Sa of the length of fabric 2, the layer 4 of the length of fabric 1 overlaps the layer 4a of the length of fabric 2 and the layer 3 of the length of fabric 1 is side-by-side with the layer 3a of the fabric 2 without overlapping. Thus, the overlapping side margins of the lengths of reinforcing fabric 1, 2 interfit as shown to reduce to a minimum the increase in thickness brought about by the overlapping of the side margins of the two lengths of reinforcing fabric 1, 2 whilst at the same time preserving the mechanical integrity of the reinforcement over the region of the overlap.Moreover, because the rovers or yarns 7 in the overlapping layers 4, 4a, 5, 5a and 6, 6a extend in the same directions the rovings or yarns in the overlapping layers can intermingle or inter-sperse to a certain extent as allowed by the stitching, e.g. under the effects of heat and pressure, to further reduce the thickness of the reinforcement in the region of the overlap between the lengths of reinforcing fabric 1, 2.
Figure 2 illustrates a length of reinforcing fabric 12 according to another embodiment of the invention. The length of reinforcing fabric 12 is similar to the lengths of reinforcing fabric 1, 2 except that the layer 6b thereof extends beyond the layer 5b at each of the lateral side margins thereof and each of the other layers 3b, 4b. 5b terminates short of an adjacent layer at each lateral side edge thereof so that the reinforcing fabric 12 is stepped at each lateral side margin thereof as shown in Figure 2.Reinforcing fabric 12 provides a useful junction fabric between lengths of reinforcing fabric la, 2a according to the embodiment of Figure 1 and enables, for example, work to progress in either direction from opposite sides of the reinforcing fabric 12 or for work to be continued if work has previously been terminated and synthetic resinous material with which the lengths of fabric 1, 2 have been impregnated has been allowed to cure or set.
In use, lengths of reinforcing fabric 1, 2 or la, 12, 2a are laid side-by-side in overlapping relation, e.g. in a mould, and are impregnated with synthetic resinous material which is allowed to cure or set to form a reinforced plastics article.
The synthetic resinous plastics material may be a thermosetting or thermo-plastics resin depending upon requirements. If a thermo-setting resin is used then the article may be formed and the resin cured under heat and pressure. If a thermo-plastics resin is used then the article may be formed under heat and pressure and the article then cooled to set the resin.
It will be understood from the foregoing that the present invention enables reinforced plastics articles to be produced from overlapped lengths of reinforcing fabric with only a minimal increase in the thickness of the reinforcement in the region of said overlap.
Claims (36)
1. A reinforcing fabric for plastics, the fabric comprising a plurality of superimposed layers, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two of the layers extending in different directions, said layers being stitched together and each layer having at least one lateral side edge which terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer.
2. A reinforcing fabric according to Claim 1, wherein at least one layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer.
3. A reinforcing fabric according to Claim 1 or 2, having an outer layer one lateral side edge of which terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge of which is coterminous with the corresponding lateral side edge of the adjacent layer.
4. A reinforcing fabric according to Claim 3, wherein the rovings or yarns in said outer layer extend longitudinally of the fabric.
5. A reinforcing fabric according to Claim 3 or 4, wherein, with the exception of said outer layer, each layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the corresponding lateral side edge of said adjacent layer, whereby the lateral side margins of the fabric are stepped in opposite directions.
6. A reinforcing fabric according to Claim 3, wherein both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and wherein both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the fabric are stepped.
7. A reinforcing fabric according to Claim 6, wherein the rovings or yarns in the other outer layer extend longitudinally of the fabric.
8. A reinforcing fabric according to any one of the preceding claims, having at least a first layer the rovings or yarns of which extend at 0o with respect to the longitudinal direction of the fabric, at least a second layer the rovings or yarns of which extend at 450 to the rovings or yarns of said first layer and at least a third layer the rovings or yarns of which extend at 900 to the rovings or yarns of the first layer.
9. A reinforcing fabric according to Claim 8, having at least a fourth layer the rovings or yarns of which extend at 450 to the rovings or yarns of said first layer and at 900 to the rovings or yarns of said second layer.
10. A reinforcing fabric according to any one of the preceding claims, having first and second layers, first stitching connecting the rovings or yarns in each of said first and second layers to one another and connecting said first and second layers together, at least one further layer, second stitching connecting the rovings or yarns in said at least one further layer to one another, and third stitching connecting said at least one further layer to said first and second layers.
11. A reinforcing fabric according to any one of the preceding claims, wherein the lateral side edges of said layers each terminate short of or extend beyond the lateral side edges of an adjacent layer by substantially the same amount.
12. A reinforcing fabric according to any one of the preceding claims, wherein the rovings or yarns in each of said layer are of glass fibre, Aramid fibre or carbon fibre or mixtures thereof.
13. A reinforcing fabric according to any one of the preceding claims, wherein rovings or yarns of thermo-plastic resinous material are interspersed with said rovings or yarns of reinforcing material in at least one of said layers and/or wherein at least one sheet or strip of thermoplastics resinous material is inserted between at least two of said layers, whereby the fabric is formable under heat and pressure.
14. A method of producing a reinforcing fabric for plastics, the method comprising the steps of:
(a) producing a plurality of layers each consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two layers extending in different directions;
(b) superimposing said layers one upon another so that at least one lateral side edge of each layer terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer, and
(c) stitching together said layers.
15. A method according to Claim 14, comprising super-imposing said layer one upon another so that at least one layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer.
16. A method according to Claim 14 or 15, comprising superimposing said layers one upon another so that one lateral side edge of an outer layer terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge in coterminous with the corresponding lateral side edge of the adjacent layer.
17. A method according to Claim 16, which comprises producing said outer layer so that the rovings or yarns thereof will extend longitudinally of the fabric.
18. A method according to Claim 16 or 17, wherein, with the exception of said outer layer, said layers are super-imposed one upon another so that each layer has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the corresponding lateral side edge of said adjacent layer, whereby the lateral side margins of the fabric are stepped in opposite directions.
19. A method according to Claim 14, comprising super-imposing said layers so that both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and so that both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the fabric are stepped.
20. A method according to Claim 19, wherein the other outer layer is produced so that the rovings or yarns thereof will extend longitudinally of the fabric.
21. A method according to any one of Claims 14 to 20, which comprises producing and/or superimposing said layers so that the rovings or yarns of at least a first layer extend at 00 with respect to the longitudinal direction of the fabric, the rovings or yarns of at least a second layer extend at 450 to the rovings or yarns of said first layer, and the rovings or yarns of at least a third layer extend at 900 to the rovings or yarns of said first layer.
22. A method according to Claim 21, which comprising producing and/or superimposing said layers so that the rovings or yarns of at least a fourth layer extend at 450 to the rovings or yarns of the first layer and at 900 to the rovings or yarns of said second layer.
23. A method according to any one of Claims 14 to 22, comprising the steps of:
(i) producing first and second superimposed layers,
(ii) stitching the superimposed first and second layers to stitch together the rovings or yarns in each layer and the layers themselves,
(iii) producing at least one further layer,
(iv) stitching together the rovings or yarns in said at least one further layer,
(v) superimposing said first and second layers with said at least one further layer, and
(vi) stitching together the superimposed layers.
24. A method according to any one of Claims 14 to 23, wherein said layers are superimposed with the lateral side edges thereof terminating short of or extending beyond the lateral side edges of an adjacent layer by substantially the same amount.
25. A method according to any one of Claims 14 to 24, wherein the rovings or yarns in each of said layers are of glass fibre,
Aramid fibre or carbon fibre or mixtures thereof.
26. A method according to any one of Claims 14 to 25, which comprises interspersing rovings or yarns of thermoplastics material with said rovings or yarns of reinforcing material in at least one of said layers and/or inserting at least one sheet or strip of thermo-plastics resinous material between at least two of said layers before said layers are stitched together, whereby to produce a formable reinforcing fabric.
27. A method of forming a reinforced plastics article, the method comprising the steps of:
(a) obtaining a reinforcing fabric comprising a plurality of superimposed layers, each layer consisting of a plurality of unidirectional non-woven rovings or yarns of reinforcing material laid side-by-side, the rovings or yarns in at least two of the layers extending in different directions, said layers being stitched together and each layer having at least one lateral side edge which terminates short of or extends beyond the corresponding lateral side edge of an adjacent layer,
(b) laying at least two lengths of said fabric side-by-side in overlapping relation so that a lateral side margin of at least one layer of one of said lengths overlaps adjacent lateral side margin of the corresponding layer of the other of said lengths,
(c) impregnating the fabric with synthetic resinous material, and
(d) curing or setting the synthetic resinous material.
28. A method according to Claim 27, wherein the rovings or yarns in an outer layer of said fabric extend longitudinally of the fabric and wherein the said outer layers of the at least two lengths of fabric are arranged side-by-side without overlap.
29. A method according to Claim 28, wherein the adjacent lateral side margins of the at least two lengths of fabric are stepped in opposite directions so that they interfit when overlapped.
30. A method according to Claim 29, comprising the steps of:
(i) obtaining a first length of reinforcing fabric wherein both lateral side edges of an outer layer extend beyond the lateral side edges of the adjacent layer and wherein both lateral side edges of each other layer terminate short of the lateral side edges of an adjacent layer, whereby the lateral side margins of the first length of fabric are stepped,
(ii) obtaining second and third lengths of reinforcing fabric wherein, with the exception of an outer layer one lateral side edge of which terminates short of the corresponding lateral side edge of the adjacent layer and the other lateral side edge of which is coterminous with the corresponding lateral side edge of the adjacent layer, each layer of each of said second and third lengths has one lateral side edge terminating short of the corresponding lateral side edge of an adjacent layer and the other lateral side edge extending beyond the other lateral side edge of said adjacent layer, whereby the opposite side margins of each of the second and third lengths are stepped in opposite directions, and
(iii) overlapping the second and third lengths of reinforcing fabric with the first length of reinforcing fabric on opposite sides thereof so that the overlapping margins interfit.
31. A method according to any one of Claims 27 to 30, wherein the rovings or yarns in the corresponding layers of the at least two lengths of reinforcing fabric extend in the same direction.
32. A method according to any one of Claims 27 to 31, wherein said at least two lengths of reinforcing fabric are laid sideby-side in overlapping relationship in a mould.
33. A method according to any one of Claims 27 to 32, wherein said synthetic resinous material is cured or set under heat or pressure.
34. A reinforcing fabric for plastics, substantially as herein described with reference to Figure 1 or Figure 2 of the accompanying drawings.
35. A method of producing a reinforcing fabric for plastics, substantially as herein described with reference to Figure 1 or
Figure 2 of the accompanying drawings.
36. A method of producing a reinforced plastics article, substantially as herein described.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9021729A GB2249050A (en) | 1990-10-05 | 1990-10-05 | Reinforcing fabric for plastics |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9021729A GB2249050A (en) | 1990-10-05 | 1990-10-05 | Reinforcing fabric for plastics |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9021729D0 GB9021729D0 (en) | 1990-11-21 |
| GB2249050A true GB2249050A (en) | 1992-04-29 |
Family
ID=10683314
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9021729A Withdrawn GB2249050A (en) | 1990-10-05 | 1990-10-05 | Reinforcing fabric for plastics |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2249050A (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0627514A1 (en) * | 1993-05-19 | 1994-12-07 | Synteen Gewebe Technik Gmbh | Flat structures' reinforcing or armouring fabric |
| EP0754795A1 (en) * | 1995-07-17 | 1997-01-22 | Aerospatiale Societe Nationale Industrielle | Process and system for making an armature for a part made of composite material |
| EP0816061A3 (en) * | 1996-07-04 | 1998-11-25 | DORNIER GmbH | CFC separating laminate |
| WO2000009321A1 (en) * | 1998-08-15 | 2000-02-24 | Bae Systems Plc | Composite material construction |
| WO2003050340A3 (en) * | 2001-12-06 | 2004-03-25 | Saertex Wagener Gmbh & Co Kg | Method for producing a fiber-based composite material and composite material so produced |
| WO2019101975A1 (en) * | 2017-11-24 | 2019-05-31 | Saertex Gmbh & Co. Kg | Unidirectional laid nonwoven and use thereof |
| RU2777410C2 (en) * | 2017-11-24 | 2022-08-03 | ЗАЕРТЕКС ГМБХ унд КО. КГ | Unidirectional straight fabric and its use |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB891121A (en) * | 1957-05-07 | 1962-03-14 | Dracone Developments Ltd | Improvements in or relating to flexible barges or storage vessels |
| US3960626A (en) * | 1971-01-08 | 1976-06-01 | Martin Marietta Corporation | Method of making high performance ablative tape |
-
1990
- 1990-10-05 GB GB9021729A patent/GB2249050A/en not_active Withdrawn
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB891121A (en) * | 1957-05-07 | 1962-03-14 | Dracone Developments Ltd | Improvements in or relating to flexible barges or storage vessels |
| US3960626A (en) * | 1971-01-08 | 1976-06-01 | Martin Marietta Corporation | Method of making high performance ablative tape |
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0627514A1 (en) * | 1993-05-19 | 1994-12-07 | Synteen Gewebe Technik Gmbh | Flat structures' reinforcing or armouring fabric |
| EP0754795A1 (en) * | 1995-07-17 | 1997-01-22 | Aerospatiale Societe Nationale Industrielle | Process and system for making an armature for a part made of composite material |
| FR2736941A1 (en) * | 1995-07-17 | 1997-01-24 | Aerospatiale | METHOD AND SYSTEM FOR PRODUCING A REINFORCEMENT FOR A COMPOSITE MATERIAL PART |
| US5914002A (en) * | 1995-07-17 | 1999-06-22 | Aerospatiale Societe Nationale Industrielle | Method and system for producing a reinforcement for a composite component |
| EP0816061A3 (en) * | 1996-07-04 | 1998-11-25 | DORNIER GmbH | CFC separating laminate |
| US5993929A (en) * | 1996-07-04 | 1999-11-30 | Dornier Gmbh | Carbon fiber reinforced separating laminate |
| WO2000009321A1 (en) * | 1998-08-15 | 2000-02-24 | Bae Systems Plc | Composite material construction |
| JP3369579B2 (en) | 1998-08-15 | 2003-01-20 | ビーエーイー・システムズ・パブリック・リミテッド・カンパニー | Composite material structure |
| US6582792B1 (en) | 1998-08-15 | 2003-06-24 | Bae Systems Plc | Composite material construction |
| WO2003050340A3 (en) * | 2001-12-06 | 2004-03-25 | Saertex Wagener Gmbh & Co Kg | Method for producing a fiber-based composite material and composite material so produced |
| WO2019101975A1 (en) * | 2017-11-24 | 2019-05-31 | Saertex Gmbh & Co. Kg | Unidirectional laid nonwoven and use thereof |
| RU2777410C2 (en) * | 2017-11-24 | 2022-08-03 | ЗАЕРТЕКС ГМБХ унд КО. КГ | Unidirectional straight fabric and its use |
| US12480238B2 (en) | 2017-11-24 | 2025-11-25 | Saertex Gmbh & Co. Kg | Unidirectional laid nonwoven and use thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9021729D0 (en) | 1990-11-21 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |