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GB2482475A - Yarn with carbon fibres - Google Patents

Yarn with carbon fibres Download PDF

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Publication number
GB2482475A
GB2482475A GB1012905.4A GB201012905A GB2482475A GB 2482475 A GB2482475 A GB 2482475A GB 201012905 A GB201012905 A GB 201012905A GB 2482475 A GB2482475 A GB 2482475A
Authority
GB
United Kingdom
Prior art keywords
yarn
tape
fibres
carbon fibre
short
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Withdrawn
Application number
GB1012905.4A
Other versions
GB201012905D0 (en
Inventor
Mahmudul Hossain Akonda
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB1012905.4A priority Critical patent/GB2482475A/en
Publication of GB201012905D0 publication Critical patent/GB201012905D0/en
Publication of GB2482475A publication Critical patent/GB2482475A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/16Yarns or threads made from mineral substances
    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/06Threads formed from strip material other than paper
    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/38Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00Inorganic fibres
    • D10B2101/10Inorganic fibres based on non-oxides other than metals
    • D10B2101/12Carbon; Pitch

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

The invention provides a new yarn comprising short (0.5-100mm) carbon fibre nonwoven veil or web. The carbon fibres may be virgin fibres. The veil or web may be slit into a tape which is then wrapped with a polymer, glass, ceramic, steel, carbon fibre or any other filament based on organic or inorganic materials. The yarn may be spun by a variety of spinning techniques such as self, mechanical, falls, bonding, aero-dynamic and air suction. The veil may contain short polymer, inorganic, organic or natural fibres. The carbon fibre content can be from 0.1% to 99.9%. The yarn may be used for aerospace, automotive, construction, medicinal applications or sports products.

Description

SHORT CARBON FIBRE COMPOSITE YARN FROM CARBON FIBRE'S NONWOVEN VEIL
Field of the invention
1. This invention concerns a novel approach to a new product of short carbon fibre composite yarn from carbon-polymer fibre's nonwoven veil. Specifically, this invention provides tape yarns, which are obtained from short carbon fibre nonwoven veil materials.
Background to the invention
2. The main advantages of carbon fibre are considerable lower density and high tensile strength. Therefore, the demand of this fibre is growing rapidly worldwide. However, the uses of this fibre are mainly in continuous filament /roving form or commingled with other polymer materials to be used into woven fabric or unidirectional lay up to make composite parts.
3. A great deal of prior art exists which details the production of continuous carbon fibre filament based yarn. However, some drawbacks are associated with the continuous carbon fibre tows, which is less drapability of the fabric.
4. Alternatively, the continuous carbon fibre filament tow can be stretched broken (convert into shorter length) and combined with any of continuous polymer filaments to be used in composite applications. However, these yarns are also expensive as the virgin continuous carbon fibres are used and the cost of the yarns can be an issue in many applications.
5. The present inventor, therefore, has examined the possibility for producing low cost carbon fibre yarn from short carbon fibres without using any continuous carbon fibre filaments or continuous virgin carbon fibres tows.
6. Whilst the prior art, there are many references to the production of short carbon fibre yarns, all of these require virgin carbon fiber filaments or tows, where the continuous filaments are stretched and broken into discontinuous form and blended I commingled with continuous polymer filaments to convert into yarn. However, the length of stretch broken carbon fibres in the yarn is over 30 mm.
7. Whilst the prior art, some references to short carbon fibre yarns, by making of sliver from stretch broken discontinuous continuous carbon fibres (over 30 mm length) with continuous polymer filaments to convert into yarn.
8. Whilst the prior art, some reference to the short carbon fibre spun yarns, blending of short carbon fibres with short polymer fibres and making continuous carded sliver using carding process and then the sliver is spun into yarn.
9. Surprisingly, there is no short carbon fibres (1 mm -30 mm length) yarn has been produced using short carbon fibre's nonwoven veil/web or short carbon fibre's nonwoven fibrous materials.
10. The prior art, the present inventor has produced a very fine yarn from short virgin carbon fibre (1-30 mm length) nonwoven veil with satisfactory strength, which is much cheaper than other counterpart yarn materials.
Summary of the Invention
11. Therefore, according to a first aspect of the present invention there is provided a yarn comprising virgin and short (1mm -30 mm length) carbon fibers.
12. In the context of the present invention, nonwoven veil/web was made using short virgin carbon fibres. is used to make continuous yarn.
13. In the context of the present invention, the short carbon fiber contain nonwoven veil was converted into yarn by slitting and wrapping.
14. The short carbon fibres for using in the nonwoven veil preparation can be 0.5mm -30mm length for blending with the other polymer fibres.
15. The short carbon fibres for using in the nonwoven veil preparation can be 0.5mm - 30mm length for well dispersion in the processing fluid or water.
16. The short carbon fibres are used with the other short polymer fibres for making flexible nonwoven veil/web.
17. The short polymer fibres for using in the nonwoven veil preparation with short carbon fibres can be 0.1mm -30mm length.
18. The linear density of short polymer fibres can be from 1 dtex to I O0dtex for proper blending with short carbon fibres.
19. The mass per unit area of the short carbon fibre's veil can be 0001-3Ogm/m2 20. All the short carbon fibres in the nonwoven veil can be perfectly or partly aligned.
21. The present invention, there is provided a product flow chart for the production of a continuous tape yarn from short carbon fibre's nonwoven veil materials, said method comprising the steps of: (a) Short carbon fibre nonwoven web/veil / fibrous sheet (b) Slitting the web into tape / ribbon/ strip (c) Wrapping the tape/ribbon/strip (d) Formation of continuous tape /ribbon wrap yarn 22. The short carbon fibre nonwoven veil containing polymer fibres is sllitted into narrow strip/tape/ribbon.
23. The width of the strip/tape of nonwoven veil can be 0.5mm to 100mm to convert into yarn 24. The narrow tapes/strips of short carbon fibre nonwoven veil was converted into continuous yarn by wrapping the strip.
25. Wrap spinning process was used to convert the nonwoven veil into yarn structure, where extra polymer filament was used for wrapping of the veil's strip.
26. The number of wraps or turns in the yarn can be 1 to 5000 per meter.
27. Single strip and multi strips of nonwoven veil was processed to make yarn with different mass per unit length.
28. The short carbon fibre content of the tape yarn can be from 0.1% to 99.9% by weight
Description of the drawings
29. Schematic diagrams of the invention are described in the drawings, in which: Figure 1 (a) is an illustration of typical nonwoven veil/web made from short carbon fibres and other polymer fibres and Figure 1(b) is an illustration of a typical strips made of nonwoven web to convert into yarn. The schematic diagram for yarn making technique is presented in Figure 2. Figure 3 represented the structure of continuous tape yarn made of short carbon fibre nonwoven web strips.
Detailed Description of the Invention
30. The present invention provides a new product "short carbon fibre tape yarn" using short virgin carbon fiber nonwoven veil.
31. The sources of short or discontinuous carbon fibres can be virgin, sized or un-sized format.
32. The length of short carbon fibre prior to making tape yarn from veil can be 1mm to 30 mm.
33. The density of carbon fibres can be from 1.14 -2.3 gm/cm3 with size or un-size format.
34. The short carbon fibres were blended with chopped polymer fibres and then the blended fibres were used to produce the nonwoven veil I web. The length of chopped polymer fibres can be 0.01 mm to 30 mm.
35. The short carbon fibre nonwoven web was produced using wet laying technique, where the fibres impregnated in water bath and then the blended fibres and water mixture were pumped onto a screen to make nonwoven veil.
36. In making of nonwoven veil from short carbon fibres, any types of polymer based fibres such as thermoplastic or thermoset fiber or their powders can be used with short carbon fibres 37. In making of nonwoven veil from short carbon fibres, other reinforcing fibres such as glass, ceramic, steel can be used with short carbon fibres.
38. In making the short carbon fibre's nonwoven veil, the short carbon can be used from 0.5% to 99% by weight for required mass per unit area of the veil.
39. Preferably, formatting the short carbon fibre's tape yarn includes at least another thermoplastic polymer fibres with short carbon fibres such as polyethylene or polypropylene, polyethylene terephthalate or polybutylene terephthalate, polyamides, polyethersulphone (PES), polyaryletheretherketones (PEEK), PEKK, PPS fibres or polymer substance or their powders 40. Preferably, formatting the short carbon fibre's tape yarn includes at least another thermoset polymer fibres or thermoset polymer substance with short carbon fibres such as resin fibres (epoxy, phenolic), PEI or any other thermoset polymers, polymers substance or their powders.
41. The linear density I mass per unit length of the yarn can be from 1 tex -3000 tex

Claims (18)

  1. CLAIMS1. A yarn made of short carbon fibre's nonwoven veil.
  2. 2. A yarn as claimed in claim 1 wherein said tape yarn comprises short virgin carbon fibre.
  3. 3. The veil tape yarn as claimed in claim 1 and 2 comprises short polymer matrix fibres.
  4. 4. A yarn as claimed in claim 1, 2 and 3 wherein said the strip of nonwoven veil is converted into yarn.
  5. 5. A yarn as claimed in claim I to 4 wherein said the nonwoven veil is slitted/cut into a narrow strips /tape/ribbon to convert into yarn.
  6. 6. A yarn as claimed in claim 1 to 5 wherein said the mass per unit area of nonwoven veil is 0.1-1 00 gm/m2 to convert into yarn.
  7. 7. A yarn as claimed in claim 1 to 6 wherein said the carbon fibre has a density of 1.14 - 2.3 gm/cm3.
  8. 8. A yarn as claimed in claim 1 to 7 wherein said the short carbon fibre length is 0.5 mm -mm.
  9. 9. A yarn as claimed in claim 1 to 8 wherein said the short carbon fibre can be sized or unsized format.
  10. 10. A yarn as claimed in claim 1 to 9 wherein said the yarn comprises at least one other polymer fibre with short carbon fibres.
  11. 11. A yarn as claimed in claim ito 10 wherein said the length short polymer fibre is 0.01 mm -30 mm.
  12. 12. A yarn as claimed in claim 1 to 11 wherein said the linear density of the polymer fibre is 0.ldtex to 50dtex.
  13. 13. A yarn as claimed in claim 1 to 12 wherein said the yarn comprise polymer powders or polymeric substances.
  14. 14. A yarn as claimed in claim 1 to 13 wherein said the nonwoven veil comprises any water soluble adhesive substances.
  15. 15. A yarn as claimed in claim 1 to 13 wherein said the nonwoven veil comprises any resin polymers or resin soluble adhesive substances
  16. 16. A yarn as claimed in claim 1 to 15 wherein said the length short carbon fibre is form 1mm to 100mm.
  17. 17. A yarn as claimed in claim 1 to 16 wherein said the short carbon fibre content of the yarn is from 1-99.9% by weight.
  18. 18. A method as claimed in 1 to 17 wherein said the thickness of nonwoven veil is 0.0001 mm to 20 mm.9. A method as claimed in 1 to 18 wherein said the width of the slitted /cut strip is 0.01 mm to 500 mm to convert into yarn.20. A yarn as claimed in claim 1 to 19 wherein said the yarn comprises at least one of other thermoplastic filament/fibres/fibrous elements or adhesive or powder substance.21. A yarn as claimed in claim I to 20 wherein said the yarn comprises at least one of other fibre thermoset resin filament/fibres/fibrous elements or adhesive or powder subsatnce.22. A yarn as claimed in claim 1 to 21 wherein said the yarn comprises any other organic, inorganic and natural fibres or natural substances.23. A yarn as claimed in claim 1 to 23 wherein said spinning operation comprises hollow spindle spinning, wrap spinning.24. A yarn as claimed in claim 1 to 23 wherein said spinning operation comprises self twisting, mechanical twisting, falls twisting, chemical bonding, thermal bonding or hot pressing and any other techniques.25. A tape spun yarn as claimed in any claim wherein said comprise powder spraying, hot air injecting or micro wave techniques.26. A tape yarn as claimed in any previous claims wherein said comprises braiding technique or any winding techniques.27. A tape spun yarn as claimed in previous claims wherein said twisting of web tape comprises aero dynamic I air suction technique.28. The tape spun yarn as claimed in 1 to 23 or any claim wherein said the carbon fibre content is 1-99.9% by weight.29. The tape spun yarn as claimed in 1 to 23 wherein said the linear density of tape spun yarn is from 0.Oltex to 3000tex and 0.OOlgm/m to 50 gm/m.30. The tape spun yarn as claimed in I to 23 wherein said the number of wraps or turns in the yarn is from 1 to 5000 per meter.31. The tape spun yarn as claimed in 1 to 23 wherein said the wrapping thread is glass, ceramic, steel, carbon fibres or any other filaments based on organic or inorganic materials.32. The tape yarn as claimed in any one of claims is for composite applications including aerospace, automotive, construction, medicinal applications, or sports products.
GB1012905.4A 2010-08-02 2010-08-02 Yarn with carbon fibres Withdrawn GB2482475A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1012905.4A GB2482475A (en) 2010-08-02 2010-08-02 Yarn with carbon fibres

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1012905.4A GB2482475A (en) 2010-08-02 2010-08-02 Yarn with carbon fibres

Publications (2)

Publication Number Publication Date
GB201012905D0 GB201012905D0 (en) 2010-09-15
GB2482475A true GB2482475A (en) 2012-02-08

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Application Number Title Priority Date Filing Date
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Country Status (1)

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GB (1) GB2482475A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108431312A (en) * 2016-08-25 2018-08-21 日本泰克斯株式会社 Twist yarn Dian fibrillation yarn Dian carbon fiber covering yarns and preparation method thereof
CN110565223A (en) * 2019-08-21 2019-12-13 武汉纺织大学 High-speed large-package spinning method for velvet anti-wrinkle composite yarn
US20200369011A1 (en) * 2017-12-26 2020-11-26 Cytec Industries Inc. Fire retardant veil for use in composite materials

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4519201A (en) * 1982-09-08 1985-05-28 Toon John J Process for blending fibers and textiles obtained from the fiber blends
EP1696057A1 (en) * 2003-12-17 2006-08-30 Kureha Corporation Method for producing pitch-based carbon fiber sliver and spun yarn
KR100839124B1 (en) * 2007-03-30 2008-06-26 주식회사 진흥기공 Composite fiber and heat-resisting composite fiber yarn
US20100155006A1 (en) * 2008-12-22 2010-06-24 Kimberly-Clark Worldwide, Inc. Conductive Webs and Process For Making Same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4519201A (en) * 1982-09-08 1985-05-28 Toon John J Process for blending fibers and textiles obtained from the fiber blends
EP1696057A1 (en) * 2003-12-17 2006-08-30 Kureha Corporation Method for producing pitch-based carbon fiber sliver and spun yarn
KR100839124B1 (en) * 2007-03-30 2008-06-26 주식회사 진흥기공 Composite fiber and heat-resisting composite fiber yarn
US20100155006A1 (en) * 2008-12-22 2010-06-24 Kimberly-Clark Worldwide, Inc. Conductive Webs and Process For Making Same

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108431312A (en) * 2016-08-25 2018-08-21 日本泰克斯株式会社 Twist yarn Dian fibrillation yarn Dian carbon fiber covering yarns and preparation method thereof
EP3505662A4 (en) * 2016-08-25 2020-07-01 Japan Matex Co., Ltd. Twisted yarn, opened yarn, carbon fiber-covered twisted yarn, and method for manufacturing these
US10844523B2 (en) 2016-08-25 2020-11-24 Japan Matex Co., LTD Twisted yarn, opened yarn, carbon fiber-covered twisted yarn, and method for manufacturing these
US11060211B2 (en) 2016-08-25 2021-07-13 Japan Matex Co., LTD Twisted yarn, opened yarn, carbon fiber-covered twisted yarn, and method for manufacturing these
CN108431312B (en) * 2016-08-25 2021-12-21 日本泰克斯株式会社 Twisted yarn left-falling split yarn and left-falling carbon fiber covering yarn and preparation method thereof
US20200369011A1 (en) * 2017-12-26 2020-11-26 Cytec Industries Inc. Fire retardant veil for use in composite materials
CN110565223A (en) * 2019-08-21 2019-12-13 武汉纺织大学 High-speed large-package spinning method for velvet anti-wrinkle composite yarn
CN110565223B (en) * 2019-08-21 2021-11-12 武汉纺织大学 High-speed large-package spinning method for velvet anti-wrinkle composite yarn

Also Published As

Publication number Publication date
GB201012905D0 (en) 2010-09-15

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