GB2482475A - Yarn with carbon fibres - Google Patents
Yarn with carbon fibres Download PDFInfo
- 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- Withdrawn
Links
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 69
- 229910052799 carbon Inorganic materials 0.000 title claims abstract description 69
- 239000000835 fiber Substances 0.000 claims abstract description 48
- 229920000642 polymer Polymers 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims abstract description 12
- 238000009987 spinning Methods 0.000 claims abstract description 6
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 3
- 239000000919 ceramic Substances 0.000 claims abstract description 3
- 239000011521 glass Substances 0.000 claims abstract description 3
- 239000010959 steel Substances 0.000 claims abstract description 3
- 238000010276 construction Methods 0.000 claims abstract 2
- 229910010272 inorganic material Inorganic materials 0.000 claims abstract 2
- 239000011147 inorganic material Substances 0.000 claims abstract 2
- 239000011368 organic material Substances 0.000 claims abstract 2
- 239000000126 substance Substances 0.000 claims description 8
- 239000000843 powder Substances 0.000 claims description 7
- 239000002131 composite material Substances 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 229920001169 thermoplastic Polymers 0.000 claims description 3
- 239000004416 thermosoftening plastic Substances 0.000 claims description 2
- 239000000853 adhesive Substances 0.000 claims 4
- 230000001070 adhesive effect Effects 0.000 claims 4
- 238000009954 braiding Methods 0.000 claims 1
- 238000007731 hot pressing Methods 0.000 claims 1
- 239000011159 matrix material Substances 0.000 claims 1
- 239000005445 natural material Substances 0.000 claims 1
- 238000005507 spraying Methods 0.000 claims 1
- 239000004634 thermosetting polymer Substances 0.000 claims 1
- 238000004804 winding Methods 0.000 claims 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 4
- 239000004917 carbon fiber Substances 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920001652 poly(etherketoneketone) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/16—Yarns or threads made from mineral substances
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/06—Threads formed from strip material other than paper
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/38—Threads 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
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/10—Inorganic fibres based on non-oxides other than metals
- D10B2101/12—Carbon; 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)
- CLAIMS1. A yarn made of short carbon fibre's nonwoven veil.
- 2. A yarn as claimed in claim 1 wherein said tape yarn comprises short virgin carbon fibre.
- 3. The veil tape yarn as claimed in claim 1 and 2 comprises short polymer matrix fibres.
- 4. A yarn as claimed in claim 1, 2 and 3 wherein said the strip of nonwoven veil is converted into yarn.
- 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. 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. 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. A yarn as claimed in claim 1 to 7 wherein said the short carbon fibre length is 0.5 mm -mm.
- 9. A yarn as claimed in claim 1 to 8 wherein said the short carbon fibre can be sized or unsized format.
- 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. A yarn as claimed in claim ito 10 wherein said the length short polymer fibre is 0.01 mm -30 mm.
- 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. A yarn as claimed in claim 1 to 12 wherein said the yarn comprise polymer powders or polymeric substances.
- 14. A yarn as claimed in claim 1 to 13 wherein said the nonwoven veil comprises any water soluble adhesive substances.
- 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. A yarn as claimed in claim 1 to 15 wherein said the length short carbon fibre is form 1mm to 100mm.
- 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. 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.
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 |
Family
ID=42799419
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1012905.4A Withdrawn GB2482475A (en) | 2010-08-02 | 2010-08-02 | Yarn with carbon fibres |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2482475A (en) |
Cited By (3)
| 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)
| 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 |
-
2010
- 2010-08-02 GB GB1012905.4A patent/GB2482475A/en not_active Withdrawn
Patent Citations (4)
| 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)
| 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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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |