US20220112637A1 - Hybrid reinforcement fabric - Google Patents
Hybrid reinforcement fabric Download PDFInfo
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- US20220112637A1 US20220112637A1 US17/268,688 US201917268688A US2022112637A1 US 20220112637 A1 US20220112637 A1 US 20220112637A1 US 201917268688 A US201917268688 A US 201917268688A US 2022112637 A1 US2022112637 A1 US 2022112637A1
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- fibers
- fabric
- stitching
- glass
- hybrid reinforcing
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- 239000004744 fabric Substances 0.000 title claims abstract description 199
- 230000002787 reinforcement Effects 0.000 title abstract description 36
- 229920005989 resin Polymers 0.000 claims abstract description 46
- 239000011347 resin Substances 0.000 claims abstract description 46
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 45
- 239000003365 glass fiber Substances 0.000 claims abstract description 29
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 26
- 239000004917 carbon fiber Substances 0.000 claims abstract description 26
- 239000000835 fiber Substances 0.000 claims description 76
- 239000011521 glass Substances 0.000 claims description 51
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 50
- 229910052799 carbon Inorganic materials 0.000 claims description 48
- 239000000203 mixture Substances 0.000 claims description 13
- 229920000728 polyester Polymers 0.000 claims description 12
- OANVFVBYPNXRLD-UHFFFAOYSA-M propyromazine bromide Chemical compound [Br-].C12=CC=CC=C2SC2=CC=CC=C2N1C(=O)C(C)[N+]1(C)CCCC1 OANVFVBYPNXRLD-UHFFFAOYSA-M 0.000 claims description 6
- 238000001802 infusion Methods 0.000 abstract description 44
- 239000002131 composite material Substances 0.000 abstract description 12
- 230000015572 biosynthetic process Effects 0.000 abstract description 9
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 abstract description 6
- 238000000034 method Methods 0.000 abstract description 6
- 230000008569 process Effects 0.000 abstract description 4
- 239000012783 reinforcing fiber Substances 0.000 description 63
- 238000012360 testing method Methods 0.000 description 25
- 238000004513 sizing Methods 0.000 description 13
- 239000000463 material Substances 0.000 description 7
- 239000004593 Epoxy Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 5
- 230000008901 benefit Effects 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 4
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- 229910021389 graphene Inorganic materials 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 3
- 229920001225 polyester resin Polymers 0.000 description 3
- 239000004645 polyester resin Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 2
- 239000007822 coupling agent Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
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- 229920003002 synthetic resin Polymers 0.000 description 2
- 206010003402 Arthropod sting Diseases 0.000 description 1
- 229920002748 Basalt fiber Polymers 0.000 description 1
- VNWKTOKETHGBQD-AKLPVKDBSA-N carbane Chemical compound [15CH4] VNWKTOKETHGBQD-AKLPVKDBSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
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Images
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
- D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
-
- 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
- D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
- D10B2101/06—Glass
-
- 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
-
- 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
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/02—Cross-sectional features
- D10B2403/024—Fabric incorporating additional compounds
- D10B2403/0241—Fabric incorporating additional compounds enhancing mechanical properties
- D10B2403/02412—Fabric incorporating additional compounds enhancing mechanical properties including several arrays of unbent yarn, e.g. multiaxial fabrics
-
- 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
- D10B2505/00—Industrial
- D10B2505/02—Reinforcing materials; Prepregs
Definitions
- the inventive concepts relate generally to fibrous reinforcement materials and, more particularly, to a hybrid fabric including glass fibers and carbon fibers.
- Glass fiber reinforcement materials exhibit good mechanical properties, including strength, strain, and compression; are relatively inexpensive; and are readily infused with a resin. However, the elastic modulus of the glass fiber reinforcement materials is low, which can present design limitations.
- Carbon fiber reinforcement materials exhibit good mechanical properties, including stiffness and tensile strength, at a low density. However, the carbon fiber reinforcement materials are low in strain, low in compressive strength, and relatively expensive. Furthermore, the carbon fiber reinforcement materials can be difficult to infuse with a resin.
- Conventional carbon-containing reinforcement fabrics have attempted to solve this problem by pre-impregnating the carbon tow used to form the fabric.
- resin is applied to the carbon fibers prior to the fabric being placed in a mold to form a composite structure.
- the carbon tow is also spread (i.e., the individual carbon fibers separated) to accelerate the rate of infusion of the carbon tow.
- Such a “prepreg” fabric can introduce processing, storage, and handling difficulties.
- the invention relates generally to a hybrid reinforcement fabric that includes glass fibers and carbon fibers, a method of producing the hybrid reinforcement fabric, and a composite part formed from the hybrid reinforcement fabric.
- a hybrid reinforcing fabric comprises a plurality of first fibers oriented in a first direction; a plurality of second fibers oriented in the first direction; a plurality of third fibers oriented in a second direction; and a stitching yarn maintaining the first fibers, the second fibers, and the third fibers in their respective orientations.
- the first fibers are glass fibers.
- the second fibers are carbon fibers.
- the third fibers are glass fibers, carbon fibers, or both glass and carbon fibers.
- the first direction is 0 degrees.
- the second direction is different from the first direction, wherein the second direction is within the range of 0 degrees to 90 degrees.
- the first fibers and the second fibers constitute between 91 wt.
- the third fibers constitute between 0.5 wt. % and 9 wt. % of the fabric.
- the glass fibers constitute between 65 wt. % to 95 wt. % of the fabric
- the carbon fibers constitute between 5 wt. % to 35 wt. % of the fabric.
- the stitching yarn constitutes less than 3 wt. % of the fabric.
- the stitching yarn is a polyester yarn.
- the stitching yarn has a linear mass density within the range of 60 dTex to 250 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 85 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 200 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 225 dTex.
- the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a tricot stitching pattern.
- the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a symmetric double tricot stitching pattern.
- the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being an asymmetric double tricot stitching pattern.
- the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a symmetric diamant stitching pattern.
- the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being an asymmetric diamant stitching pattern.
- the stitching yarn defines a stitching length between 3 mm to 6 mm. In one exemplary embodiment, the stitching yarn defines a stitching length of 5 mm. In one exemplary embodiment, the stitching yarn defines a stitching length of 4 mm.
- the first fibers are glass fibers and the third fibers are glass fibers, wherein a glass composition of the first fibers differs from a glass composition of the third fibers.
- the hybrid reinforcing fabric further comprises a plurality of fourth fibers oriented in a third direction, wherein the third fibers are glass fibers and the fourth fibers are glass fibers, and wherein a glass composition of the third fibers is the same as a glass composition of the fourth fibers.
- an absolute value of the second direction is equal to an absolute value of the third direction.
- a difference between the first direction and the second direction is greater than or equal to 45 degrees.
- a difference between the first direction and the second direction is greater than or equal to 80 degrees.
- a linear mass density of the first fibers is between 600 Tex and 4,800 Tex.
- the third fibers are glass fibers, wherein a linear mass density of the third fibers is between 68 Tex and 300 Tex.
- the second fibers are fed from one or more carbon tows having a size in the range of 6K to 50K.
- an areal weight of the second fibers is between 80 g/m 2 and 500 g/m 2 .
- the second fibers constitute 7 wt. % of the fabric, wherein an areal weight of the fabric is 2,500 g/m 2 .
- the second fibers constitute 15 wt. % of the fabric, wherein an areal weight of the fabric is 1,300 g/m 2 .
- the second fibers constitute 15 wt. % of the fabric, wherein an areal weight of the fabric is 1,400 g/m 2 .
- the second fibers constitute 25 wt. % of the fabric, wherein an areal weight of the fabric is 1,300 g/m 2 .
- the hybrid reinforcing fabric contains no resin, i.e., none of the fibers forming the fabric are pre-impregnated with a resin.
- a polyester resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 9 minutes. In one case, where the fabric had a carbon content of 15%, the infusion rate was 0.41 cm per minute.
- an epoxy resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 16 minutes. In one case, where the fabric had a carbon content of 15%, the infusion rate was 0.23 cm per minute.
- an epoxy resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 8 minutes. In one case, where the fabric had a carbon content of 7%, the infusion rate was 0.419 cm per minute.
- an epoxy resin has an infusion rate through the hybrid reinforcing fabric in the first direction of between 0.238 cm per minute and 0.5 cm per minute.
- a polyester resin has an infusion rate through the hybrid reinforcing fabric in the first direction of 0.73 cm per minute.
- the fabric has an infusion rate through the fabric in a direction perpendicular to the first direction of 0.3 cm per minute.
- the fabric is infused with a resin that is cured to form a composite article.
- the article is a wind turbine blade or related component (e.g., spar cap).
- FIGS. 1A-1D illustrate a hybrid reinforcing fabric, according to an exemplary embodiment of the invention.
- FIG. 1A is a top plan view of the hybrid reinforcing fabric.
- FIG. 1B is a bottom plan view of the hybrid reinforcing fabric.
- FIG. 1C is a detailed view of the circle A in FIG. 1A .
- FIG. 1D is a detailed view of the circle B in FIG. 1B .
- FIGS. 2A-2C illustrate stitching patterns that can be used in the hybrid reinforcing fabric of FIG. 1 .
- FIG. 2A shows a tricot stitching pattern.
- FIG. 2B shows an asymmetric double tricot stitching pattern.
- FIG. 2C shows an asymmetric diamant stitching pattern.
- FIG. 3 is a diagram illustrating a through thickness infusion speed (TTIS) test for measuring the infusion rate of a fabric.
- TTIS through thickness infusion speed
- FIGS. 4A-4B illustrate an in-plane infusion test (IPIT) test for measuring the infusion rate of a fabric.
- IPIT in-plane infusion test
- FIG. 5 is a graph illustrating the results of the IPIT test of FIG. 4 performed on two (2) different fabrics to measure the infusion rate (in the x-direction) of the fabrics.
- FIG. 6 is a graph illustrating the results of the IPIT test of FIG. 4 performed on two (2) different fabrics to measure the infusion rate (in the y-direction) of the fabrics.
- inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings and will be described herein in detail various exemplary embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the inventive concepts. Accordingly, the inventive concepts are not intended to be limited to the specific embodiments illustrated herein.
- a hybrid reinforcement fabric made up primarily of glass fibers and carbon fibers can be produced that is an effective reinforcement for structural components (e.g., wind turbine blades) and that exhibits an acceptable rate of infusion.
- the inventive concepts provide a hybrid reinforcement fabric comprising glass fibers and carbon fibers.
- the hybrid reinforcement fabric can be readily infused at an acceptable infusion speed, without requiring that the carbon fiber tows used to form the hybrid reinforcement fabric be spread or pre-impregnated with resin.
- the inventive fabric provides for an effective one-step (i.e., in the mold) infusion process during composite part formation.
- the inventive concepts also encompass a method of producing the hybrid reinforcing fabric.
- the inventive concepts also encompass a composite part formed from the hybrid reinforcing fabric.
- a hybrid reinforcement fabric 100 is constructed from both glass reinforcing fibers 102 and carbon reinforcing fibers 104 , as shown in FIGS. 1A-1D .
- any suitable glass reinforcing fibers 102 can be used in the hybrid reinforcement fabric 100 .
- fibers made from E glass, H glass, S glass, an AR glass types can be used.
- basalt fibers can be used in place of some or all of the glass reinforcing fibers 102 .
- the glass reinforcing fibers 102 have a diameter within the range of 13 ⁇ m to 24 ⁇ m.
- the glass reinforcing fibers 102 in the hybrid reinforcement fabric 100 are glass fiber strands 102 (fed from one or more glass rovings) made up of many individual continuous glass filaments.
- any suitable carbon reinforcing fibers 104 can be used in the hybrid reinforcement fabric 100 .
- the carbon reinforcing fibers 104 have a diameter within the range of 5 ⁇ m to 11 ⁇ m.
- the carbon reinforcing fibers 104 in the hybrid reinforcement fabric 100 are carbon fiber strands 104 (fed from one or more carbon tows) made up of many individual continuous carbon filaments.
- the hybrid reinforcement fabric 100 is a non-crimp fabric, wherein the fibers 102 , 104 are arranged in their respective positions/orientations and then held together by a stitching yarn 106 .
- the stitching yarn 106 is made of polyester.
- the stitching yarn 106 has a linear mass density between 60 dTex and 250 dTex.
- FIGS. 2A-2C A tricot stitching pattern 200 in which reinforcing fibers 202 (e.g., the fibers 102 , 104 ) are held together by a stitching yarn 206 (e.g., the stitching yarn 106 ) is shown in FIG. 2A .
- An asymmetric double tricot stitching pattern 200 in which the reinforcing fibers 202 (e.g., the fibers 102 , 104 ) are held together by the stitching yarn 206 (e.g., the stitching yarn 106 ) is shown in FIG. 2B .
- FIG. 2C An asymmetric diamant (diamond-like) stitching pattern 200 in which the reinforcing fibers 202 (e.g., the fibers 102 , 104 ) are held together by the stitching yarn 206 (e.g., the stitching yarn 106 ) is shown in FIG. 2C .
- FIGS. 1C-1D illustrate a tricot stitching pattern used in the fabric 100 .
- the stitching pattern 200 is a repeating series of stitches, with transitions between each individual stich portion 220 defining a stitching length 222 (see FIG. 2 A).
- the stitching length 222 is another variable that can influence the rate of infusion of the fabric 100 .
- the stitching length 222 will be within the range of 3 mm to 6 mm.
- the stitching length 222 is 4 mm.
- the stitching length 222 is 5 mm.
- the hybrid reinforcement fabric 100 is a unidirectional fabric, wherein between 91 wt. % to 99 wt. % of the reinforcing fibers 102 , 104 are oriented in a first direction and 0.5 wt. % to 9 wt. % of the reinforcing fibers 102 , 104 are oriented in one or more other directions (e.g., second and third directions).
- the first direction will be 0° (lengthwise direction of the fabric).
- the second direction is different from the first direction.
- the second direction will generally be between greater than 0° and less than or equal to 90°.
- the third direction is different from the first direction.
- the third direction will generally be greater than 0° and less than or equal to 90°.
- the third direction may be the same as the second direction (such that there are only two distinct fiber orientations in the fabric). Otherwise, the third direction will typically be equal to the negative orientation of the second direction.
- the first direction is 0°
- the second direction is 80°
- the third direction is ⁇ 80°.
- all of the reinforcing fibers oriented in the second direction are glass reinforcing fibers 102 .
- all of the reinforcing fibers oriented in the third direction are glass reinforcing fibers 102 .
- the glass reinforcing fibers 102 oriented in the first direction include a different glass composition than the glass reinforcing fibers 102 oriented in the second direction.
- the glass reinforcing fibers 102 oriented in the first direction include a different glass composition than the glass reinforcing fibers 102 oriented in the third direction.
- the glass reinforcing fibers 102 oriented in the second direction include the same glass composition as the glass reinforcing fibers 102 oriented in the third direction.
- the hybrid reinforcement fabric 100 comprises between 65 wt. % to 95 wt. % of glass reinforcing fibers 102 and between 5 wt. % to 35 wt. % of carbon reinforcing fibers 104 .
- the stitching yarn 106 comprises a maximum of 3 wt. % of the fabric 100 .
- the linear mass density of the glass reinforcing fibers 102 being fed in the first direction is between 1,200 Tex and 4,800 Tex.
- the linear mass density of the glass reinforcing fibers 102 being fed in the non-first direction is between 68 Tex and 300 Tex.
- the tow size of the carbon reinforcing fibers 104 being fed in the first direction is between 6K and 50K.
- the nomenclature #k means that the carbon tow is made up of # ⁇ 1,000 individual carbon filaments.
- the areal weight of the carbon reinforcing fibers 104 in the fabric 100 is between 80 g/m 2 to 500 g/m 2 .
- the hybrid reinforcement fabric 100 has approximately 7 wt. % of carbon reinforcing fibers 104 , with the fabric 100 having an areal weight of approximately 2,500 g/m 2 .
- the hybrid reinforcement fabric 100 has approximately 15 wt. % of carbon reinforcing fibers 104 , with the fabric 100 having an areal weight of approximately 1,300 g/m 2 .
- the hybrid reinforcement fabric 100 has approximately 15 wt.
- the hybrid reinforcement fabric 100 has approximately 25 wt. % of carbon reinforcing fibers 104 , with the fabric 100 having an areal weight of approximately 1,300 g/m 2 .
- the glass reinforcing fibers 102 may have a chemistry applied thereon during formation of the fibers 102 .
- This surface chemistry typically in an aqueous form, is called a sizing.
- the sizing can include components such as a film former, lubricant, coupling agent (to promote compatibility between the glass fibers and the polymer resin), etc. that facilitate formation of the glass fibers and/or use thereof in a matrix resin.
- the glass reinforcing fibers 102 include a polyester compatible sizing.
- the glass reinforcing fibers 102 include an epoxy compatible sizing.
- the carbon reinforcing fibers 104 may have a chemistry applied thereon during formation of the fibers 104 .
- This surface chemistry typically in an aqueous form, is called a sizing.
- the sizing can include components such as a film former, lubricant, coupling agent (to promote compatibility between the carbon fibers and the polymer resin), etc. that facilitate formation of the carbon fibers and/or use thereof in a matrix resin.
- the carbon reinforcing fibers 104 include a polyester compatible sizing.
- the carbon reinforcing fibers 104 include an epoxy compatible sizing.
- the sizing can also include additives beyond those conventionally associated with the fiber forming process.
- the sizing can include one or more additives that impart or otherwise improve properties of the glass reinforcing fibers 102 , the carbon reinforcing fibers 104 , and/or the composite materials (e.g., structural components) reinforced thereby.
- One exemplary additive is graphene.
- at least a portion of the glass reinforcing fibers 102 and/or at least a portion of the carbon reinforcing fibers 104 have a sizing applied thereon, during formation of the fibers, that includes graphene.
- the glass reinforcing fibers 102 and/or the carbon reinforcing fibers 104 may also have a post-coating applied thereto. Unlike a sizing, the post-coating is applied after formation of the fibers. As with the sizing discussed above, the post-coating can include one or more additives that impart or otherwise improve properties of the glass reinforcing fibers 102 , the carbon reinforcing fibers 104 , and/or the composite materials (e.g., structural components) reinforced thereby.
- One exemplary additive is graphene.
- At least a portion of the glass reinforcing fibers 102 and/or at least a portion of the carbon reinforcing fibers 104 have a post-coating applied thereon, after formation of the fibers, that includes graphene.
- hybrid reinforcing fabrics disclosed herein e.g., the hybrid reinforcement fabric 100
- these components/properties include the glass content, the carbon content, the glass-carbon ratio, the stitching yarn composition, the stitching pattern, and the stitching length used in the hybrid reinforcing fabrics.
- the TTIS test will be explained with reference to FIG. 3 .
- multiple layers 302 of a fabric 304 to be tested e.g., the hybrid reinforcement fabric 100
- many layers 302 of the fabric 304 are used for the TTIS test 300 .
- the number of layers 302 is based on a target “testing thickness.” In some exemplary embodiments, the target thickness is 30 mm.
- a vacuum foil 308 is placed over the layers 302 on top of the table 306 to form an airtight enclosure 350 (i.e., vacuum bag).
- a supply 310 of resin 312 is situated below, or otherwise in proximity to, the table 306 , such that the resin 312 can be drawn into the enclosure 350 (e.g., through one or more openings (not shown) in the bottom of the table 306 ) below the layers 302 of the fabric 304 .
- the resin 312 is located remote from the table 306 , but is fed thereto through a supply hose (not shown).
- An opening 320 in the vacuum bag formed from the foil 308 is interfaced with a hose 322 so that a vacuum source (not shown) can be used to evacuate air from the enclosure 350 and suck the resin 312 through the fabric 304 .
- the resin 312 is pulled from the supply 310 into the enclosure 350 (see arrow 330 ); through the layers 302 of the fabric 304 (see arrows 332 ); and out the opening 320 through the hose 322 (see arrow 334 ).
- the only path for the resin 312 to travel is through the layers 302 of the fabric 304 , i.e., through the thicknesses (z-direction) of the layers 302 of the fabric 304 .
- the TTIS test 300 measures the amount of time it takes until the resin 312 is first visible on an upper surface 340 of a top layer 302 of the fabric 304 .
- This amount of time (e.g., in minutes) is used as a measure of the rate of infusion of the fabric 304 .
- the TTIS test 300 can be used to compare the rates of infusion of different fabrics, so long as the other testing parameters are substantially the same. Additionally, for comparison purposes, the fabrics should have similar grammage.
- IPIT in-plane infusion test
- All of the layers of the fabric 404 in the enclosure 410 are aligned with one another so as to face in the same direction (e.g., the first orientation of each layer of the fabric 404 aligns with the first orientation of each other layer of the fabric 404 ) within the enclosure 410 .
- the vacuum foil 408 (and tape) form the airtight enclosure 410 except for an input opening 412 and an output opening 414 formed near opposite ends of the fabric 404 .
- a supply of resin 420 is situated adjacent to, or otherwise in proximity to, the input opening 412 .
- the resin 420 can be drawn into the enclosure 410 through the input opening 412 .
- the resin 420 is located remote from the table 406 , but is fed thereto through a supply hose (not shown) interfaced with the input opening 412 .
- the output opening 414 on the other side of the enclosure 410 , is interfaced with a hose (not shown) so that a vacuum source 422 can be used to evacuate air from the enclosure 410 and suck the resin 420 through the fabric 404 .
- the resin 420 is pulled from the supply into the enclosure 410 (see arrow 430 ); through the layers of the fabric 404 (see arrows 440 in FIG. 4B ); and out the opening 414 through the hose (see arrow 432 ).
- the only path for the resin 420 to travel is through the layers of the fabric 404 , i.e., through the length (x-direction, production direction) or width (y-direction) of the layers of the fabric 404 , depending on the orientation of the fabric 404 between the openings 412 , 414 of the enclosure 410 .
- the resin channels within the layers of the fabric 404 are used to transport the resin 420 .
- the IPIT test 400 measures the distance covered by the resin 420 over time. A flow front (distance) of the resin 420 is recorded after 2, 4, 6, 8, 10, 12, 16, 20, 26, 32, 38, 44, 50, 55, and 60 minutes. The current distance that the resin 420 has traveled through the fabric 404 is referred to as the infusion length. The measured amount of time (e.g., in minutes) relative to the infusion length (e.g., in centimeters) is used as a measure of the rate of infusion of the fabric 404 . The IPIT test 400 can be used to compare the rates of infusion of different fabrics, so long as the other testing parameters are substantially the same. Additionally, for comparison purposes, the fabrics should have similar warp grammage.
- the first fabric contained only glass reinforcing fibers (i.e., no carbon reinforcing fibers), and served as the reference fabric.
- the second fabric contained 15% carbon reinforcing fibers (and, thus, 85% glass reinforcing fibers), and was produced according to the general inventive concepts.
- the measurements for the first fabric (UD 1200) are provided in Table 1.
- the measurements for the inventive hybrid fabric (15% carbon content) are provided in Table 2.
- FIG. 5 is a graph 500 that shows the results of the IPIT test 400 performed on two (2) different fabrics to measure the infusion rate (in the x-direction) of the fabrics.
- a first fabric 502 is made up of 100% glass reinforcing fibers (i.e., no carbon reinforcing fibers), uses a polyester stitching yarn, uses a stitching yarn of 110 dTex, and uses a stitching length of 5 mm.
- a second fabric 504 is made up of 85% glass reinforcing fibers and 15% carbon reinforcing fibers, uses a polyester stitching yarn, uses a stitching yarn of 220 dTex, and uses a stitching length of 4 mm.
- the first fabric 502 corresponds to the fabric detailed in Table 1 above, while the second fabric 504 corresponds to the fabric detailed in Table 2 above.
- FIG. 6 is a graph 600 illustrating the results of the IPIT test 400 performed on two (2) different fabrics to measure the infusion rate (in the y-direction) of the fabrics.
- a first fabric 602 is made up of 100% glass reinforcing fibers (i.e., no carbon reinforcing fibers), uses a polyester stitching yarn, uses a stitching yarn of 110 dTex, and uses a stitching length of 5 mm.
- a second fabric 604 is made up of 85% glass reinforcing fibers and 15% carbon reinforcing fibers, uses a polyester stitching yarn, uses a stitching yarn of 220 dTex, and uses a stitching length of 4 mm.
- the first fabric 602 corresponds to the fabric detailed in Table 1 above, while the second fabric 604 corresponds to the fabric detailed in Table 2 above.
- the hybrid reinforcing fabrics described herein can be combined with a resin matrix, such as in a mold, to form a composite article.
- a resin matrix such as in a mold
- Any suitable resin system can be used.
- the resin is a vinyl ester resin.
- the resin is a polyester resin.
- the resin is an epoxy resin.
- the resin includes a viscosity modifier.
- any suitable composite forming process can be used, such as vacuum-assisted resin transfer molding (VARTM).
- VARTM vacuum-assisted resin transfer molding
- the composite article is reinforced by the hybrid reinforcing fabric.
- the composite article is a wind turbine blade or related component (e.g., spar cap).
- the hybrid reinforcing fabrics disclosed and suggested herein may achieve improved mechanical properties (versus a comparable glass-only fabric).
- a hybrid reinforcing fabric (having a 15% carbon content) can exhibit a modulus improvement of approximately 30% and a fatigue improvement between 40% and 50%, as compared to a similar glass-only fabric (e.g., having the same grammage, such as 1,323 g/m 2 ).
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Abstract
Description
- This application claims priority to and any benefit of U.S. Provisional Patent Application No. 62/720,427, filed Aug. 21, 2018, the entire content of which is incorporated herein by reference.
- The inventive concepts relate generally to fibrous reinforcement materials and, more particularly, to a hybrid fabric including glass fibers and carbon fibers.
- It is known to use glass fibers to reinforce structural components, such as wind turbine blades. It is likewise known to use carbon fibers to reinforce structural components, such as wind turbine blades. These structural components are often formed by hand laying a collection of the fibers (e.g., in the form of a fabric) into a mold, filling the mold with a resin, and curing the resin to form the part.
- Glass fiber reinforcement materials exhibit good mechanical properties, including strength, strain, and compression; are relatively inexpensive; and are readily infused with a resin. However, the elastic modulus of the glass fiber reinforcement materials is low, which can present design limitations.
- Carbon fiber reinforcement materials exhibit good mechanical properties, including stiffness and tensile strength, at a low density. However, the carbon fiber reinforcement materials are low in strain, low in compressive strength, and relatively expensive. Furthermore, the carbon fiber reinforcement materials can be difficult to infuse with a resin.
- It would be desirable to combine glass fibers and carbon fibers into a hybrid reinforcement material for use in reinforcing structural components, so as to take advantage of each fiber's respective strengths while compensating for each fiber's respective weaknesses. However, when fabrics are made with only carbon tows, the very thin carbon fibers that are bundled together lead to poor infusion speed.
- Conventional carbon-containing reinforcement fabrics have attempted to solve this problem by pre-impregnating the carbon tow used to form the fabric. In other words, resin is applied to the carbon fibers prior to the fabric being placed in a mold to form a composite structure. In some instances, the carbon tow is also spread (i.e., the individual carbon fibers separated) to accelerate the rate of infusion of the carbon tow. Such a “prepreg” fabric can introduce processing, storage, and handling difficulties.
- In view of the above, there is an unmet need for a hybrid reinforcement fabric including glass fibers and carbon fibers, which can be readily infused with resin at an acceptable infusion speed.
- The invention relates generally to a hybrid reinforcement fabric that includes glass fibers and carbon fibers, a method of producing the hybrid reinforcement fabric, and a composite part formed from the hybrid reinforcement fabric.
- In one exemplary embodiment, a hybrid reinforcing fabric is provided. The hybrid reinforcing fabric comprises a plurality of first fibers oriented in a first direction; a plurality of second fibers oriented in the first direction; a plurality of third fibers oriented in a second direction; and a stitching yarn maintaining the first fibers, the second fibers, and the third fibers in their respective orientations. The first fibers are glass fibers. The second fibers are carbon fibers. The third fibers are glass fibers, carbon fibers, or both glass and carbon fibers. The first direction is 0 degrees. The second direction is different from the first direction, wherein the second direction is within the range of 0 degrees to 90 degrees. The first fibers and the second fibers constitute between 91 wt. % and 99.5 wt. % of the fabric. The third fibers constitute between 0.5 wt. % and 9 wt. % of the fabric. In the fabric, the glass fibers constitute between 65 wt. % to 95 wt. % of the fabric, and the carbon fibers constitute between 5 wt. % to 35 wt. % of the fabric.
- In one exemplary embodiment, the stitching yarn constitutes less than 3 wt. % of the fabric.
- In one exemplary embodiment, the stitching yarn is a polyester yarn.
- In one exemplary embodiment, the stitching yarn has a linear mass density within the range of 60 dTex to 250 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 85 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 200 dTex. In one exemplary embodiment, the stitching yarn has a linear mass density greater than 225 dTex.
- In one exemplary embodiment, the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a tricot stitching pattern.
- In one exemplary embodiment, the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a symmetric double tricot stitching pattern.
- In one exemplary embodiment, the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being an asymmetric double tricot stitching pattern.
- In one exemplary embodiment, the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being a symmetric diamant stitching pattern.
- In one exemplary embodiment, the stitching yarn forms a stitching pattern through the fabric, the stitching pattern being an asymmetric diamant stitching pattern.
- In one exemplary embodiment, the stitching yarn defines a stitching length between 3 mm to 6 mm. In one exemplary embodiment, the stitching yarn defines a stitching length of 5 mm. In one exemplary embodiment, the stitching yarn defines a stitching length of 4 mm.
- In one exemplary embodiment, the first fibers are glass fibers and the third fibers are glass fibers, wherein a glass composition of the first fibers differs from a glass composition of the third fibers.
- In one exemplary embodiment, the hybrid reinforcing fabric further comprises a plurality of fourth fibers oriented in a third direction, wherein the third fibers are glass fibers and the fourth fibers are glass fibers, and wherein a glass composition of the third fibers is the same as a glass composition of the fourth fibers.
- In one exemplary embodiment, an absolute value of the second direction is equal to an absolute value of the third direction.
- In one exemplary embodiment, a difference between the first direction and the second direction is greater than or equal to 45 degrees.
- In one exemplary embodiment, a difference between the first direction and the second direction is greater than or equal to 80 degrees.
- In one exemplary embodiment, a linear mass density of the first fibers is between 600 Tex and 4,800 Tex.
- In one exemplary embodiment, the third fibers are glass fibers, wherein a linear mass density of the third fibers is between 68 Tex and 300 Tex.
- In one exemplary embodiment, the second fibers are fed from one or more carbon tows having a size in the range of 6K to 50K.
- In one exemplary embodiment, an areal weight of the second fibers is between 80 g/m2 and 500 g/m2.
- In one exemplary embodiment, the second fibers constitute 7 wt. % of the fabric, wherein an areal weight of the fabric is 2,500 g/m2.
- In one exemplary embodiment, the second fibers constitute 15 wt. % of the fabric, wherein an areal weight of the fabric is 1,300 g/m2.
- In one exemplary embodiment, the second fibers constitute 15 wt. % of the fabric, wherein an areal weight of the fabric is 1,400 g/m2.
- In one exemplary embodiment, the second fibers constitute 25 wt. % of the fabric, wherein an areal weight of the fabric is 1,300 g/m2.
- In general, the hybrid reinforcing fabric contains no resin, i.e., none of the fibers forming the fabric are pre-impregnated with a resin.
- In one exemplary embodiment, a polyester resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 9 minutes. In one case, where the fabric had a carbon content of 15%, the infusion rate was 0.41 cm per minute.
- In one exemplary embodiment, an epoxy resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 16 minutes. In one case, where the fabric had a carbon content of 15%, the infusion rate was 0.23 cm per minute.
- In one exemplary embodiment, an epoxy resin has an infusion rate through a thickness of the hybrid reinforcing fabric (approximately 30 mm) of 8 minutes. In one case, where the fabric had a carbon content of 7%, the infusion rate was 0.419 cm per minute.
- In one exemplary embodiment, an epoxy resin has an infusion rate through the hybrid reinforcing fabric in the first direction of between 0.238 cm per minute and 0.5 cm per minute.
- In one exemplary embodiment, a polyester resin has an infusion rate through the hybrid reinforcing fabric in the first direction of 0.73 cm per minute.
- In one exemplary embodiment, the fabric has an infusion rate through the fabric in a direction perpendicular to the first direction of 0.3 cm per minute.
- In one exemplary embodiment, the fabric is infused with a resin that is cured to form a composite article. In one exemplary embodiment, the article is a wind turbine blade or related component (e.g., spar cap).
- Other aspects, advantages, and features of the inventive concepts will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings.
- For a fuller understanding of the nature and advantages of the inventive concepts, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
-
FIGS. 1A-1D illustrate a hybrid reinforcing fabric, according to an exemplary embodiment of the invention.FIG. 1A is a top plan view of the hybrid reinforcing fabric.FIG. 1B is a bottom plan view of the hybrid reinforcing fabric.FIG. 1C is a detailed view of the circle A inFIG. 1A .FIG. 1D is a detailed view of the circle B inFIG. 1B . -
FIGS. 2A-2C illustrate stitching patterns that can be used in the hybrid reinforcing fabric ofFIG. 1 .FIG. 2A shows a tricot stitching pattern.FIG. 2B shows an asymmetric double tricot stitching pattern.FIG. 2C shows an asymmetric diamant stitching pattern. -
FIG. 3 is a diagram illustrating a through thickness infusion speed (TTIS) test for measuring the infusion rate of a fabric. -
FIGS. 4A-4B illustrate an in-plane infusion test (IPIT) test for measuring the infusion rate of a fabric. -
FIG. 5 is a graph illustrating the results of the IPIT test ofFIG. 4 performed on two (2) different fabrics to measure the infusion rate (in the x-direction) of the fabrics. -
FIG. 6 is a graph illustrating the results of the IPIT test ofFIG. 4 performed on two (2) different fabrics to measure the infusion rate (in the y-direction) of the fabrics. - While the inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings and will be described herein in detail various exemplary embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the inventive concepts. Accordingly, the inventive concepts are not intended to be limited to the specific embodiments illustrated herein.
- Unless otherwise defined, the terms used herein have the same meaning as commonly understood by one of ordinary skill in the art encompassing the inventive concepts. The terminology used herein is for describing exemplary embodiments of the inventive concepts only and is not intended to be limiting of the inventive concepts. As used in the description of the inventive concepts and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, the term “between” when defining a range is intended to be inclusive of the specified end points as well, unless the context clearly indicates to the contrary.
- It has been discovered that by controlling one or more specific product variables including, but not necessarily limited to, glass content, carbon content, glass-carbon ratio, stitching yarn composition, stitching pattern, and stitching length, a hybrid reinforcement fabric made up primarily of glass fibers and carbon fibers can be produced that is an effective reinforcement for structural components (e.g., wind turbine blades) and that exhibits an acceptable rate of infusion.
- Accordingly, the inventive concepts provide a hybrid reinforcement fabric comprising glass fibers and carbon fibers. The hybrid reinforcement fabric can be readily infused at an acceptable infusion speed, without requiring that the carbon fiber tows used to form the hybrid reinforcement fabric be spread or pre-impregnated with resin. Thus, the inventive fabric provides for an effective one-step (i.e., in the mold) infusion process during composite part formation. The inventive concepts also encompass a method of producing the hybrid reinforcing fabric. The inventive concepts also encompass a composite part formed from the hybrid reinforcing fabric.
- In an exemplary embodiment of the invention, a
hybrid reinforcement fabric 100 is constructed from bothglass reinforcing fibers 102 andcarbon reinforcing fibers 104, as shown inFIGS. 1A-1D . - Any suitable
glass reinforcing fibers 102 can be used in thehybrid reinforcement fabric 100. For example, fibers made from E glass, H glass, S glass, an AR glass types can be used. In some exemplary embodiments, basalt fibers can be used in place of some or all of theglass reinforcing fibers 102. In general, theglass reinforcing fibers 102 have a diameter within the range of 13 μm to 24 μm. Typically, theglass reinforcing fibers 102 in thehybrid reinforcement fabric 100 are glass fiber strands 102 (fed from one or more glass rovings) made up of many individual continuous glass filaments. - Any suitable
carbon reinforcing fibers 104 can be used in thehybrid reinforcement fabric 100. In general, thecarbon reinforcing fibers 104 have a diameter within the range of 5 μm to 11 μm. Typically, thecarbon reinforcing fibers 104 in thehybrid reinforcement fabric 100 are carbon fiber strands 104 (fed from one or more carbon tows) made up of many individual continuous carbon filaments. - The
hybrid reinforcement fabric 100 is a non-crimp fabric, wherein thefibers stitching yarn 106. In some embodiments, thestitching yarn 106 is made of polyester. In some embodiments, thestitching yarn 106 has a linear mass density between 60 dTex and 250 dTex. - Any stitching pattern suitable to hold the
fibers fabric 100 together can be used. Variousexemplary stitching patterns 200 are shown inFIGS. 2A-2C . Atricot stitching pattern 200 in which reinforcing fibers 202 (e.g., thefibers 102, 104) are held together by a stitching yarn 206 (e.g., the stitching yarn 106) is shown inFIG. 2A . An asymmetric doubletricot stitching pattern 200 in which the reinforcing fibers 202 (e.g., thefibers 102, 104) are held together by the stitching yarn 206 (e.g., the stitching yarn 106) is shown inFIG. 2B . An asymmetric diamant (diamond-like)stitching pattern 200 in which the reinforcing fibers 202 (e.g., thefibers 102, 104) are held together by the stitching yarn 206 (e.g., the stitching yarn 106) is shown inFIG. 2C .FIGS. 1C-1D illustrate a tricot stitching pattern used in thefabric 100. - In general, the
stitching pattern 200 is a repeating series of stitches, with transitions between eachindividual stich portion 220 defining a stitching length 222 (see FIG. 2A). Thestitching length 222 is another variable that can influence the rate of infusion of thefabric 100. Typically, thestitching length 222 will be within the range of 3 mm to 6 mm. In some exemplary embodiments, thestitching length 222 is 4 mm. In some exemplary embodiments, thestitching length 222 is 5 mm. - The
hybrid reinforcement fabric 100 is a unidirectional fabric, wherein between 91 wt. % to 99 wt. % of the reinforcingfibers fibers - Typically, the first direction will be 0° (lengthwise direction of the fabric).
- The second direction is different from the first direction. The second direction will generally be between greater than 0° and less than or equal to 90°.
- The third direction is different from the first direction. The third direction will generally be greater than 0° and less than or equal to 90°.
- The third direction may be the same as the second direction (such that there are only two distinct fiber orientations in the fabric). Otherwise, the third direction will typically be equal to the negative orientation of the second direction.
- In the
hybrid reinforcement fabric 100 shown inFIGS. 1A-1D , the first direction is 0°, the second direction is 80°, and the third direction is −80°. - In some exemplary embodiments, all of the reinforcing fibers oriented in the second direction are
glass reinforcing fibers 102. - In some exemplary embodiments, all of the reinforcing fibers oriented in the third direction are
glass reinforcing fibers 102. - In some exemplary embodiments, the
glass reinforcing fibers 102 oriented in the first direction include a different glass composition than theglass reinforcing fibers 102 oriented in the second direction. - In some exemplary embodiments, the
glass reinforcing fibers 102 oriented in the first direction include a different glass composition than theglass reinforcing fibers 102 oriented in the third direction. - In some exemplary embodiments, the
glass reinforcing fibers 102 oriented in the second direction include the same glass composition as theglass reinforcing fibers 102 oriented in the third direction. - The
hybrid reinforcement fabric 100 comprises between 65 wt. % to 95 wt. % ofglass reinforcing fibers 102 and between 5 wt. % to 35 wt. % ofcarbon reinforcing fibers 104. Thestitching yarn 106 comprises a maximum of 3 wt. % of thefabric 100. - The linear mass density of the
glass reinforcing fibers 102 being fed in the first direction is between 1,200 Tex and 4,800 Tex. The linear mass density of theglass reinforcing fibers 102 being fed in the non-first direction (i.e., the second/third directions) is between 68 Tex and 300 Tex. - The tow size of the
carbon reinforcing fibers 104 being fed in the first direction is between 6K and 50K. The nomenclature #k means that the carbon tow is made up of #×1,000 individual carbon filaments. - The areal weight of the
carbon reinforcing fibers 104 in thefabric 100 is between 80 g/m2 to 500 g/m2. In some exemplary embodiments, thehybrid reinforcement fabric 100 has approximately 7 wt. % ofcarbon reinforcing fibers 104, with thefabric 100 having an areal weight of approximately 2,500 g/m2. In some exemplary embodiments, thehybrid reinforcement fabric 100 has approximately 15 wt. % ofcarbon reinforcing fibers 104, with thefabric 100 having an areal weight of approximately 1,300 g/m2. In some exemplary embodiments, thehybrid reinforcement fabric 100 has approximately 15 wt. % ofcarbon reinforcing fibers 104, with thefabric 100 having an areal weight of approximately 1,400 g/m2. In some exemplary embodiments, thehybrid reinforcement fabric 100 has approximately 25 wt. % ofcarbon reinforcing fibers 104, with thefabric 100 having an areal weight of approximately 1,300 g/m2. - As known in the art, the
glass reinforcing fibers 102 may have a chemistry applied thereon during formation of thefibers 102. This surface chemistry, typically in an aqueous form, is called a sizing. The sizing can include components such as a film former, lubricant, coupling agent (to promote compatibility between the glass fibers and the polymer resin), etc. that facilitate formation of the glass fibers and/or use thereof in a matrix resin. In some exemplary embodiments, theglass reinforcing fibers 102 include a polyester compatible sizing. In some exemplary embodiments, theglass reinforcing fibers 102 include an epoxy compatible sizing. - Likewise, as also known in the art, the
carbon reinforcing fibers 104 may have a chemistry applied thereon during formation of thefibers 104. This surface chemistry, typically in an aqueous form, is called a sizing. The sizing can include components such as a film former, lubricant, coupling agent (to promote compatibility between the carbon fibers and the polymer resin), etc. that facilitate formation of the carbon fibers and/or use thereof in a matrix resin. In some exemplary embodiments, thecarbon reinforcing fibers 104 include a polyester compatible sizing. In some exemplary embodiments, thecarbon reinforcing fibers 104 include an epoxy compatible sizing. - The sizing can also include additives beyond those conventionally associated with the fiber forming process. For example, the sizing can include one or more additives that impart or otherwise improve properties of the
glass reinforcing fibers 102, thecarbon reinforcing fibers 104, and/or the composite materials (e.g., structural components) reinforced thereby. One exemplary additive is graphene. In some exemplary embodiments, at least a portion of theglass reinforcing fibers 102 and/or at least a portion of thecarbon reinforcing fibers 104 have a sizing applied thereon, during formation of the fibers, that includes graphene. - In some exemplary embodiments, the
glass reinforcing fibers 102 and/or thecarbon reinforcing fibers 104 may also have a post-coating applied thereto. Unlike a sizing, the post-coating is applied after formation of the fibers. As with the sizing discussed above, the post-coating can include one or more additives that impart or otherwise improve properties of theglass reinforcing fibers 102, thecarbon reinforcing fibers 104, and/or the composite materials (e.g., structural components) reinforced thereby. One exemplary additive is graphene. In some exemplary embodiments, at least a portion of theglass reinforcing fibers 102 and/or at least a portion of thecarbon reinforcing fibers 104 have a post-coating applied thereon, after formation of the fibers, that includes graphene. - The hybrid reinforcing fabrics disclosed herein (e.g., the hybrid reinforcement fabric 100) have combinations of structural components and/or properties that improve the resin infusion rate of the fabrics, even when the reinforcing fibers making up the fabric are not pre-impregnated with resin. As noted above, these components/properties include the glass content, the carbon content, the glass-carbon ratio, the stitching yarn composition, the stitching pattern, and the stitching length used in the hybrid reinforcing fabrics.
- One test for the measuring the resin infusion rate of a fabric is called the through thickness infusion speed (TTIS) test. The TTIS test will be explained with reference to
FIG. 3 . In theTTIS test 300,multiple layers 302 of afabric 304 to be tested (e.g., the hybrid reinforcement fabric 100) are placed on an infusion table 306. In general,many layers 302 of thefabric 304 are used for theTTIS test 300. Typically, the number oflayers 302 is based on a target “testing thickness.” In some exemplary embodiments, the target thickness is 30 mm. Avacuum foil 308 is placed over thelayers 302 on top of the table 306 to form an airtight enclosure 350 (i.e., vacuum bag). - A
supply 310 ofresin 312 is situated below, or otherwise in proximity to, the table 306, such that theresin 312 can be drawn into the enclosure 350 (e.g., through one or more openings (not shown) in the bottom of the table 306) below thelayers 302 of thefabric 304. In some exemplary embodiments, theresin 312 is located remote from the table 306, but is fed thereto through a supply hose (not shown). Anopening 320 in the vacuum bag formed from thefoil 308 is interfaced with ahose 322 so that a vacuum source (not shown) can be used to evacuate air from theenclosure 350 and suck theresin 312 through thefabric 304. - In this manner, the
resin 312 is pulled from thesupply 310 into the enclosure 350 (see arrow 330); through thelayers 302 of the fabric 304 (see arrows 332); and out theopening 320 through the hose 322 (see arrow 334). Given the close-fitting dimensions of thelayers 302 of thefabric 304 within theenclosure 350, the only path for theresin 312 to travel is through thelayers 302 of thefabric 304, i.e., through the thicknesses (z-direction) of thelayers 302 of thefabric 304. TheTTIS test 300 measures the amount of time it takes until theresin 312 is first visible on anupper surface 340 of atop layer 302 of thefabric 304. This amount of time (e.g., in minutes) is used as a measure of the rate of infusion of thefabric 304. TheTTIS test 300 can be used to compare the rates of infusion of different fabrics, so long as the other testing parameters are substantially the same. Additionally, for comparison purposes, the fabrics should have similar grammage. - Another test for the measuring the resin infusion rate of a fabric is called the in-plane infusion test (IPIT) test. The IPIT test will be explained with reference to
FIGS. 4A-4B . In theIPIT test 400, five (5) layers of afabric 404 to be tested (e.g., the hybrid reinforcement fabric 100) are placed on an infusion table 406. Avacuum foil 408 is placed over the edges of the layers on top of the table 406, and sealed to the table 406 (e.g., using tape), to form an airtight enclosure 410 (i.e., vacuum bag). - All of the layers of the
fabric 404 in theenclosure 410 are aligned with one another so as to face in the same direction (e.g., the first orientation of each layer of thefabric 404 aligns with the first orientation of each other layer of the fabric 404) within theenclosure 410. - The vacuum foil 408 (and tape) form the
airtight enclosure 410 except for aninput opening 412 and anoutput opening 414 formed near opposite ends of thefabric 404. - A supply of
resin 420 is situated adjacent to, or otherwise in proximity to, theinput opening 412. As configured, theresin 420 can be drawn into theenclosure 410 through theinput opening 412. In some exemplary embodiments, theresin 420 is located remote from the table 406, but is fed thereto through a supply hose (not shown) interfaced with theinput opening 412. Theoutput opening 414, on the other side of theenclosure 410, is interfaced with a hose (not shown) so that avacuum source 422 can be used to evacuate air from theenclosure 410 and suck theresin 420 through thefabric 404. - In this manner, the
resin 420 is pulled from the supply into the enclosure 410 (see arrow 430); through the layers of the fabric 404 (seearrows 440 inFIG. 4B ); and out theopening 414 through the hose (see arrow 432). Given the close-fitting dimensions of the layers of thefabric 404 within theenclosure 410, the only path for theresin 420 to travel is through the layers of thefabric 404, i.e., through the length (x-direction, production direction) or width (y-direction) of the layers of thefabric 404, depending on the orientation of thefabric 404 between theopenings enclosure 410. Thus, only the resin channels within the layers of thefabric 404 are used to transport theresin 420. - The
IPIT test 400 measures the distance covered by theresin 420 over time. A flow front (distance) of theresin 420 is recorded after 2, 4, 6, 8, 10, 12, 16, 20, 26, 32, 38, 44, 50, 55, and 60 minutes. The current distance that theresin 420 has traveled through thefabric 404 is referred to as the infusion length. The measured amount of time (e.g., in minutes) relative to the infusion length (e.g., in centimeters) is used as a measure of the rate of infusion of thefabric 404. TheIPIT test 400 can be used to compare the rates of infusion of different fabrics, so long as the other testing parameters are substantially the same. Additionally, for comparison purposes, the fabrics should have similar warp grammage. - Two (2) different fabrics were assessed using the
IPIT test 400 to measure the infusion rate in both the x-direction and the y-direction. The first fabric contained only glass reinforcing fibers (i.e., no carbon reinforcing fibers), and served as the reference fabric. The second fabric contained 15% carbon reinforcing fibers (and, thus, 85% glass reinforcing fibers), and was produced according to the general inventive concepts. The measurements for the first fabric (UD 1200) are provided in Table 1. The measurements for the inventive hybrid fabric (15% carbon content) are provided in Table 2. -
TABLE 1 Time (min.) Length (Y) (cm) Length (X) (cm) 2 6.5 9.5 4 7.4 11.0 6 8.2 12.3 8 8.7 13.3 10 9.1 14.1 12 9.4 14.6 16 10.1 15.6 20 10.7 16.5 26 11.4 17.7 32 12.2 18.9 38 12.9 19.9 44 13.5 20.8 50 13.9 21.7 55 14.2 22.3 60 14.7 22.8 -
TABLE 2 Time (min.) Length (Y) (cm) Length (X) (cm) 2 8.1 11.5 4 9.0 13.8 6 9.9 15.4 8 10.7 16.9 10 11.5 18.1 12 11.9 19.1 16 12.6 20.7 20 13.1 22.1 26 14.4 23.9 32 15.2 25.8 38 16.0 27.3 44 16.8 28.8 50 17.4 30.2 55 18.0 31.4 60 18.5 32.4 -
FIG. 5 is agraph 500 that shows the results of theIPIT test 400 performed on two (2) different fabrics to measure the infusion rate (in the x-direction) of the fabrics. Afirst fabric 502 is made up of 100% glass reinforcing fibers (i.e., no carbon reinforcing fibers), uses a polyester stitching yarn, uses a stitching yarn of 110 dTex, and uses a stitching length of 5 mm. Asecond fabric 504 is made up of 85% glass reinforcing fibers and 15% carbon reinforcing fibers, uses a polyester stitching yarn, uses a stitching yarn of 220 dTex, and uses a stitching length of 4 mm. Thefirst fabric 502 corresponds to the fabric detailed in Table 1 above, while thesecond fabric 504 corresponds to the fabric detailed in Table 2 above. -
FIG. 6 is agraph 600 illustrating the results of theIPIT test 400 performed on two (2) different fabrics to measure the infusion rate (in the y-direction) of the fabrics. Afirst fabric 602 is made up of 100% glass reinforcing fibers (i.e., no carbon reinforcing fibers), uses a polyester stitching yarn, uses a stitching yarn of 110 dTex, and uses a stitching length of 5 mm. Asecond fabric 604 is made up of 85% glass reinforcing fibers and 15% carbon reinforcing fibers, uses a polyester stitching yarn, uses a stitching yarn of 220 dTex, and uses a stitching length of 4 mm. Thefirst fabric 602 corresponds to the fabric detailed in Table 1 above, while thesecond fabric 604 corresponds to the fabric detailed in Table 2 above. - The hybrid reinforcing fabrics described herein (e.g., the hybrid reinforcement fabric 100) can be combined with a resin matrix, such as in a mold, to form a composite article. Any suitable resin system can be used. In some exemplary embodiments, the resin is a vinyl ester resin. In some exemplary embodiments, the resin is a polyester resin. In some exemplary embodiments, the resin is an epoxy resin. In some exemplary embodiments, the resin includes a viscosity modifier.
- The infusion rate of various resin systems through different embodiments of a hybrid reinforcing fabric (e.g., differing carbon contents) are shown in Table 3 below.
-
TABLE 3 Resin 7 % Carbon 15 % Carbon 25% Carbon infusion rate epoxy 8 min 16 min 16 min through a thickness (0.419 cm/min) (0.23 cm/min) of the fabric polyester 9 min (approximately 30 mm) (0.41 cm/min) infusion rate epoxy 32 cm in 60 min 32 cm in 60 min 30 cm in 60 min through the (0.6 cm/min) (0.6 cm/min) (0.5 cm/min) fabric in the polyester 44 cm in 60 min first direction (0.73 cm/min) infusion rate epoxy 20 cm in 60 min 18 cm in 60 min through the fabric (0.33 cm/min) (0.3 cm/min) in the second polyester 16 cm in 60 min direction (0.27 cm/min) - Any suitable composite forming process can be used, such as vacuum-assisted resin transfer molding (VARTM). The composite article is reinforced by the hybrid reinforcing fabric. In some exemplary embodiments, the composite article is a wind turbine blade or related component (e.g., spar cap). The hybrid reinforcing fabrics disclosed and suggested herein may achieve improved mechanical properties (versus a comparable glass-only fabric). For example, a hybrid reinforcing fabric (having a 15% carbon content) can exhibit a modulus improvement of approximately 30% and a fatigue improvement between 40% and 50%, as compared to a similar glass-only fabric (e.g., having the same grammage, such as 1,323 g/m2).
- The above description of specific embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the structures and concepts disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as defined herein and by the appended claims, and equivalents thereof.
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US11753754B2 (en) | 2018-08-21 | 2023-09-12 | Owens Corning Intellectual Capital, Llc | Multiaxial reinforcing fabric with a stitching yarn for improved fabric infusion |
US11913148B2 (en) | 2018-08-21 | 2024-02-27 | Owens Corning Intellectual Capital, Llc | Hybrid reinforcement fabric |
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CN107225817A (en) * | 2017-06-13 | 2017-10-03 | 泰山玻璃纤维有限公司 | A kind of enhanced compound pre- orientation fabric |
CN107458046A (en) * | 2017-09-07 | 2017-12-12 | 浙江成如旦新能源科技股份有限公司 | A kind of fiber blended fabric |
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- 2019-08-16 WO PCT/US2019/046742 patent/WO2020041104A1/en unknown
- 2019-08-16 CN CN201980060150.2A patent/CN112703280A/en active Pending
- 2019-08-16 CA CA3110168A patent/CA3110168A1/en active Pending
- 2019-08-16 EP EP19762030.5A patent/EP3841236A1/en active Pending
- 2019-08-16 US US17/268,688 patent/US20220112637A1/en active Pending
- 2019-08-16 MX MX2021001955A patent/MX2021001955A/en unknown
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US5591933A (en) * | 1992-06-01 | 1997-01-07 | Alliedsignal Inc. | Constructions having improved penetration resistance |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11753754B2 (en) | 2018-08-21 | 2023-09-12 | Owens Corning Intellectual Capital, Llc | Multiaxial reinforcing fabric with a stitching yarn for improved fabric infusion |
US11913148B2 (en) | 2018-08-21 | 2024-02-27 | Owens Corning Intellectual Capital, Llc | Hybrid reinforcement fabric |
Also Published As
Publication number | Publication date |
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MX2021001955A (en) | 2021-06-23 |
CN112703280A (en) | 2021-04-23 |
CA3110168A1 (en) | 2020-02-27 |
BR112021003190A2 (en) | 2021-05-11 |
WO2020041104A1 (en) | 2020-02-27 |
EP3841236A1 (en) | 2021-06-30 |
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