阅读说明：本技术 一种多层组合结构立体织物及其制备方法 (Multilayer combined structure three-dimensional fabric and preparation method thereof ) 是由 乔志炜 刘延友 陈建剑 程海霞 朱梦蝶 于 2020-12-28 设计创作，主要内容包括：本发明公开了一种多层组合结构立体织物及其制备方法,立体织物包括至少一个由一个立体编织结构层和至少一个针刺结构层构成的结构单元,每一结构单元及相邻两个结构单元均通过针刺工艺Z向连接；所述立体编织结构层为2.5D结构层、三向正交结构层或细编穿刺结构层。本发明通过将2.5D、三向正交、细编穿刺结构与针刺结构有机地结合为结构与功能一体性的复合材料,针刺结构承载材料的隔热保温性能,编织结构承载材料的高比强度、高比模量、抗冲击等力学性能,所得复合材料既满足其使用要求,还可实现快速、低成本生产。(The invention discloses a multilayer combined structure three-dimensional fabric and a preparation method thereof, wherein the three-dimensional fabric comprises at least one structural unit consisting of a three-dimensional weaving structural layer and at least one needling structural layer, and each structural unit and two adjacent structural units are connected in the Z direction through a needling process; the three-dimensional woven structure layer is a 2.5D structure layer, a three-dimensional orthogonal structure layer or a fine woven puncture structure layer. According to the invention, the 2.5D, three-way orthogonal and fine-woven puncture structure and the needling structure are organically combined into the composite material with structural and functional integrity, the heat insulation performance of the bearing material of the needling structure and the mechanical properties of the bearing material of the woven structure, such as high specific strength, high specific modulus, impact resistance and the like, so that the obtained composite material not only meets the use requirements, but also can be produced quickly and at low cost.)

1. A multilayer combined structure three-dimensional fabric is characterized by comprising at least one structural unit, wherein the structural unit is composed of a three-dimensional weaving structural layer and at least one needling structural layer, and each structural unit and two adjacent structural units are connected in the Z direction through a needling process; the three-dimensional woven structure layer is a 2.5D structure layer, a three-dimensional orthogonal structure layer or a fine woven puncture structure layer.

2. The multilayer combined structure three-dimensional fabric as claimed in claim 1, wherein the whole fabric is connected in a Z direction by a sewing process on the basis of a needling process.

3. The multilayer combined structure three-dimensional fabric as claimed in claim 1 or 2, wherein the needling structure layer comprises a plurality of needling units, and the needling units are composed of fiber net tires and/or fiber cloth.

4. The multilayer combined structure three-dimensional fabric as claimed in claim 1 or 2, wherein the three-dimensional weaving structure layer is an equal density fabric or a variable density fabric.

5. The multilayer combined structure three-dimensional fabric as claimed in claim 4, wherein the density of the variable density fabric is changed along one or more of the thickness direction, the width direction or the length direction, the variable density three-dimensional fabric is connected through a layer connecting structure, the interfaces of different density areas are connected in layers, the yarns are continuous, and the whole body is continuously woven and formed.

6. The multilayer combined structure three-dimensional fabric as claimed in claim 5, wherein the variable density fabric realizes density variation of the three-dimensional fabric along thickness direction, width direction and length direction through fabric structure variation, yarn type variation, yarn fineness variation, yarn strand number ratio variation, warp density variation or weft density variation.

7. The multilayer combined structure three-dimensional fabric as claimed in claim 1 or 2, wherein the volume density of the three-dimensional weaving structure layer is 0.7-1.3 g/cm³The volume density of the needled structure layer is 0.1-0.9 g/cm³The needling depth is 8-25 mm/needling, and the needling density is 5-30 needles/cm³。

8. The multilayer composite structure three-dimensional fabric according to claim 1, wherein the multilayer composite structure three-dimensional fabric has a shape of a cylinder, a flat plate, a cone, a truncated cone or a curved surface.

9. The multilayer composite structure three-dimensional fabric according to claim 1, wherein the material of the multilayer composite structure three-dimensional fabric is one or more of quartz fiber, glass fiber, carbon fiber, silicon carbide fiber, mullite fiber and silicon nitride fiber.

10. The method for preparing the multilayer combined structure three-dimensional fabric as claimed in any one of claims 1 to 9, which is characterized by comprising the following steps:

(1) preparing 2.5D three-way orthogonal or fine-woven three-dimensional woven structure layer fabric according to a set shape;

(2) cutting the needle-punched structural layer fabric with the shape matched with that of the step (1);

(3) laminating the 2.5D and three-way orthogonal or fine-woven three-dimensional knitting structure layer fabric and the needle-punched structure layer fabric according to the set layer number and the combined structure;

(4) and carrying out superposition needling according to the set needling process parameters to form the multilayer combined three-dimensional fabric.

11. The method of claim 10, wherein the step (4) comprises the step of needling the face layer and the bottom layer, respectively, while the needle-punched structure layer is used as the face layer and the bottom layer of the fabric.

Technical Field

The invention relates to the technical field of spinning, in particular to a multilayer combined structure three-dimensional fabric and a preparation method thereof.

Background

The needling process is to utilize triangular or other needles with barbed edges to repeatedly needle the fluffy fiber web, the barbed needles on the barbed needles drive fibers on the fiber web to penetrate through the fiber web layer along with the barbed needles, the fibers are intertwined with each other in the movement process, the fibers move up and down under the action of friction force, the fibers which move up and down generate certain extrusion on the fiber web, so that the fiber web is compressed, and when the barbed needles exit from the fiber web, the fibers are separated from the barbed needles and are left in the Z direction of the fabric in an approximately vertical pin state, so that a non-woven product with certain strength, density, elasticity and other properties is formed; and forming a three-dimensional preform with interlayer connection by lamination needling. The needle-punched fabric has the characteristics of high forming speed and low manufacturing cost, but the interlayer connection performance of the needle-punched fabric is not as good as that of a 2.5D, three-way orthogonal, fine-knitting and puncturing knitting structure. The 2.5D three-way orthogonal fine-woven puncture structure is a three-dimensional fabric which is formed by interweaving X, Y, Z three-way fibers according to a specific rule and has excellent interlayer connection performance and mechanical property, but the production period is long, and the preparation cost is high.

Disclosure of Invention

The invention aims to provide a multilayer combined structure three-dimensional fabric and a preparation method thereof, wherein a 2.5D, three-way orthogonal and fine-woven puncture structure and a needle structure are organically combined into a composite material with structural and functional integrity, the heat insulation performance of the needle structure bearing material and the mechanical properties of the woven structure bearing material, such as high specific strength, high specific modulus, impact resistance and the like are achieved.

The technical scheme adopted by the invention is as follows:

a multilayer combined structure three-dimensional fabric comprises at least one structural unit, wherein the structural unit is composed of a three-dimensional weaving structural layer and at least one needling structural layer, and each structural unit and two adjacent structural units are connected in the Z direction through a needling process; the three-dimensional woven structure layer is a 2.5D structure layer, a three-dimensional orthogonal structure layer or a fine woven puncture structure layer.

Further, on the basis of the needling process, the Z direction of the whole fabric is strengthened and connected through a sewing process.

Further, the needling structure layer comprises a plurality of needling units, and each needling unit consists of a fiber net tire and/or fiber cloth.

Further, the three-dimensional weaving structure layer is an equal-density fabric or a variable-density fabric.

Furthermore, the density of the variable-density fabric changes along one direction or more than two directions of the thickness direction, the width direction or the length direction, the variable-density three-dimensional fabric is connected through a layer connecting structure, the interfaces of different density areas are connected in an interlayer mode, yarns are continuous, and the variable-density three-dimensional fabric is integrally and continuously woven and formed.

Further, the density of the variable-density fabric is changed along the thickness direction, the width direction and the length direction of the three-dimensional fabric through fabric structure change, yarn type change, yarn fineness change, yarn strand number proportion change, warp density change or weft density change.

Further, the volume density of the three-dimensional weaving structure layer is 0.7-1.3 g/cm³The volume density of the needled structure layer is 0.1-0.9 g/cm³The needling depth is 8-25 mm/needling, and the needling density is 5-30 needles/cm³。

Further, the shape of the multilayer composite structure three-dimensional fabric is cylindrical, flat plate, conical, truncated cone or curved surface.

Further, the multilayer composite structure three-dimensional fabric is made of one or more than two of quartz fibers, glass fibers, carbon fibers, silicon carbide fibers, mullite fibers or silicon nitride fibers.

The preparation method of the multilayer combined structure three-dimensional fabric comprises the following steps:

(1) preparing 2.5D three-way orthogonal or fine-woven three-dimensional woven structure layer fabric according to a set shape;

(2) cutting the needle-punched structural layer fabric with the shape matched with that of the step (1);

(3) laminating the 2.5D and three-way orthogonal or fine-woven three-dimensional knitting structure layer fabric and the needle-punched structure layer fabric according to the set layer number and the combined structure;

(4) and carrying out superposition needling according to the set needling process parameters to form the multilayer combined three-dimensional fabric.

Further, the step (4) includes a step of needling the surface layer and the bottom layer respectively when the needle-punched structure layer is used as the surface layer and the bottom layer of the fabric.

The invention has the beneficial effects that:

1. the multilayer combined structure three-dimensional fabric is formed by laminating one or more of 2.5D, three-way orthogonal and fine-woven three-dimensional knitting structures with a needling structure layer and then implanting fibers in a Z direction of a joint area for interlayer connection through a needling process, and the obtained fabric combines the production characteristics of rapidness and low cost of the needling process and the characteristics of excellent mechanical properties of the 2.5D, three-way orthogonal and fine-woven three-dimensional knitting structure fabric, so that the use requirement of a composite material can be met, and the cost reduction and the efficiency improvement of the production of the composite material can be realized.

2. The invention adopts the combination of the 2.5D variable-density three-dimensional knitted fabric and the needling process, the 2.5D variable-density three-dimensional knitted fabric has the advantages of various organizational structures, large fabric size control range, strong designability, compact structure, good integrity, simple weaving process, suitability for continuous weaving and the like, and the multilayer combined structure three-dimensional fabric formed by the two structures has the advantages of low thermal expansion coefficient, high heat resistance, high specific strength, high specific modulus, impact resistance, wear resistance, ageing resistance and the like, and can be widely applied to the fields of automobiles, aviation, aerospace, mechanical manufacturing, petroleum and the like.

Drawings

Fig. 1 is a schematic partial sectional view showing a three-dimensional fabric of a flat plate-shaped multilayer composite structure including one structural unit according to embodiment 1 of the present invention.

Fig. 2 is a schematic cross-sectional view of a three-dimensional fabric of cylindrical multi-layer composite structure comprising two structural units according to embodiment 2 of the present invention.

Fig. 3 is a schematic cross-sectional view showing a three-dimensional fabric of a double-side needle-punched flat plate-shaped multi-layer composite structure comprising one structural unit according to embodiment 3 of the present invention.

Fig. 4 is a schematic cross-sectional view of a variable density 2.5D structure layer according to embodiment 4 of the invention.

Detailed Description

In order to better understand the present invention, the following examples are further provided to illustrate the present invention, but the present invention is not limited to the following examples.

Example 1

Referring to fig. 1 and 2, the present embodiment provides a three-dimensional fabric with a double-layer flat plate-shaped composite structure, which includes a structural unit, wherein the three-dimensional fabric is a quartz fiber composite fabric, and the shape and size of the three-dimensional fabric are 150 × 15+20 mm. The structural unit consists of a 2.5D structural layer 11 and a needling structural layer; the 2.5D structural layer 11 is a bottom layer of fabric, and has a thickness of 15mm and a bulk density of 0.9g/cm³(ii) a The needling structure layer comprises a plurality of needling units 12 consisting of a layer of quartz fiber five-piece satin cloth 122 and a layer of quartz fiber net tire 121, the thickness of the needling structure layer is 20mm, and the volume of the needling structure layer isThe density was 0.4g/cm³。

The preparation method of the double-layer combined structure three-dimensional fabric in the embodiment 1 comprises the following steps:

(1)2.5 preparation of the structural layer 11:

firstly, selecting 190tex multiplied by 1 strand of high-strength quartz fiber as warp yarn, 190tex multiplied by 6 strand of high-strength quartz fiber as weft yarn, wherein the warp density of the fabric is 9 pieces/cm, and the weft density is 3 pieces/cm;

secondly, determining the total number n of rows of the warp yarns to be 142 rows according to the set width, and determining the total number n of layers of the warp yarns to be 20 layers according to the set thickness;

thirdly, arranging main warp yarns, wherein the arrangement mode of the warp yarns is that the upper layer is 10 layers, the lower layer is 10 layers, 2 heddle eyes are arranged between the upper layer and the lower layer at intervals, adopting a No. 45 reed, enabling every two rows of 142 warp yarns to form a group and sequentially penetrating reed dent, and preparing 2.5D structural fabric according to a heald lifting structure;

(2) horizontally placing the 2.5D structural fabric prepared in the step (1), laying a first needling unit 12 on the surface of the fabric, and according to the needling depth of 15mm and the needling density of 13 needles/cm²Performing needling on the parameters; connecting the 2.5D structural layer 11 with the first needling unit 12 through Z-direction fiber layers;

(3) laying a second needling unit on the surface of the fabric obtained in the step (2); according to the needling depth of 15mm and the needling density of 13 needles/cm²Performing needling on the parameters;

(4) and (5) repeating the step (3) until the last needling unit finishes needling, and finishing the preparation of the three-dimensional fabric of the example 1.

Example 2:

referring to fig. 2, the present embodiment provides a three-dimensional fabric with a cylindrical combined structure, which is composed of an inner structural unit and an outer structural unit, the three-dimensional fabric is a carbon fiber combined fabric, T70012K carbon fibers are implanted in the overall Z direction of the fabric, and the shape and size of the fabric is Φ 150 × (10+15+5+15) × 150 mm. The inner layer structural unit consists of a 2.5D structural layer 21 and a first needling structural layer 22, wherein the 2.5D structural layer 21 is a fabric inner layer with the thickness of 10mm and the volume density of 0.8g/cm³(ii) a The first needling structure layer 22 comprises a plurality of layers with the surface density of 200g/m²Carbon fiber cloth and a layer surfaceThe density is 60g/m²The needling unit consists of a carbon fiber net tire, wherein the thickness of a first needling structure layer 15 is 15mm, and the volume density is 0.5g/cm³(ii) a The outer structural unit consists of a three-way orthogonal structural layer 23 and a second needled structural layer 24, the three-way orthogonal structural layer 23 is laminated on the outer surface of the needled structural layer 22, the thickness of the three-way orthogonal structural layer 23 is 5mm, and the volume density is 0.88g/cm³(ii) a The second needling structure layer 24 consists of a plurality of layers with the surface density of 200g/m²The carbon fiber cloth and one layer of the carbon fiber cloth have the surface density of 60g/m²Carbon fiber net tire; the second needled structure layer 24 has a thickness of 15mm and a bulk density of 0.6g/cm³The second needled structure layer 24 is a face layer of fabric.

The preparation method of the double-layer combined structure three-dimensional fabric implemented in the embodiment 2 comprises the following steps:

(1)2.5D preparation of the structural layer 21, selecting T70012K multiplied by 2 strands of carbon fibers as warp yarns, selecting T70012K multiplied by 2 strands of carbon fibers as weft yarns, and obtaining a warp density of 9 pieces/cm and a weft density of 3 pieces/cm; the total number n of the warp yarns is 4; the inner layer 424 rows and the outer layer 480 rows complete the preparation of the 2.5D structural layer 21 according to the lifting heald structure;

(2) preparation of the orthogonal three-dimensional structural layer 23: selecting T70012K multiplied by 1 strands of carbon fibers as warp yarns, selecting T70012K multiplied by 1 strands of carbon fibers as weft yarns, and obtaining warp density of 8 pieces/cm and weft density of 3 pieces/cm; the total number n of the warp yarns is 5; the inner layer is 502 rows, the outer layer is 528 rows, and the preparation of the orthogonal three-way structural layer 23 is completed according to the organization rule;

(3) horizontally placing the 2.5D structural layer 21 fabric prepared in the step (1), laying a first needling unit of a first needling structural layer 22 on the outer surface of the fabric, and needling the fabric according to the needling depth of 17mm and the needling density of 15 needles/cm²Needling is carried out on the parameters to ensure that the 2.5D structural layer 21 is connected with the first needling unit layer through the Z-direction fiber layer;

(4) laying a second needling unit on the surface of the fabric obtained in the step (3); according to the needling depth of 17mm and the needling density of 15 needles/cm²Performing needling on the parameters;

(5) repeating the step (4) until the last needling unit of the first needling structure layer 22 finishes needling;

(6) in step (5)) Sequentially laying a three-dimensional orthogonal structure layer 23 and a first needling unit of a second needling structure layer 24 on the outer surface of the obtained fabric, wherein the needling depth is 19mm, and the needling density is 12 needles/cm²Needling is carried out on the parameters, so that the three-way orthogonal structure layer 23 is connected with the first needling unit layers of the first needling structure layer 22 and the second needling structure layer 24 through Z-direction fiber layers;

(7) laying a second needling unit of a second needling structure layer 24 on the surface of the fabric obtained in the step (6); according to the needling depth of 19mm and the needling density of 12 needles/cm²Performing needling on the parameters;

(8) repeating the step (7) until the last needling unit of the second needling structure layer 24 finishes needling,

(9) and (3) implanting T70012K multiplied by 2 strands of carbon fibers 25 into the Z direction of the three-dimensional fabric obtained in the step (8) to increase the overall interlayer performance of the fabric, thereby completing the preparation of the three-dimensional fabric of the example 1.

Example 3:

referring to fig. 3, the present embodiment provides a three-dimensional fabric with a double-layer flat plate-shaped composite structure, which includes a structural unit, wherein the three-dimensional fabric is a composite fabric of mullite fiber and quartz fiber, and the shape and size of the three-dimensional fabric are 150 × 20+15+20 mm. The structural unit consists of a fine-woven puncture structural layer 32, a first needling structural layer 31 and a second needling structural layer 33; the first needled structure layer 31 is a bottom layer of fabric, and has a thickness of 20mm and a bulk density of 0.7g/cm³(ii) a The fine-woven puncture structure layer 32 is the middle layer of the fabric, the raw material is mullite fiber cloth, the Z direction is quartz fiber, and the surface density of the fiber cloth is 300g/m²The thickness of the material is 15mm, and the volume density is 0.9g/cm³(ii) a The second needled structure layer 33 is a face layer of fabric having a thickness of 20mm and a bulk density of 0.7g/cm³(ii) a The first needled structure layer 31 and the second needled structure layer 33 have the same structure and comprise a plurality of layers with the surface density of 290g/m²The quartz fiber five-piece satin cloth and one layer of the surface density of the quartz fiber five-piece satin cloth are 60g/m²A needling unit consisting of a quartz fiber web.

The preparation method of the double-layer combined structure three-dimensional fabric in the embodiment 3 comprises the following steps:

(1) preparation of the fine woven puncture structure layer 32: and laminating and pressurizing the mullite fiber cloth, and replacing the Z-direction quartz fiber to finish the preparation of the fine-woven puncture structural layer 32.

(2) Horizontally placing the fine woven puncture structure layer 32 fabric prepared in the step (1), laying a first needling unit of a first needling structure layer 31 on the upper surface of the fabric, and setting the needling depth to be 17mm and the needling density to be 17 needles/cm²The fine knitting puncture structure layer 32 is connected with the first puncture unit layer of the first puncture structure layer 31 through the Z-direction fiber layer;

(3) laying a second needling unit of the first needling structure layer 31 on the surface of the fabric obtained in the step (2); according to the needling depth of 17mm and the needling density of 17 needles/cm²Performing needling on the parameters;

(4) repeating the step (3) until the last needling unit of the first needling structure layer 31 finishes needling;

(5) reversely placing the fabric prepared in the step (4), wherein the first needling structure layer 31 is placed below, and the fine knitting needling structure layer 32 is placed above;

(6) laying a first needling unit of a second needling structure layer 33 on the upper surface of the fabric of the fine-woven needling structure layer 32, wherein the needling depth is 17mm and the needling density is 17 needles/cm²The fine knitting puncture structure layer 32 is connected with the first puncture unit layer of the second puncture structure layer 33 through the Z-direction fiber layer;

(7) laying a second needling unit of a second needling structure layer 33 on the surface of the fabric obtained in the step (6); according to the needling depth of 17mm and the needling density of 17 needles/cm²Performing needling on the parameters;

(8) and (5) repeating the step (7) until the last needling unit of the second needling structure layer 33 finishes needling, and finishing the preparation of the three-dimensional fabric.

Example 4

The structure of the embodiment is basically the same as that of the embodiment 1, and the structure also comprises a structural unit, wherein the structural unit consists of a variable-density 2.5D structural layer and a needling structural layer; the difference is that the structure and the preparation method of the 2.5D structural layer are different from those of embodiment 1, and the structure and the preparation method of the 2.5D structural layer of this embodiment are as follows:

the structure and process parameters of the variable density 2.5D structure layer are shown in table 1 below:

TABLE 1

The preparation method of the variable-density 2.5D structural layer comprises the following steps:

1. arranging the number of warp yarn layers in each density area according to the requirements of the size of the fabric, the weave structure of each area with different density and the density;

2. passing each warp yarn of each layer through a warp yarn tension control device to control the tension of the warp yarns;

3. according to the arrangement of the warp yarn layer number, a first warp yarn of each layer of warp yarn penetrates into a first row of harness wires one by one, and then penetrates into the same reed dent; the second warp of each layer of warp penetrates into the second row of heddles one by one, then penetrates into the same reed dent, and the warp of each layer penetrates into the corresponding heddles one by one according to the rule, and then penetrates into the corresponding reed dent;

4. adjusting the tension of the warp yarns one by one to ensure that the warp yarns meet weaving requirements;

5. according to the requirements of a set fabric weave structure, the heald lifting device starts to circularly move from bottom to top or from top to bottom to drive corresponding warps to circularly move from bottom to top or from top to bottom, and each movement forms an equal-height opening, and the specific movement steps are as follows in sequence:

5.1, separate weaving of an orthorhombic three-way structure of the first density zone 41 in the thickness direction;

5.2, weaving an interface joint 42 of the first density area in the thickness direction and the second density area in the thickness direction, and weaving a shallow cross-linking structure of the second density area 43 in the thickness direction;

5.3, weaving a junction 44 of the second density area in the thickness direction and the interface of the third density area in the thickness direction, and weaving a shallow cross-direct connection structure of the third density area 45 in the thickness direction;

6. after an opening is formed each time, a weft yarn is introduced by a weft insertion device, after the weft insertion is finished, a beating-up device horizontally moves towards a fabric fell, and the weft yarn is beaten into the fell to finish beating-up;

7. and after beating-up is finished, pulling the fabric to a forming direction for a certain distance according to the set weft density of the fabric, and after pulling is finished, carrying out the next motion cycle until the weaving of the whole fabric is finished.

Horizontally placing the prepared 2.5D structural fabric, laying a needling structural layer on the surface of the fabric, and according to the needling depth of 15mm and the needling density of 13 needles/cm²The three-dimensional fabric of example 4 was prepared by the overlap needling.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.