The present subject matter described herein, in general, relates to the field of multilayer reinforced fabrics. More particularly, the present subject matter relates to super finish multilayer fiberglass fabric without visible pattern.
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Glass fiber is a material consisting of numerous extremely fine fibers of glass generally termed as glass roving/threads. These roving/threads are generally warp knitted together and converted into a fabric. The roving/thread are fed to warp-knitting machine and each end of the roving/treads are passed through a needle. The knitting elements form loops and bind the warp yarns together. Further polyester yarns are used to stitch the layers together.
Another way of fabricating glass fiber involves needle punching as a nonwoven process by which the fibres are mechanically entangled to produce a nonwoven fabric by repeated penetration of barbed needles through a preformed dry fibrous web. In the process the needle board is mounted on a beam which is given an up and down reciprocating motion by means of an eccentric crank mechanism. As a result, the fibers are mechanically interlocked, thereby providing the mechanical strength.
Further to produce multilayer fabric like Glass Fibre Reinforced Polymer (GFRP), conventionally the Polyester Spun lace Veil would be stitched over a layered fiberglass roving. In accordance with the exemplary prior disclosure the fiberglass fabrics like Chopped Strand Mat (CSM) is stitched together with surface veils, and non-woven core layers using polyester texturized yarn. Since the surface veil is stitched with the glass fibre stitching marks are left on the final product which are visible on closer look. Further stitching process takes additional time after needling process which increases the cycle time, and mechanical strength of product around stitched portions may be poor due to stress concentration adding to fatigue failure and thus reducing lifespan of the product.
Further for better resin infusion it is important to ensure high flowability, less resistance and drag of the materials. These aspects are also important from point of view to better moldability and shaping of glass fibre materials.
From the aesthetic perspective the visibility of the stitching pattern on the GFRP surface impacts the applicability of GFRP where surface finish of the machine or the object is most important for better performance and less resistance and drag due in high speed application for e.g., high end products like super cars, Tanks or Vessels and Pipes, Filament winding profiles, Automotive Parts, Amusement Sector, Wind energy (blades and nacelle covers) etc. matrix and reinforcement.
Thus, there is a long-standing need for an improved process to produce Bonding of Multilayer Fiberglass Fabric without stitching that alleviates the aforementioned-technical challenges/drawbacks.
This summary is provided to introduce the concepts related to a process and product enabling super finish for Glass Fibre Reinforced (GFR) by bonding multilayer fiberglass fabric without stitching and the concepts are further described in the detail description. This summary is not intended to identify essential features of the claimed subject matter, nor it is intended to use in determining or limiting the scope of claimed subject matter.
In one implementation process of obtaining a super finished fiberglass fabric is disclosed. The method for the process as disclosed may comprise a selection of first fabrics. Further selecting a second non-woven fabric. Selecting a veil. Further positioning the first fabric, the second non-woven fabric and a veil such that the veil encloses the first fabric and the second fabric. The first fabric, the second non-woven fabric and the veil are fed into a set of rollers, wherein the feeding is done such that all the three fabrics are stretched to have tension. Further needle punching the three layers together enabling entanglement of the threads of the three layers.
In another implementation of the present disclosure a method for bonding multiple layers of non-woven fiberglass fabric without stitching is disclosed. The method comprising step of selecting at least two material from chopped strand mat, veil, woven roving, and/or Polypropylene core, wherein the areal weight of the at least two selected material is in the range of 40 g/m2 to 1000 g/m2. Further mounting a first material on a first roll stand and a second material on a second roll. The first material is selected from veil, Polypropylene core, or chopped strand mat, and second material is selected from chopped strand mat, Polypropylene core, or woven roving. The method as disclosed further comprises punching the at least one first material over the at least one second material using a plurality of needles in the needle punch to bond the material together, wherein the needle punching bonds the multiple layer by mechanical entanglement of the thread.
In another implementation of the present disclosure a method for another exemplary embodiment for bonding multiple layers of non-woven fiberglass fabric without stitching is disclosed. In accordance with the exemplary embodiment at least one first material is mounted on a first roll stand, wherein the at least one first material is selected from veil, Polypropylene core, or chopped strand mat, wherein areal weight of the at least one material is in the range of 40 g/m2 to 450 g/m2. Further in accordance with the embodiment the method comprises mounting at least one second material on a second roll stand. The at least second material is selected from chopped strand mat, Polypropylene core, or woven roving, wherein areal weight of the at least one material is in the range of 180 g/m2 to 1000 g/m2. The at least one first material and the at least one second material is simultaneously fed in to an input roller. The input roller is configured to press together the at least one first material and the at least one second material, and is advanced towards a needle punch. The method further comprises punching the at least one first material over the at least one second material using a plurality of needles in the needle punch to bond the material together, wherein the needle punching bonds the multiple layer by mechanical entanglement of the thread.
The detailed description is described with reference to the accompanying figures. In the Figures, the right-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
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In one embodiment the method (600) may comprise post-processing (603) which may further comprise processes such as winding, in which the output product may be winded either manually or automatically. further, the post processing (603) may involve packing and palletizing which may comprise that the processed output from the processing (602) step is packed and palletized in accordance with quality requirements. Further, the post-processing (603) may comprise dispatching, wherein the final product is dispatched at delivery station.
In another embodiment of method (600), raw materials may be Polyester veil with areal weight 40 GSM and Chopped Strand Mat (CSM) with areal weight 450 GSM. Therefore, total areal weight is 490 GSM. First, polyester veil may be loaded and set in first roll stand. Next, CSM may be loaded and set in second roll stand. Further, layer sequence may be maintained as follows:
Further, both layer insert in top and bottom input roller for process. Further, needle punching at top input side needle board and top output side needle board may be started. Further, both bottom needle board may be stationary. Here, needle number 36 may be used and 2 punching boards may be working in single side at top. Further, draft may be maintained around −5% between input roller and output roller. Further, single side needle punching may be carried out at single side rpm 586. Further, punching density may be maintained at 230 stock/min maintained. Further, line speed at 3.6 meter/min is maintained. Further, both of two layers may bind by needle punch. After the process is completed manual winding may be done to wind the product. Further, winded rolls may be edge cut by slitter machine while maintaining width of rolls 1250 MM or any desired size. Further, finished rolls are packed with roll number, batch number and wrapped in plastic. Further, finished rolls are ready for dispatch.
In another embodiment of method (600), raw materials may be Polypropylene core (PP core) with areal weight 180 GSM core and Chopped Strand Mat (CSM) with areal weight 450 GSM. Further, Polypropylene core may be loaded first set in first roll stand. Therefore, total areal weight is 630 GSM. Next, CSM may be loaded set in second roll stand. Further, Layer sequence may be maintained as follows;
Further, two layers may be insert in first top and bottom input roller for process. Further, top input side needle board punching may be started and bottom input side needle board may be stationary. Further, at output side top and bottom needle boards may be stationary. Here needle number 36 may be used and 1 needle board punching at top single side is working. Further, draft may be maintained at −10% between input roller and output roller. Further, needle punching on single side is at 406 RPM. Further, punching density may be maintained at 80 stock/min. Further, line speed may be maintained at 7.1 meter/min. Further, both the two layers are binding by needle punch. After the process is completed manual winding may be carried out. Further, winded rolls may be edge cut by slitter machine with rolls width 1250 MM or any desired size. Further, finished rolls are packed with roll number, batch number and plastic wrap. Finally, the finished rolls are ready for dispatch.
In yet another embodiment of method (600), raw materials at input may be Chopped Strand Mat (CSM) with areal weight 450 GSM and polypropylene core (PP core) with areal weight 180 GSM and another Chopped Strand Mat (CSM) with areal weight 450 GSM. Therefore, total areal weight is 1080 GSM. Further, tolerance may be maintained at +/_10%. Initially, first Chopped Strand Mat (CSM) may be loaded and set in first roll stand. Next, polypropylene core may be loaded and set in second roll stand. Further, CSM may be loaded and set in third roll stand. Further, layer sequence may be maintained as follows:
Further, all three layers may be inserted in first top and bottom input roller for process. Further, punching may start at top input side needle board and bottom input put side needle board. Both output needle boards may be stationary. Here, needle number 36 may be used and 2 needle boards may be used for punching on both side. Further, draft maintain (−10%) between input roller and output roller. Further, needle punching speed on single side may be maintained at 496 RPM. Further, punching density may be maintained at 80 stock/min. Further, line speed 8.7 meter/min. Further, all three layers may be binding by needle punch. After completion of the process by manual winding may be carried out. Further, winded rolls may be edge cut by the slitter machine with rolls width of 1250 MM or any desired size. Further, finished rolls may be packed with roll number, batch number and plastic wrap. Finally, finished rolls are ready for dispatch.
In another embodiment of method (600), raw materials may be Chopped Strand Mat (CSM) with areal weight 450 GSM, Polypropylene core (PP core) with areal weight 180 GSM, and Woven Roving with areal weight 832 GSM. Therefore, total areal weight is 1462 GSM. Further, CSM is loaded first set in first roll stand. Next, Polypropylene core (PP core) is loaded and set in second roll stand. Further, loading third Woven Roving 832 GSM set in third roll stand. Further, the layer sequence may be maintained as follows
Further, all three Layer insert in first top and bottom input roller for process. Further, top input, bottom input and top output, bottom output side needle board punching start. All needle board are working. Here, needle number 36 may be used and 4 needle boards may be used for punching on both sides. Further, draft may be maintained at −5% between input roller and output roller. Further, on both side needle punching is done at 582 RPM. Further, punching density may be maintained at 120 stock/min. Further, line speed may be maintained at 4.5 meter/min. Further, all three layers are binding by needle punch. After the process completed the manual winding may be. Further, winded rolls may be edge cut by slitter machine with rolls width at 1250 MM or any size desired. Further, finish rolls are packed with roll number, batch number and plastic wrap. Finally, the final product is ready for dispatch.
Now, in one embodiment of method (600) raw materials at input may be Chopped Strand Mat (here onwards CSM) with areal weight 450 Gram per square meter (here onwards GSM) and Woven Roving with areal weight 832 GSM. Therefore, total areal weight is 1282 GSM. First, the Chopped Strand Mat (CSM) may be loaded and set in first roll stand. Next, Woven Roving may be loaded and set in second roll stand.
Further, layer sequence may be maintained as follows:
Further, above two layers may be inserted in first top and bottom input roller for processing. Further, needle punching may start at top input, bottom input and top output, bottom output sides by needle boards. Further, it is ensured that all needle boards are working. Here, needle number 36 may be used and 4 needle boards are needle punching on both sides. Further, draft may be maintained around −5% between input roller and output roller. Further, needle punching may be carried out at both sides speed of 412 rpm. Further, punching density may be maintained at 120 stock/min. Further, line speed may be maintained at 4.8 meter/min. Further, two layers are binding by needle punching. After the process is completed manual winding may be carried out. Further, rolls edge may be cut by slitter machine with rolls width of 1250 mm or any desired size. Further, finished rolls may be packed with roll number, batch number and plastic wrap. Further, the finished rolls may be ready for dispatch.
In all the embodiments explained above needles mounted on needle board. Each needle may be of specific dimension like diameter, height and number of barbs for example. A needle number 36 may have following dimensions may have 0.7 MM thickness and 6 number of barbs and 3 inch height. Further, each needle board may comprise 15000 or more needles depending on requirements by clients. Further, in all above embodiments bonding mechanisms may be mechanical or chemical or solvent based or resin based bonding agents which may be reactive or non-reactive in nature. Reactive bonding agent may be chemicals which undergo reactions upon bonding with it's constituents or the fabric layers and non-reactive bonding agents may be those which do not react with it's constituents or with the fabric they are interacting with.
In all the embodiments explained above the width of rolls may vary from 0.5 meters to 2.5 meters or any desired size as per requirements of clients.
The embodiments illustrated, especially related to the production of GFRP has following advantages:
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For limiting the scope of the invention, a subsequent Complete Specification will be filed to determine the true scope and content of this disclosure.
The present application claims priority from U.S. provisional Patent Application No. 63/254,530 filed on Oct. 11, 2021.
Number | Date | Country | |
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63254530 | Oct 2021 | US |