Patent Application
20250129526
This application claims priority to Chinese Patent Application No. 202311361184.X, filed on Oct. 19, 2023, the content of which is incorporated herein by reference in its entirety.
The present application belongs to the field of textile technology and specifically relates to a high-strength and tear-resistant fabric.
As a product branch of fabrics, webbing has long been used as a fastening material and/or sling for securing, binding, or lifting various objects. When such fastening materials and/or slings are used in certain scenarios, such as animal anti-tear restraint webbing or outdoor climbing safety webbing, their outer surface often comes into contact with the teeth of animals or sharp stones. The movement or penetration of teeth or sharp stones on the outer surface of the webbing can cause abrasion, and in severe cases, the webbing can be bitten or torn, leading to animals escaping from the restraint webbing or climbers falling, thereby endangering public safety.
To improve the situation where existing webbing is easily worn, bitten, or torn due to the penetration of sharp objects, single high-strength polyethylene fibers (such as SPECTRA® polyethylene fibers) or aramid fibers (such as KEVLAR® fibers) are often used. However, although webbing made from a single high-strength polyethylene fiber or aramid fiber can meet actual usage requirements beyond expectations, its price is relatively high, resulting in higher production costs, which is unfavorable. On the other hand, to reduce production costs, it is also easy to think of blending high-strength polyethylene fibers or aramid fibers with other lower-priced fibers. However, there are many types of lower-priced fibers available for blending, and it is difficult to determine the blending ratio, resulting in the abrasion resistance and anti-bite, anti-tear performance of the webbing made from the blend usually not meeting expectations.
Given the above-mentioned shortcomings, it is necessary to provide a high-strength and tear-resistant fabric with lower production costs.
The main purpose of the present application is to provide a high-strength and tear-resistant fabric to solve the technical problem of high production costs of webbing made from a single high-strength polyethylene fiber or aramid fiber, or poor determination of the types of lower-priced fibers when blending with high-strength polyethylene fibers or aramid fibers, as well as poor tear-resistant performance of the fabric made after blending.
To achieve the above purpose, the present application proposes a high-strength and tear-resistant fabric comprising:
Furthermore, the elongation of the fabric is about 1% to about 10%.
Furthermore, the polyethylene filament is a high-performance polyethylene filament.
Furthermore, the high-performance polyethylene filament is an ultra-high molecular weight polyethylene filament.
Furthermore, the first fabric yarn is a weft yarn, and the second fabric yarn is a warp yarn.
Furthermore, the second fabric yarn is an untwisted composite yarn.
Furthermore, the core of the untwisted composite yarn is a polyester filament, and the covering yarn is a polyethylene filament, at least partially covering the core.
Furthermore, the core can be composed of at least one polyester filament, and/or the covering yarn can be composed of at least one polyethylene filament.
Furthermore, the surface of the covering yarn is provided with a hydrophobic and oil-repellent coating.
Furthermore, the second fabric yarn can also be a twisted composite yarn.
Furthermore, the polyethylene filament in the twisted composite yarn is at least a single filament, and/or the polyester filament is at least a single filament.
Furthermore, the polyethylene filament and the polyester filament in the twisted composite yarn are twisted in the “S” or “Z” direction.
Furthermore, when the second fabric yarn is an untwisted or twisted composite yarn, the mass percentage of the polyethylene filament in the second fabric yarn is 40% to 57%.
Furthermore, the linear density of the polyethylene filament is 60 to 400 deniers, and the linear density of the polyester filament is 900 to 1000 deniers.
Furthermore, the mass percentage of the polyethylene filament is further 45% to 55%.
Furthermore, the mass percentage of the polyethylene filament is further 49% to 50%.
Furthermore, the mass percentage of the polyethylene filament is further 50%.
Furthermore, in the fabric, the mass percentage of the polyethylene filament is further 20% to 25%.
Furthermore, the fabric is a webbing.
Furthermore, the webbing is a woven webbing or a knitted webbing.
The various aspects of the present application are further described below.
Unless otherwise defined or specified, all professional and scientific terms used in this document have the same meaning as those familiar to skilled practitioners in the field. Furthermore, any methods and materials that are similar or equivalent to those described herein can be applied to the methods of the present application.
Unless explicitly stated and limited, the term “or” used in the present application includes the relationship of “and”. The term “and” is equivalent to the Boolean logic operator “AND”, while the term “or” is equivalent to the Boolean logic operator “OR”, and “AND” is a subset of “OR”.
It should be understood that although terms such as “first”, “second”, etc. may be used herein to describe different components, these components should not be limited by these terms. These terms are merely used to distinguish one component from another. Therefore, the first component can be referred to as the second component without departing from the teachings of the present disclosure.
In the present application, the terms “mainly composed of . . . ” and “composed of . . . ” are included in the terms “comprising”, “including”, or “consisting of”.
Unless otherwise specified and limited, the terms “connected”, “linked”, and “connected” in the present application should be broadly interpreted. For example, it can be a fixed connection or a connection through an intermediate medium, it can be an internal connection within two components or an interaction relationship between two components. For ordinary practitioners in the field, the specific meanings of the above terms in this application can be understood based on specific situations.
For example, if a component (or part) is referred to as being on another component, coupled to, or connected to another component, then the one component can be directly formed on, coupled to, or connected to the other component, or there may be one or more intermediate components between them. Conversely, if the phrase “directly on . . . ”, “directly coupled to . . . ”, or “directly connected to . . . ” is used, it means that there are no intermediate components. Other words used to describe the relationship between components should be similarly interpreted, such as “between . . . ” and “directly between . . . ”, “attached” and “directly attached”, “adjacent” and “directly adjacent”, etc.
It should also be noted that the terms “front”, “back”, “left”, “right”, “top”, and “bottom” used in the following descriptions refer to the directions in the figures. The terms “inner” and “outer” respectively indicate the direction towards or away from the geometric center of a specific component. It should be understood that here, these terms are used to describe the relationship between one component, layer, or region relative to another component, layer, or region as shown in the figures. In addition to the orientations described in the figure, these terms should also include other orientations of the device.
Other aspects of the present application are apparent to those skilled in the art due to the disclosure in this document.
To illustrate the technical solutions of the present disclosure or the prior art more clearly, specific embodiments of the present application will be described below concerning the accompanying drawings. The accompanying drawings in the following description are merely some embodiments of the present application, and ordinary skilled practitioners in the field can obtain other drawings and other embodiments based on these drawings without exerting creative labor.
It should also be noted that the illustrations provided in the following embodiments are only intended to illustrate the basic concepts of the present disclosure. The drawings only show the components related to the present application, rather than the actual number, shape, and size of the components in the actual implementation. The configuration, quantity, and proportion of the components in the actual implementation can be arbitrarily changed, and the layout of the components may be more complex. For example, the thickness of the components in the drawings may be exaggerated for clarity.
Due to the high production cost of fabrics made from single high-strength polyethylene fibers or aromatic polyamide fibers, and the technical problem of difficulty in determining the type of lower-priced fibers when blending with high-strength polyethylene fibers or aromatic polyamide fibers, as well as poor tear resistance of fabrics made from the blended fibers.
To achieve the above objectives, as shown in
In the fabric, the mass percentage of polyethylene filament yarn is not less than 15% and not greater than 50%.
It should be noted that the mass fraction of polyethylene terephthalate (PET) in the polyester filament yarn is greater than 85%. Suitable examples of polyethylene terephthalate for the preparation of polyester filament yarn can be found in U.S. Pat. Nos. 5,235,893B2 and 6,395,386B2.
It should be noted that the term “fabric” describes a structure that can include one or more fiber layers, with or without attachment or consolidation between the multiple fiber layers. The term “filament yarn” refers to long and slender fibers, with length dimensions much greater than the transverse dimensions of width and height. The cross-section of the filament yarn described herein can be circular or non-circular, such as elliptical, with a circular cross-section being the preferred option. The term “composite yarn” refers to a combination of multiple individual filaments, essentially forming a “yarn bundle”, with the individual filaments being filament yarns.
It should be noted that the term “denier (D)” refers to a unit of linear density, equal to the mass (in grams) of fiber per 9000 meters. The “tensile modulus” of a fiber represents the material's resistance to deformation and is expressed as the ratio of strength change in grams per denier (g/d) to the change in strain expressed as a fraction of the original fiber length (inches/inch).
The polyethylene filament yarn and polyester filament yarn should have appropriate linear density. The suitable linear density of the polyethylene filament yarn can be about 40 to 500 denier, or about 50 to 450 denier, or about 60 to 400 denier, or about 70 to 350 denier, or about 80 to 300 denier, or about 90 to 250 denier, or about 100 to 200 denier, or about 110 to 150 denier. The suitable linear density of the polyester filament yarn can be about 600 to 1300 denier, preferably about 650 to about 1250 denier, more preferably about 700 to about 1200 denier, even more preferably about 750 to 1150 denier, still more preferably about 800 to 1100 denier, further preferably about 850 to 1050 denier, and even more preferably about 900 to 1000 denier. In a preferred embodiment, the linear density of the polyethylene filament yarn is about 60 to 400 denier, or about 70 to 400 denier, or about 80 to 400 denier, or about 90 to 400 denier, or about 100 to 400 denier, or about 110 to 400 denier. The linear density of the polyester filament yarn is about 900 to 1000 denier, or about 910 to 1000 denier, or about 920 to 1000 denier, or about 930 to 1000 denier, or about 940 to 1000 denier, or about 950 to 1000 denier.
The minimum tensile modulus of the polyethylene filament yarn is at least 155 g/d, and preferably has a fracture energy of at least about 9 J/g or higher, as measured by ASTM D2256.
For polyester yarn or polyethylene yarn, their corresponding filament yarns have better strength compared to staple fiber yarns, mainly due to the higher continuity of filament yarns, which easily form a tighter fiber structure during processing, thereby improving the strength and tear resistance of the fabric. In contrast, staple fiber yarns have poor interlacing between fibers, making them prone to breakage, which adversely affects the strength of the fabric.
In a preferred embodiment, the elongation of the fabric is about 1% to about 10%.
In a preferred embodiment, the first fabric yarn 1 is the warp yarn, and the second fabric yarn 2 is the weft yarn.
It should be noted that the second fabric yarn 2 is set as the weft yarn in the fabric to provide the desired tensile strength and tear resistance to the fabric, which can be obtained through weaving or knitting. “Weaving” is intended to include any fabric made by interlacing at least two yarns at right angles. Generally, such fabrics are made by interlacing a group of yarns called the warp yarns with another group of yarns called the weft yarns or filling yarns. Woven fabrics can have various weave patterns, such as plain weave, satin weave, twill weave, unbalanced weave, etc. Plain weave is the most common, where the first fabric yarn 1 and the second fabric yarn 2 are woven together in an orthogonal 0°/90° direction. “Knitting” is intended to include structures formed by interlocking a series of loops of one or more yarns using needles or threads, such as warp knitted fabrics (e.g., tricot warp knitted fabric, Milanese warp knitted fabric, or Raschel warp knitted fabric) and weft knitted fabrics (e.g., circular or flat).
In a preferred embodiment, as shown in
In a preferred embodiment, the core of the untwisted multifilament yarn is made of polyester filament yarn, and the wrapping yarn of the untwisted multifilament yarn is made of polyethylene filament yarn, with the wrapping yarn at least partially covering the core.
It should be noted that the use of wrapping yarn is intended to enhance the strength and tear resistance of the untwisted multifilament yarn and provide protection to the core, and the wrapping yarn can be composed of at least a single polyethylene filament yarn to meet the requirements of practical applications.
In a preferred embodiment, when the second fabric yarn 2 is an untwisted multifilament yarn, the mass percentage of polyethylene filament yarn is about 40% to about 57%, more preferably about 45% to about 55%, even more preferably about 49% to about 50%, still more preferably about 50%.
In a preferred embodiment, the surface of the wrapping yarn is coated with a hydrophobic and olcophobic coating.
It should be noted that the polyester filament yarn, as the core, is composed of at least a single polyester filament yarn. This configuration itself is not intentionally designed to provide strength and tear resistance in conjunction with the wrapping yarn. However, the inventors unexpectedly discovered that the fabric containing the aforementioned core yarn and wrapping yarn exhibits excellent strength and tear resistance under certain conditions, which will be described later. Additionally, the hydrophobic and olcophobic coating on the wrapping yarn allows the second fabric yarn 2 to maintain a certain self-cleaning property, making it more convenient to use the fabric. This is especially useful when the fabric is used as an animal anti-tear restraint strap or outdoor climbing safety strap, as it can help prevent stains from adhering to the fabric to some extent.
In a preferred embodiment, the polyethylene monofilament is a high-performance polyethylene filament.
It should be noted that the configuration of the high-performance polyethylene filament allows it to exhibit elastic response to the load applied to the fabric while also limiting the overall stretching of the fabric. The high-performance polyethylene filament is preferably made of a fiber containing ultra-high molecular weight polyethylene (UHMWPE), such as Spectra®, Dyneema®, or Tekmilon™. Suitable examples of ultra-high molecular weight polyethylene for long filament fiber preparation can be found in U.S. Pat. Nos. 4,411,854B2, 4,413,110B2, and 4,422,993B2.
In a preferred embodiment, as shown in
It should be noted that the polyethylene filament and the polyester filament in the second fabric yarn 2 can be twisted together using conventional twisting equipment and techniques, resulting in a double helix structure. The polyethylene filament and the polyester filament used for twisting are each at least a single filament.
In a preferred embodiment, the polyethylene filament and the polyester filament in the second fabric yarn 2 are twisted in either an “S” direction or a “Z” direction. For example, a single polyethylene filament and a single polyester filament are twisted together in an “S” or “Z” direction to form a twisted yarn bundle. It should be noted that twisting can enhance the strength of the twisted yarn bundle.
In a preferred embodiment, the polyethylene monofilament is a high-performance polyethylene filament.
As a preferred embodiment, the second fabric yarn 2 is a twisted multifilament yarn, and when the second fabric yarn 2 is an untwisted multifilament yarn, the mass percentage of the polyethylene filament in the second fabric yarn 2 is about 40% to about 57%, more preferably about 45% to about 55%, even more preferably about 49% to about 50%, and still more preferably about 50%.
It should be noted that the inventors of the present application have also unexpectedly discovered that in the fabric, when the mass percentage of the polyethylene filament is about 20% to 25%, the fabric formed by the second fabric yarn 2 presented in the form of a twisted multifilament yarn or an untwisted multifilament yarn, in conjunction with the first fabric yarn 1, exhibits particularly ideal strength and tear resistance characteristics.
As a preferred embodiment, the fabric is a webbing, particularly an animal anti-tear restraint webbing or an outdoor climbing safety webbing.
It should be noted that currently, polyethylene fibers and aromatic polyamide fibers are more expensive than polyamide fibers and polyester fibers. By adopting the technical solution disclosed in this application, it is possible to maximize the reduction of fabric production costs while ensuring fabric strength and tear resistance performance.
The following examples and comparative examples (taking animal anti-tear restraint webbing as an example) are provided to further illustrate the technical effect of the disclosed technical solution, which can maximize the reduction of fabric production costs while ensuring fabric strength and tear resistance performance.
Note: The sample webbing is referred to as Sample C. The first fabric yarn 1 of Sample C is the warp yarn, which is a 1000 denier polyester filament yarn. The second fabric yarn 2 is the weft yarn, which is a twisted yarn consisting of a 1000 denier polyester filament yarn and a 400 denier polyethylene filament. The width of Sample C is 25 mm, and the thickness is 2.7 mm. The mass percentage of the polyethylene filament in the second fabric yarn 2 is about 50% to 57%, and the mass percentage of the polyethylene filament in the webbing is about 20% to 25%.
Referring to
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample B. The warp yarn of Sample B is a 1000 denier polyester filament yarn, with the same number of warp yarns as in Example 1. The weft yarn is a twisted yarn consisting of a 1000 denier polyester filament yarn and a 400 denier polyethylene filament, with the same number of weft yarns as in Example 1. The width of Sample B is 25 mm, and the thickness is 2.7 mm. The mass percentage of the polyethylene filament in the weft yarn is greater than 57%, and the mass percentage of the polyethylene filament in the webbing is greater than 25%.
Referring to
It should be noted that for pure polyester filament yarn and polyethylene filament yarn, the strength of the polyethylene filament yarn should be lower than that of the polyester filament yarn. However, the inventors unexpectedly found that in Example 1 and Comparative Example 1, increasing the mass percentage of the polyethylene filament in the weft yarn did not result in better tear resistance performance for Sample B compared to Sample C. On the contrary, the test results of Comparative Example 1 were inferior to Example 1.
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample E. Both the warp yarn and the weft yarn of Sample E are made of 400 denier polyethylene filament yarn. The width of Sample E is 25 mm, and the thickness is 2.5 mm.
Referring to
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample A. Sample A is a nylon webbing, with both the warp yarn and the weft yarn made of 390 denier linear density polyamide (Polyamide) filament fibers. The width of Sample A is 25 mm, and the thickness is 2.3 mm.
Referring to
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample D. Both the warp yarn and the weft yarn of Sample D are made of 390 denier nylon/Kevlar filament yarns. The width of Sample D is 25 mm, and the thickness is 2.4 mm.
Referring to
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample F. The warp yarn of Sample F is made of 840 denier nylon/Kevlar filament yarn, and the weft yarn is twisted yarn consisting of 840 denier nylon filament yarn and 400 denier polyethylene filament yarn. The width of Sample F is 25 mm, and the thickness is 2.4 mm.
Referring to
Note: The testing procedure is the same as Example 1. The sample webbing is referred to as Sample G. Sample G is a nylon/polyethylene webbing, with the warp yarn made of 840 denier nylon/Kevlar filament yarn and the weft yarn twisted yarn consisting of 840 denier nylon filament yarn and 400 denier polyethylene filament yarn. The width of Sample G is 25 mm, and the thickness is 2.2 mm.
Referring to
In summary, the test result rating for each sample category is as follows:
Based on this application, those skilled in the art in the relevant field should understand that one aspect described herein can be independently implemented from any other aspect and can be combined in various ways with two or more of these aspects. For example, any number and aspect described in this document can be used to implement the device and/or practice the method. Additionally, structures and/or functional embodiments other than those described in this document can be used to implement the device and/or practice the method.
It should be noted that the above embodiments can be freely combined as needed. The above description is only a preferred embodiment of the present application. It should be pointed out that, for those skilled in the art in this technical field, various improvements and modifications can be made without departing from the principles of the present application, and these improvements and modifications should also be considered within the scope of the present application.
All the references mentioned in this application are cited in this application as references, just as if each reference were cited individually. Furthermore, it should be understood that after reading the above content of the present application, those skilled in the art can make various changes or modifications to the present application, and these equivalent forms are also within the scope defined by the claims attached to this application.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202311361184.X | Oct 2023 | CN | national |
