Four-axis fabric characteristics and application development

Japan’s “Fiber and Industry” recently reported that Mingda Corporation has developed a new fabric “four-axis fabric” under the trade name “Tetras”. This fabric consists of warp yarns, weft yarns, and diagonal yarns consisting of left and right yarns. constitute. The four-axis fabric has morphological stability, impact resistance, tear resistance, uniformity as a composite material, curved surface forming performance, curl resistance, and distortion resistance as compared with a biaxial fabric consisting only of warp yarns and weft yarns. With its extremely characteristic properties, it overcomes some of the weaknesses of the two-axis fabrics and can be used in sports, leisure, civil engineering, transportation, aerospace, medical aid, and energy.

1, development background

The company Mingda Co., Ltd., a development company of "four-axis fabrics," was founded in 1968 in Kurashiki City, Okayama Prefecture. The company has been developing, producing, selling, weaving special wide-thick fabrics for civil-use materials, slings for loading and unloading, and other products, and considering how to survive in the improvement of technological strength and competitiveness in China, Korea, Taiwan Province, and Southeast Asia. The employees united and implemented further fabric development and use research. In order to differentiate itself from other countries and regions, the Asia-based region, including Japan, will implement new product development that meets the requirements of users in the industrial materials field, and will rapidly implement the transfer. The fabric weaving technology developed in the four-axis fabric development technology is recognized by users. It includes special wide-width thick fabrics for use in hoisting and transporting applications, civil engineering, etc., and narrow-width fabrics for the reinforcement of reinforced concrete, and so on. Many aspects of fabric product orders have increased.

With regard to four-axis fabrics, we started with research and development with a view to starting the idea of ​​"manufacturing rattan chairs" in the 1970s and "if this can be automated...". We purchased the old looms at the time and started production of parts based on our own ideas. After about one year, we completed the first machine. Principles can be imaginary looms, but they are far from the mass production machines and continue to be further studied. At that time, the development of the spreader for loading and unloading was also carried out at the same time. The development of the four-axis fabric was temporarily interrupted until there was a spreader track. In the 1980s, the world's first mass-produced four-axis fabric automatic loom was again challenged, and it took about 20 years to undergo trial-production and improvement for many times. Now, four-axis fabric weaving machines have been developed to achieve stable production. Shaft fabric automatic loom. In addition, the four-axis fabric Tetras (Tetras), Tetra-axial (four-axis), and the four-axis woven fabrics have been proposed as a practical production system.

FIG. 1 is a conceptual diagram showing a four-axis fabric. The four-axis fabric is composed of warp yarns, weft yarns, and oblique yarns composed of left and right yarns.

Now, this four-axis fabric has formed a pillar of the company's fabric products. The four-axis fabric can be made of a wide variety of materials such as polyester, nylon, aramid, glass fiber, carbon fiber, or a combination of different materials depending on the content required.

Now, fabrics have been produced that use a variety of materials for warp, weft, and oblique yarns, including warp and weft yarns: polyester processed yarns, diagonal yarns: polyester filaments; warp yarns, weft yarns: vinylon, diagonal yarns: vinylon; warp yarns, weft yarns : Carbon fiber, diagonal yarn: aramid, warp, weft yarn: aramid, diagonal yarn: aramid, etc. We are looking forward to the use of these fibers in the aerospace field, large-scale structure field, clothing/decoration field, interest/hobby industry, construction It is implemented in a variety of applications including structural materials and safety protection.

Figure 1 Conceptual view of a four-axis fabric

2, the mechanical properties of four-axis fabric

In recent years, in the fields of sports, leisure products, audio products, automotive parts, and transportation equipment, composite materials using fabrics have utilized thin-walled, lightweight, high-toughness, impact resistance, morphological stability, and design. Sex and other advantages are used. However, the conventional woven fabric is a biaxial fabric composed of warps and weft yarns, which is easily deformed in the direction of the inclined surface, has a drawback such as poor tear resistance, and is a problem to be solved in the search for the application of a durable material. Therefore, we have developed the world's first mass-produced four-axis fabric automatic loom that has never before been available, and provide such a fabric. Due to the existence of the oblique yarn, it is superior to shape stability, distortion characteristics, and stress homogenization. In the field of aerospace, we can look forward to the use of NASA (United States Aeronautics and Space Agency) and the use of aircraft. It is the technology of the Barry Limerich Corporation. A comparison of the Table 1 and biaxial fabrics shows the characteristics of the four-axis fabric. In terms of the stability of the morphology, 3 impact resistance, and the uniformity of the 4 composites, the evaluation was performed from the difference between the biaxial fabrics and the tetraaxial fabrics. As for the strength change of the morphological stability, the biaxial fabrics were comparatively warped in the warp and weft directions. The morphological change in the direction of migration is significantly larger; the tetraaxial fabric "Teterlaz" is morphologically stable in any direction. From the point of view of damage, the two-axis fabrics are generally destroyed for the first time, and the damage energy is relatively small. After the yarn of the four-axis fabric “Tetras” breaks in the axial direction, the yarns in the direction of the oblique surface are The multi-stage breakage after the breakage, compared with the two-axis fabric, greatly increases the damage energy. For this reason, impact resistance and good stability are characteristics of four-axis fabrics. The two-axis fabrics involved in the stress analysis of laminate fabric materials are different from the four-axis fabric “Tetras”. The two-axis fabrics have negative shear stress in the upper left and lower right parts, and the other parts are positive shear stress effects. Therefore, the stress from the negative to the positive boundary is large and becomes a cause of deformation, wrinkles, and backlash. However, the four-axis fabric "Tetras" has uniform stress and stable morphology.

Table 1 Differences between four-axis and two-axis fabrics

3, the characteristics of four-axis fabric automatic loom

A 4-axis fabric automatic loom consists of a tilted bobbin holder (consisting of a plurality of bobbins or warping shafts) that can rotate in the straight surface of the weaving surface, a device for supplying oblique yarns and warp yarns in the weaving surface, and a weft yarn casting device. Shuttle device, beat-up device, fabric take-up device. The company reconsider the method of providing a diagonal yarn feeder that can turn in the orthogonal plane to the direction of travel of the fabric on an existing loom. The warp threads are inserted into the weft thread between the oblique threads. Thereafter, when one weft yarn is inserted, the oblique yarn is moved left and right to weave the fabric. In the fabric weaving sequence, adjustment of the fabric strength, optimization of the fabric density, setting of the fabric structure, timing of the beating time, accuracy of insertion of the warp yarn holding device, structure of the diagonal yarn transfer device, and practical use were performed. With various improvements such as the realization of horizontal loom speed, we have successfully developed a epoch-making 4-axis fabric automatic loom with a practical level.

The appearance of the developed four-axis loom is shown in Fig. 2. The basic specifications of the four-axis fabric that can be woven are shown in Table 2.

Figure 2 Appearance of a four-axis loom

Table 2 Basic Specification of Weavable Four-Axis Fabrics

4, the use of four-axis fabric development

About the use development of four-axis fabric "Tetras", now, interest in hobby goods in golf club (Mizuno, Mamiya Obi, Japanese club, Fujikura Rubber Industry), tennis (Mizuno), table tennis Sports equipment such as balls and badminton rackets (Mizuno), acoustics such as horn diaphragms (exploitation), and the field of earthquake resistance reinforcement (Sumitomo Forestry) at the time of housing renovation were officially put into practical use. In addition, the project organization started by a research and development team centered on local Chinese localities has begun to develop "low-cost opening and closing tent houses". Therefore, it can be installed at a low cost, and structural development for opening and closing of membrane materials is carried out. As well as the development of tent film materials using thin-walled, tear-resistant properties such as four-axis fabrics, the actual size width model testing machine envisaged has been completed. At present, various data collection and modification of existing problems, such as repeated operation confirmation and pneumatic test, are being performed, and the development of empirical experiments is continuing. In addition, we are carrying out sample supply to many fields and product development utilizing quadrilateral fabric characteristics is further active.

In particular, resin composite materials using high functional fibers such as aramid fibers, glass fibers, and carbon fibers as one of the reinforcing substrates are expected to be highly demanded in the field of transportation and transportation equipment.

5. Future development of four-axis fabrics

The four-axis fabric composed of warp yarns, weft yarns, and left and right oblique yarns has morphological stability, impact resistance, tear resistance, uniformity as a composite material, curved surface forming performance, and curl resistance when compared with two-axis fabrics. Sex, resistance to distortion and other extremely characteristic properties.

Based on these characteristics, applications ranging from the aerospace sector to the residential sector, interest, and hobby fields can be expected. Lightweight, high-strength, and twisted automotive parts and components (such as roofs, doors, engine hoods, and drive shafts), large structural parts (film structure materials such as tents, wind blades, and high-rise buildings) Tunnel repair materials, etc.), Welfare medical field (car seats, bathtubs, nursing nets, waist bust (spine and waist fixation), etc.) In the field of fashion and decoration, on the one hand, characteristic four-axis fabrics are used. As for its characteristics, it also looks forward to its design.In sports related fields (golf clubs, tennis, badminton, table tennis rackets, etc.), the use of characteristics such as twisting, bending, and impact resistance can enhance the stability and dynamic stability of the game. In the field of geotextiles, the use of reinforced materials for civil construction, as well as earthquake-resistant reinforcements in the residential sector, are applications that can be envisaged at this stage. Further, as a promising field in the future, further applications for aerospace materials can be expected. , It is easy to imagine that there are artificial satellite structural materials, solar cell fixing materials, as a pre-development The new composite materials on the way received attention from various parties.

The four-axis fabric "Tetralas" can also be woven from a combination of various materials. As a new fabric material, it can be expected to be widely used in various fields.

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