US4714642A
Expired / Lapsed
US
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Carbon fiber multifilamentary tow which is particularly suited for weaving and/or resin impregnation
Assignee: SUBJECT TO AGREEMENT RECITED SEE DOCUMENT FOR DETAILS
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Filing: 1985-06-27
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Granted: 1987-12-22
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Expires: 2005-06-27
Abstract
Abstract An improved multifilamentary tow of carbon fibers is provided which possesses a novel physical configuration that better enables it to undergo impregnation with a matrix-forming resin to form quality composite articles. The individual filaments of the tow are randomly decollimated and commingled with numerous filament cross-over points throughout the length of the multifilamentary tow in order to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrix-forming resin as evidenced by the ability of the filaments when subjected to the flaring test described herein to resist lateral expansion to a width that is as much as three times the original width. The tow commonly comprises approximately 1,000 to 50,000 filaments. Also, the filaments of the tow are substantially continuous and contain at least 70 percent carbon by weight (preferably at least 90 percent carbon by weight). In a preferred embodiment wherein the resistance to lateral expansion is the greatest, the multifilamentary bundles have been found to be capable of being readily woven with no significant productivity loss to form a quality reinforcing fabric while free of a protective size, such as that which has heretofore been required while weaving carbonaceous multifilamentary yarn bundles of the prior art.
Inventors
- 👤 J. Eugene McAliley
- 👤 Gene P. Daumit
- 👤 Frederick A. Ethridge
- 👤 James R. Crozier, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 23:20
CPC Classifications
D; D03; D03D; D03D9/00; D01; D01F; D01F9/00; D01F9/08; D01F9/12; D01F9/14; D01F9/20; D01F9/21; D01F9/22; D03D15/00; D03D15/20; D03D15/242; D03D15/275; D03D15/40; D03D15/41; D03D15/50; D03D15/573; D10; D10B; D10B2101/00; D10B2101/10; D10B2101/12; D10B2321/00; D10B2321/10; D10B2505/00; D10B2505/02; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24083; Y10T428/24091; Y10T428/24124; Y10T428/24132; Y10T428/24802; Y10T428/24826; Y10T428/30; Y10T442/00; Y10T442/20; Y10T442/2008; Y10T442/2926; Y10T442/2984
Claims Analysis
Total Claims: 66
Claim 1
Independent Claim
144 words
A multifilamentary tow of carbonaceous fibrous material which is particularly suited for use as fiber reinforcement in a resin matrix comprising approximately 1,000 to 50,000 adjacent substantially continuous filaments containing at least 70 percent carbon by weight having a length of at least 100 meters, wherein the individual filaments of said multifilamentary tow are randomly decollimated and commingled with numerous filament cross-over points throughout the length of the multifilamentary tow so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrixforming resin as evidenced by an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as three times the original width as a result of said commingling of adjacent filaments.
Claim 2
Dependent Claim
144 words
A multifilamentary tow of carbonaceous fibrous material which is particularly suited for use as fiber reinforcement in a resin matrix comprising approximately 1,000 to 50,000 adjacent substantially continuous filaments containing at least 70 percent carbon by weight having a length of at least 100 meters, wherein the individual filaments of said multifilamentary tow are randomly decollimated and commingled with numerous filament cross-over points throughout the length of the multifilamentary tow so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrixforming resin as evidenced by an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as three times the original width as a result of said commingling of adjacent filaments.
Claim 3
Dependent Claim
22 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which is formed from approximately 3,000 to 12,000 substantially continuous filaments.
Claim 4
Dependent Claim
17 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which was derived from acrylic filaments.
Claim 5
Dependent Claim
22 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 wherein the filaments contain at least 90 percent carbon by weight.
Claim 6
Dependent Claim
21 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which has a tensile strength of at least 400,000 psi.
Claim 7
Dependent Claim
21 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which has a tensile strength of at least 450,000 psi.
Claim 8
Dependent Claim
21 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which has a tensile strength of at least 500,000 psi.
Claim 9
Dependent Claim
21 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which has a tensile strength of at least 700,000 psi.
Claim 10
Dependent Claim
62 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as two times the original width as a result of said commingling of adjacent filaments.
Claim 11
Dependent Claim
64 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-half times the original width as a result of said commingling of adjacent filaments.
Claim 12
Dependent Claim
64 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-fourth times the original width as a result of said commingling of adjacent filaments.
Claim 13
Dependent Claim
55 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to retain substantially the same width as that originally exhibited as a result of said commingling of adjacent filaments.
Claim 14
Dependent Claim
18 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which is substantially free of a twist.
Claim 15
Dependent Claim
15 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which includes a twist.
Claim 16
Dependent Claim
21 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which is substantially free of a size upon its surface.
Claim 17
Dependent Claim
18 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 which bears a size upon its surface.
Claim 18
Dependent Claim
24 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 wherein the filaments have a denier per filament of approximately 0.2 to 1.5.
Claim 19
Dependent Claim
56 words
A multifilamentary tow of carbonaceous fibrous material according to claim 1 wherein said tow has a generally flattened configuration and a width of approximately 0.02 to 2.0 cm. with the greater widths within the range specified commonly being associated with a multifilamentary tow having a larger number of adjacent substantially continuous filaments within the range specified.
Claim 20
Dependent Claim
29 words
An improved substantially void-free composite article comprising a solid resinous matrix material and at least a portion of the multifilamentary tow of claim 1 incorporated therein as fibrous reinforcement.
Claim 21
Dependent Claim
165 words
A generally flattened multifilamentary tow of a carbonaceous fibrous material which is particularly suited for use as fiber reinforcement in a resin matrix having a width of approximately 0.04 to 1.0 cm. comprising approximately 3,000 to 12,000 adjacent substantially continuous filaments containing at least 90 percent carbon by weight having a length of at least 100 meters, and a tensile strength of at least 400,000 psi, wherein the individual filaments of said multifilamentary tow are randomly decollimated and commingled with numerous filament cross-over points throughout the length of the multifilamentary tow so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrixforming resin as evidenced by an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially unwisted state to resist lateral expansion to a width which is as much as two times the original width as a result of said commingling of adjacent filaments.
Claim 22
Dependent Claim
165 words
A generally flattened multifilamentary tow of a carbonaceous fibrous material which is particularly suited for use as fiber reinforcement in a resin matrix having a width of approximately 0.04 to 1.0 cm. comprising approximately 3,000 to 12,000 adjacent substantially continuous filaments containing at least 90 percent carbon by weight having a length of at least 100 meters, and a tensile strength of at least 400,000 psi, wherein the individual filaments of said multifilamentary tow are randomly decollimated and commingled with numerous filament cross-over points throughout the length of the multifilamentary tow so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrixforming resin as evidenced by an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially unwisted state to resist lateral expansion to a width which is as much as two times the original width as a result of said commingling of adjacent filaments.
Claim 23
Dependent Claim
32 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which is formed from approximately 3,000 substantially continuous filaments and has a width of approximately 0.04 to 0.4 cm.
Claim 24
Dependent Claim
32 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which is formed from approximately 6,000 substantially continuous filaments and has a width of approximately 0.06 to 0.6 cm.
Claim 25
Dependent Claim
31 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which is formed from approximately 12,000 continuous filaments and has a width of approximately 0.1 to 1.0 cm.
Claim 26
Dependent Claim
23 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which has a tensile strength of at least 450,000 psi.
Claim 27
Dependent Claim
23 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which has a tensile strength of at least 500,000 psi.
Claim 28
Dependent Claim
23 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which has a tensile strength of at least 700,000 psi.
Claim 29
Dependent Claim
66 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-half times the original width as a result of said commingling of adjacent filaments.
Claim 30
Dependent Claim
66 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-fourth times the original width as a result of said commingling of adjacent filaments.
Claim 31
Dependent Claim
57 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which exhibits an ability of the filaments of said multifilamentary tow when subjected to the flaring test described herein while in a substantially untwisted state to retain substantially the same width as that originally exhibited as a result of said commingling of adjacent filaments.
Claim 32
Dependent Claim
19 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which is substantially free of twist.
Claim 33
Dependent Claim
17 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which includes a twist.
Claim 34
Dependent Claim
22 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which is substantially free of size upon its surface.
Claim 35
Dependent Claim
20 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 which bears a size upon its surface.
Claim 36
Dependent Claim
26 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 wherein the filaments have a denier per filament of approximately 0.2 to 1.5.
Claim 37
Dependent Claim
24 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 wherein the filaments have a denier per filament of approximately 0.3.
Claim 38
Dependent Claim
24 words
A generally flattened multifilamentary tow of carbonaceous fibrous material according to claim 20 wherein the filaments have a denier per filament of approximately 0.6.
Claim 39
Dependent Claim
29 words
An improved substantially void-free composite article comprising a solid resinous matrix material and at least a portion of the multifilamentary tow of claim 20 incorporated therein as fibrous reinforcement.
Claim 40
Dependent Claim
131 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material which incorporates a plurality of unsized multifilamentary yarn bundles comprising substantially continuous carbonaceous filaments containing at least 70 percent carbon by weight wherein said multifilamentary yarn bundles are randomly decollimated and commingled with numerous filament cross-over points throughout their lengths so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrix-forming resin as evidenced by an ability of the filaments of said yarn bundles when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-half times the original width as a result of said commingling of adjacent filaments.
Claim 41
Dependent Claim
131 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material which incorporates a plurality of unsized multifilamentary yarn bundles comprising substantially continuous carbonaceous filaments containing at least 70 percent carbon by weight wherein said multifilamentary yarn bundles are randomly decollimated and commingled with numerous filament cross-over points throughout their lengths so as to create a multitude of interstices between adjacent filaments which are well adapted to receive and retain a matrix-forming resin as evidenced by an ability of the filaments of said yarn bundles when subjected to the flaring test described herein while in a substantially untwisted state to resist lateral expansion to a width which is as much as one and one-half times the original width as a result of said commingling of adjacent filaments.
Claim 42
Dependent Claim
34 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles are formed from approximately 1,000 to 50,000 substantially continuous filaments.
Claim 43
Dependent Claim
34 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles are formed from approximately 3,000 to 12,000 substantially continuous filaments.
Claim 44
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said substantially continuous carbonaceous filaments contain at least 90 percent carbon by weight.
Claim 45
Dependent Claim
30 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said substantially continuous carbonaceous filaments were derived from acrylic filaments.
Claim 46
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles have a tensile strength of at least 400,000 psi.
Claim 47
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles have a tensile strength of at least 450,000 psi.
Claim 48
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles have a tensile strength of at least 500,000 psi.
Claim 49
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles have a tensile strength of at least 700,000 psi.
Claim 50
Dependent Claim
29 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous material according to claim 38 wherein said multifilamentary yarn bundles are substantially free of a twist.
Claim 51
Dependent Claim
37 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles possess a twist of approximately 0.1 to 1.0 turn per inch when woven.
Claim 52
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said carbonaceous filaments have a denier per filament of approximately 0.2 to 1.5.
Claim 53
Dependent Claim
31 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said carbonaceous filaments have a denier per filament of approximately 0.3.
Claim 54
Dependent Claim
31 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said carbonaceous filaments have a denier per filament of approximately 0.6.
Claim 55
Dependent Claim
65 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles when subjected to the flaring test described herein while in a substantially untwisted state resist lateral expansion to a width which is as much as one and one-fourth times the original width as a result of said commingling of adjacent filaments.
Claim 56
Dependent Claim
55 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles when subjected to the flaring test described herein while in substantially untwisted state retain substantially the same width as that originally exhibited as a result of said commingling of adjacent filaments.
Claim 57
Dependent Claim
31 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles are woven in a plain weave configuration.
Claim 58
Dependent Claim
31 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles are woven in a satin weave configuration.
Claim 59
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 55 wherein said multifilamentary yarn bundles are woven in a five harness satin weave construction.
Claim 60
Dependent Claim
33 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 55 wherein said multifilamentary yarn bundles are woven in an eight harness satin weave configuration.
Claim 61
Dependent Claim
34 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles were woven while unsized by use of a shuttleless loom.
Claim 62
Dependent Claim
34 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 58 wherein said multifilamentary yarn bundles were woven while unsized by use of a rapier loom.
Claim 63
Dependent Claim
34 words
An improved woven fabric suitable for use as fibrous reinforcement in a resinous matrix material according to claim 38 wherein said multifilamentary yarn bundles were woven while unsized by use of a shuttle loom.
Claim 64
Dependent Claim
30 words
An improved woven substantially void-free composite article comprising a solid resinous matrix material and at least one layer of the fabric according to claim 38 incorporated therein as fibrous reinforcement.
Claim 65
Dependent Claim
43 words
An improved woven substantially void-free composite article according to claim 61 wherein said solid resinous matrix material is a thermoset resin selected from the group consisting of epoxy resins, polyimide resins, bismaleimide resins, vinylester resins, unsatuted polyester resins, and mixtures of the foregoing.
Claim 66
Dependent Claim
46 words
An improved woven substantially void-free composite article according to claim 61 wherein said solid resinous matrix material is a thermoplastic selected from the group consisting of polyether-etherketone resins, polyphenylenesulfide resins, polysulfone resins, saturated polyester resins, polyamide resins, polyamideimide resins, polyetherimide resins, and mixtures of the foregoing.
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USPTO Annuity & Maintenance Windows
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| 7.5 Years (Year 8) | 1994-12-21 | 1995-06-22 | 1995-12-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-12-21 | 1999-06-22 | 1999-12-22 | $7700.00 | Window Closed / Lapsed |