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Title:
A DOUBLE-LAYER ELASTIC FABRIC REFLECTING BROAD-SPECTRUM ELECTROMAGNETIC WAVE AND A PRODUCTION METHOD THEREOF
Document Type and Number:
WIPO Patent Application WO/2016/084030
Kind Code:
A1
Abstract:
The present invention relates to an electromagnetic wave reflecting elastic fabric with double-layer which reflects electromagnetic waves and a method (100) for producing this fabric. The method comprises producing a plied yarn comprising metal fibers or a metal filament, and synthetic or natural fibers or a synthetic filament (101, 102), and attaching said plied yarn to an elastic base fabric by embroidery (104).

Inventors:
BAYRAMOĞLU EVREN ÇAĞLIM (TR)
TÜRETKEN BAHATTIN (TR)
ÖZBEY NURETTIN (TR)
Application Number:
PCT/IB2015/059151
Publication Date:
June 02, 2016
Filing Date:
November 26, 2015
Export Citation:
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Assignee:
TUBITAK (TR)
International Classes:
D02G3/12; D02G3/44; D05C17/00
Domestic Patent References:
WO2004110125A22004-12-16
WO1992011899A11992-07-23
WO2010033093A12010-03-25
Foreign References:
EP1367601A12003-12-03
JP2011122290A2011-06-23
EP0644283A11995-03-22
JP2003003313A2003-01-08
DE102008036101A12010-02-11
US3882667A1975-05-13
KR101334878B12013-11-29
GB1258943A1971-12-30
US4528229A1985-07-09
US4764779A1988-08-16
US4987848A1991-01-29
EP1100300A22001-05-16
US20050229579A12005-10-20
US20100186155A12010-07-29
CN202450228U2012-09-26
US20040023576A12004-02-05
Other References:
KLAUS-PETER WEBER ET AL: "Wirkerei und Strickerei", 1 January 2004 (2004-01-01), pages 9,196,197, XP055250749, ISBN: 978-3-87150-792-2, Retrieved from the Internet [retrieved on 20160217]
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Claims:
CLAIMS

A method (100) for producing a double-layer electromagnetic wave reflecting fabric which reflects the electromagnetic waves coming over it; characterized by steps of:

creating yarns by folding together and combining metal staple or continuous mono or multi-filaments with staple or continuous mono or multi-filament synthetic fibers or yarns obtained by natural fibers (101); providing a certain twist to the created yarns so that the yarns can be embrodered without breaking of the yarns (102);

creating bobbins from the twisted yarns obtained (103);

inserting the created coils into the brode machine (104);

embrodering the yarns to an elastic surface in a certain stitch density according to size of electromagnetic wave desired to be reflected (105); and

carrying out fixing process so as to provide structural stability to the obtained surfaces (106).

A method (100) according to Claim 1, characterized by the step of creating yarns from various metals and alloys with high reflectivity characteristic such as stainless steel, silver, copper; or combining synthetic yarn, strip or copper metal monofilaments coated with metals having high reflectivity characteristic such as silver (101).

A method (100) according to Claim 1 or 2, characterized by the step of creating yarns by combining staple metal fibers or metal mono or multifilaments withnatural or staple, mono, multifilament synthetic fibers (101).

A method (100) according to Claim 3, characterized by the step of creating yarns by combining metal mono or multifilaments having circular cross section, with natural or staple or continuous mono or multifilament synthetic fibers (101).

5. A method (100) according to Claim 4, characterized by the step of applying process of twisting (102) to the yarns which are created by spinning stainless steel fibers by another textile fibers in a staple form or combining the yarn obtained from staple stainless steel fibers with natural or staple or continuous synthetic fibers (101) in order that they can be embrodered without breaking of.

6. A method (100) according to Claim 5, characterized by the step of embrodering yarns created by combining staple metal fibers or metal mono or multifilaments with natural or staple, mono, multifilament synthetic fibers to the elastic surface (105).

7. A method (100) according to Claim 6, characterized by the step of creating yarns by combing strips having metal coating on thereof, natural or synthetic textile fibres with staple or continuous mono or multifilament fibers or natural fibers (101).

8. A double-layer, elastic and electromagnetic wave reflector fabric which reflects the electromagnetic waves coming over it;

characterized by an elastic surface which is embrodered by combining metal staple, mono or multifilaments and natural or man-made textile fibers with staple or continuous mono or multi-filament fibers or natural fibers and whereon yarns with a certain twist on thereof are processed.

9. A fabric according to Claim 8, characterized by an elastic surface whereon the yarns having a certain twist on thereof and created by combining metal mono or multifilaments having circular cross section with natural or staple, mono, multifilament synthetic fibers are processed.

10. A fabric according to Claim 8 or 9, characterized by yarns density of which on the elastic surface can be adjusted according to the electromagnetic wave size desired to be reflected.

11. A fabric according to Claim 10, characterized by yarns which are created from various metals and alloys with high reflectivity characteristic such as stainless steel, silver, copper; or combining synthetic yarn, strip or copper metal monofilaments coated with metals having high reflectivity characteristic such as silver.

12. A fabric according to Claim 11, characterized by yarns which are created by combining staple metal mono or multifilaments with discontinuous or continuous mono or multifilament synthetic or natural fibers

13. A fabric according to Claim 12, characterized by ribbons coated with metals which are created by combining discontinuous or continuous mono or multifilament synthetic or natural fibers .

Description:
DESCRIPTION

A DOUBLE-LAYER ELASTIC FABRIC REFLECTING ELECTROMAGNETIC WAVES WITH WIDE BAND SPECTRUM AND A PRODUCTION METHOD THEREOF

Technical Field

The present invention relates to a double-layer elastic fabric which reflects electromagnetic waves at acceptable level and a production method of this fabric.

Background of the Invention

Electromagnetic waves are microwaves which are emitted to the environment during operation of electronic devices such as mobile phones, mobile phone signal transmitters, modems etc. Microwaves are utilized in search-rescue and detection operations for civil or military purposes. Effects of electromagnetic waves, which are known to be hazardous on human health, created a need for searching ways to keep safe from them. In order to be protected against harms of these waves, materials having characteristic of reflecting or absorbing electromagnetic waves are used. Because of their electrical conductivity characteristics, metals reflect electromagnetic waves back. This characteristic of metals is used for protecting human against harmful effects of electromagnetic waves or producing materials suitable for use under other circumstances wherein it is desired to reflect electromagnetic waves. Materials with metal content, which are produced for the purposes mentioned above, can be either layers, plates, foils comprising metal or metal-coated fabric or similar textile surfaces as well. However, materials with metal content being used for the above-mentioned purposes are multi-layered and heavy and they cannot provide reflection in a broad-spectrum frequency range. In the state of the art, it is known to use elastic yarns in fabrics having electromagnetic reflection characteristic as well. In the said fabrics, a surface is formed by processing metallic wires together with elastic-featured yarns side by side. However, due to the fact that it is lower than the elastic-featured yarns, elasticity of metal wires in the said fabrics cannot exhibit elasticity characteristic of the obtained fabric even if they are turned into surface with weaving or knitting method by being co-processed.

The Great Britain patent document no. GB1258943, an application in the state of the art, discloses a fabric for hiding from radar. The hiding phenomenon mentioned in the said patent document is to prevent an object, which is scanned by radar, from being seen by a material having a reflection close to the radar reflection around the material to be hidden. A nonwoven surface which is produced from metallic fibers made of aluminium is used and reflection characteristic of the target scanned by radar is changed in the invention disclosed in the document.

The United States patent document no. US4528229 is another application in the state of the art. In a similar way to the Great Britain patent document no. GB1258943, the said document also discloses a camouflage material for performing hiding by taking advantage of reflection characteristic of metals. It is disclosed that the metal yarns used in the said document consist of metal staple fibers or metal-coated synthetic yarns.

Whereas the United States patent document no. US4764779 discloses a parabolic antenna. The antenna structure and also the yarn and fabric structures used for producing the antenna are mentioned in the document. In the said document, the fabric used for antenna production is made of a yarn with special structure (metal ribbons are composed by being wound around a yarn located in the axis of the yarn) obtained by using fibers produced in the form of metal ribbon. The United States patent document no. US4987848 discloses a fabric which has radar reflecting characteristic and made of a nylon fiber coated with silver. The said fabric has rip-stop structure and the fibers used for fabric production are metallized by means of coating.

The International patent document no. WO2004/110125 discloses that electromagnetic shielding is provided by coatings which have electrical conductivity.

The International patent document no. W092/11899 discloses that wires of electrolytic copper-cadmium metal are wound spirally over a polyester or another kind of insulating material. It is disclosed in the document that the net, which is composed by the yarns produced in this way, and the silver-coated sheet are associated upon being placed between woven or non-woven fabric or two different insulating materials.

The European Patent document no. EP1100300 discloses a fiber structure which composes fabric for electromagnetic wave shielding. It is mentioned that there is at least 15% by weight of phenol resin in the fiber structure and this also provides an excellent fire retardancy.

The United States patent document no. US20050229579 discloses a yarn and fabric suited for shielding of electromagnetic by reflectance. The said document discloses a special composition of metallic and textile fibers and the metallic fibersforming the yarns are cut in a length between 20 and 80 mm. Natural or Man-made fibers pieced together with these fibersare again discontinuous fibers and their lengths vary between 50 and 100 mm. It is disclosed that cuts of metallic fibers are between 0.1 and 1 mm, while diameters of the textile fibers are between 0.1 and 2 mm. The International patent document no. WO2010/033093 discloses a knitted fabric structure with at least 3 layers wherein one of them is coated with an allow comprising silver, palladium, and rhodium nanoparticles and the other one includes conductive polypropylene fibers. In the said document, conductivity characteristics is provided by means of metal coating.

The United States patent document no. US2010/0186155 discloses structures of fabrics which can be used for clothing and a protective garment which will be used for electromagnetic field.

The Chinese patent document no. CN202450228 discloses an anti-electrostatic fabric which has characteristic of electromagnetic waves shielding. Metal wires and mono-filament are used in the said fabric.

In the United States patent document no. US2004/0023576A1, a fabric with electromagnetic characteristic is obtained by being woven in a flat knitting machine together with metal wires as two layered. It is disclosed that yarns used when composing the surfaces can be modified by using elastic yarns.

Summary of the Invention

An objective of the present invention is to realize a double-layer elastic fabric reflecting broad-spectrum electromagnetic wave which is lightweight, flexible and wearable and a production method of this fabric.

Another objective of the present invention is to realize a double-layer elastic fabric reflecting electromagnetic wave which has high reflectivity that does not change in broad frequency spectrum and a production method of this fabric.

Another objective of the present invention is to realize a double-layer elastic fabric reflecting electromagnetic wave which is quite close to Perfectly Electrically Conducted (PEC) metal plate reflectivity, easy-to-fab ricate and cost- effective and a production method of this fabric.

Another objective of the present invention is to realize a double-layer elastic fabric reflecting electromagnetic wave any desired region of which has been provided with electromagnetic reflectance at desired size and a production method of this fabric.

Another objective of the present invention is to realize a double-layer elastic fabric reflecting electromagnetic wave which does not lose its electromagnetic reflectance characteristic because of environmental effects and a production method of this fabric.

Detailed Description of the Invention

"A double-layer elastic fabric reflecting broad-spectrum electromagnetic wave and a production method thereof realized to fulfill the objectives of the present invention is shown in the figure attached, in which:

Figure 1 is a flow chart of the inventive method.

The inventive method (100) comprises steps of:

creating yarns by laying together and combining metal staple or continuous mono or multi-filaments, natural or man-made textile fibers with staple or continuous mono or multi -filaments or yarns obtained by natural fibers and (101);

providing a certain twist to the created yarns so that the yarns can be processed without breaking of the yarns (102);

creating bobbins from the twisted yarns obtained (103);

inserting the created bobbins into the brode machine (104); embrodering the yarns to an elastic surface in a certain stitch density according to size of electromagnetic wave desired to be reflected (105); and

carrying out fixing process so as to provide structural stability to the obtained surfaces (106).

In the elastic electromagnetic wave reflecting fabric developed by the present invention, reflectance characteristic is preferably obtained by means of stainless steel monofilament. In order to provide high-reflectance, fabrics are created by laying together stainless steel monofilaments with yarns obtained by a synthetic mono or multifilament or natural fibers (folding process) (101) and a certain twist is providing to the created yarns in order that they do not break of while being embrodered (102). Bobbins are created from the twisted yarns (103) and the bobbins are inserted into the brode machine (104). Afterwards, yarns are processed on an elastic surface in a certain stitch density according to size of electromagnetic wave desired to be reflected (105) and fixing process is applied to the obtained surface so as to provide structural stability (106) as the final step. With the method developed by the present invention, due to the fact that a yarn with %100 metal characteristic is used instead of coating, a fabric resistant to environmental conditions is obtained and use of fabric is provided for the purpose of technical textile. Usage areas of the fabric for electromagnetic reflectivity are enlarged with processing the metal yarn to an elastic surface in a desired density. Due to the fact that an electromagnetic reflectivity characteristic is given to an elastic surface, it is ensured that a surface desired to be given characteristic for protection against electromagnetic waves and electromagnetic camouflage is coated with the said fabric. In addition, it is possible with the elastic characteristic to stretch the surface wherein application is carried out in a crease-free and smooth form. Textile surfaces, which are given electromagnetic reflectivity by weaving and knitting methods, crease easily because of fabric structure and surface defects may occur in the surface wherein application will be carried out. In addition to this, it is ensured to use a fabric at interior and outdoor applications due to the fact that the fabric is obtained in a large width in a brode machine. Width of the fabric can be adjusted according to the size of the place where it will be used before production.

In embodiment of the invention, twisting process (102) is applied to the yarns which are created by spinning stainless steel by another textile fibersin a staple form or laying together the yarn obtained from staple stainless steel fibers with natural or staple or continuous synthetic fibers (101) in order that they can be processed without breaking of.

In another embodiment of the invention, metal filaments are preferably made of metals and alloys with high reflectivity characteristic such as stainless steel, silver, copper or other various metals; or wires such as synthetic yarn, strip or copper coated with metals having high reflectivity characteristic such as silver. Depending intended use, bobbin can be also obtained upon being twisted with metallic fibers, other synthetic or natural fibers or yarns made of them as well (103). Besides, other fibers or yarns with other metallic characteristic can be used in the fabric instead of stainless steel. In another embodiment of the invention, surfaces can also be used as electrical conductive surfaces required for production of electronic textiles.

In another embodiment of the invention, the yarns having a certain twist on thereof and created by combining metal mono or multifilaments having circular cross section and natural or synthetic textile fibers with staple or continuous mono or multifilament fibers are embrodered to elastic surfaces (105).

The fabric produced with the inventive method (100) comprises an elastic surface wherein yarns created by combining metal staple, mono or multifilaments and natural or synthetic textile fibers with staple or continuous mono or multifilament fibers; and having a certain twist on thereof are processed. In a preferred embodiment of the invention, the fabric comprises an elastic surface wherein yarns created by combining metal mono or multifilaments having circular cross section on thereof and natural or synthetic textile fibers with staple or continuous mono or multifilament fibers, and have a certain twist on thereof are embrodered.

In another preferred embodiment of the invention, the fabric comprises metal yarns density of which on the elastic surface can be adjusted according to the electromagnetic wave size desired to be reflected.

In another preferred embodiment of the invention, the fabric comprises yarns made of various metals and alloys with high reflectivity characteristic such as stainless steel, silver, copper or by combining synthetic yarn, strip or copper metal monofilaments coated with metals having high reflectivity characteristic such as silver.

Fabrics obtained in this way can also be used as apparel fabric because of their elastic characteristic.

Due to the fact that the fabric is produced such that it will contain 100% metal such as 100% stainless steel wires etc., electromagnetic reflectivity characteristic of this fabric is resistant to environmental conditions.

Due to the fact that the fabric, which is produced in a structure to prevent transition of electromagnetic at desired size, has metal characteristic; it reflects the waves received on thereof back and thus, this reflectivity characteristic of the fabric can be utilized so as to be seen by radar in search-rescue operations carried out by radar as well. The fabric can be used for the purpose of protection against magnetic radiation diffusion of devices such as mobile phones, computer screens, microwave ovens, etc. and it can also be used for producing protective clothes serving the purpose of reflecting electromagnetic waves. It is provided convenience for the fabric to be used in a desired form by giving elasticity characteristic to the fabric having electromagnetic reflectivity. Thereby, the fabric can be used both as technical and apparel. It is possible to give electromagnetic reflectivity to a desired region of a fabric at desired size.

Within these basic concepts, it is possible to develop a great variety of embodiments of the inventive "a double-layer elastic fabric reflecting broad- spectrum electromagnetic wave and a production method thereof, it cannot be limited to the examples disclosed herein and it is essentially according to the claims.