Mechanical characterization of hybrid yarn thermoplastic composites from multi-layer woven fabrics with function integration

Abstract

Three dimensional (3D) spacer fabrics are constructed from two dimensional (2D) woven fabrics connected by 2D woven crosslink fabrics using thermoplastic high performance hybrid yarns. Spacer fabrics present great potential in the efficient production of fiber reinforced plastic composites with adjustable mechanical properties targeted for specific applications in Lightweight engineering. The structure of the weave and the stresses placed on the fibers during the weaving process impact the mechanical properties of the finished composite. This study shows that the mechanical properties can be significantly controlled and adjusted by pattern development of the individual 2D composite structures from the 3D spacer fabric preforms constructed of orthogonal multi-layer weaves (non-crimped fiber arrangement and a gentle weaving process). Electrically conductive fibers are woven directly into various layers of the 2D woven fabrics and are therefore successfully integrated during production. This forms the basis for function integration in the composite. The weaving technology ensures a reliable contact of the conductive fibers allowing sensor networks to be integrated into the fabric for online monitoring of the fiber reinforced plastic composite component.