For demonstration purposes, we wove a fabric with 100% fiberglass first and then we replaced the fiberglass filling with a Basalt Roving.
The white color is the fiberglass, the olive-brown color is the basalt.
This type of construction, when two or more technical fibers are mixed or blended or woven into a fabric, is called a hybrid.
The result of this particular Hybrid is an increase in strength in the filling direction (due to the Basalt being used in the filling)
While this demonstration shows a very simply hybrid version made from Basalt and Fiberglass, more complicated and complex products can be engineered. As an example, S2-Glass, Kevlar or Carbon Fibers can be incorporated, either in the warp or in the fill direction or in combination of same. The fabric can have sections of just S2-Glass, then perhaps Carbon or Kevlar and then again S2 Glass and all of it can be combined by a Basalt Roving.
This unique ability allows to engineer products with various properties along one fabric.
Example Ballistic Application
Say you have a wall 12 ft wide; and say you need a high strength ballistic fiber on the left side of this wall, such as S2-Glass. Then comes a section you need to have an electromagnetic shield. This would be the section for Basalt. You may have a need for a light weight panel and decide to make use of carbon fiber and all of this could be woven into one fabric.
This example may not find a direct application and is just meant to explain some of the possibilities, but we hope it increases the reader's creativity for some interesting new designs.
We welcome to discuss the ideas you have!
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A very consistent way of chopping is done in a rotary process. A drum with a selected blade count, spaced out to the desired fiber length achieves a very high accuracy.
A predetermined strand count will be fed into the rotary chopping mechanism. The actual chopping is then done by the means of crushing the fiber, rather than cutting it. This is possible, due to the fact that glass fibers are brittle by nature.
By feeding multiple strands at the same time, you can mix fibers with various properties, as well. This allows for a predictive and cost effective blend of fibers with a property mix for optimal efficiency in the following application.
Doing so, blended chopped fibers allow for more cost effective solutions or to create complete new niche markets.
Guillotine Chopping is often done when recycling the waste materials come from the glass fiber manufacturer.
The input material can be “Spin-cakes” or other materials which have not passed the inspections. In order to be able to chop a cake, it is necessary to break it down in smaller pieces. This can be done with a table saw like process. After multiple additional chopping processes, the fibers may have somewhat more random lengths than resulting from a Rotary Chopping.
During the next steps, the fibers can be opened, dried and baled and sent to the next intended application as e.g.
a) mechanically bound, needled into a “Needlemat” for industrial insulation
b) chemically bound into an insulation batting for automotive or commercial or industrial use
c) used as a reinforcement product for panel making