Engineered composite systems

Abstract

A system for providing improved engineered-composite materials, equipment, and manufacturing processes.

Claims

1. A waterproof, non-breathable flexible laminate comprising: (a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction; (b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer; (c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer; (d) a stretchable non-breathable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and (e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer, wherein said monofilaments have diameters less than 20 microns; and wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

2. The laminate of claim 1, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45° relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90° relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90° or −90° relative to said first predetermined direction.

3. The laminate of claim 1, wherein said monofilaments comprise ultra-high molecular weight polyethylene.

4. The laminate of claim 3, wherein each of said unidirectional tape layers comprises from about 12 gsm to about 16 gsm non-breathable adhesive and from about 12 gsm to about 16 gsm ultra-high molecular weight polyethylene monofilaments.

5. The laminate of claim 3 having added abrasion resistance on the side possessing the stretchable tricot knit layer.

6. The laminate of claim 1, wherein first, second and third unidirectional tape layers include smaller areas absent monofilaments.

7. The laminate of claim 6, further comprising larger areas absent monofilaments, wherein said larger areas comprise laminar overlays of said smaller areas of said unidirectional tape layers absent monofilaments.

8. The laminate of claim 1, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

9. The laminate of claim 1, wherein said monofilaments in each of said unidirectional tape layers are extruded.

10. A waterproof, non-breathable flexible laminate comprising: (a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction; (b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer; (c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer; (d) a stretchable non-breathable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and (e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer, wherein each of said first, second and third predetermined directions are different.

11. The laminate of claim 10, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45° relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90° relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90° or −90° relative to said first predetermined direction.

12. The laminate of claim 10, wherein said monofilaments have diameters less than 20 microns; and wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

13. The laminate of claim 10, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

14. The laminate of claim 10, wherein said monofilaments in each of said first, second and third unidirectional tape layers comprise ultra-high molecular weight polyethylene.

15. The laminate of claim 12, further comprising larger areas absent monofilaments, wherein said larger areas comprise laminar overlays of portions of said unidirectional tape layers absent monofilaments.

16. A waterproof flexible laminate comprising: (a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction; (b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer; (c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer; (d) a stretchable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and (e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer, wherein said monofilaments have diameters less than 20 microns; and wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

17. The laminate of claim 16, wherein said stretchable urethane membrane film is non-breathable.

18. The laminate of claim 16, wherein said stretchable urethane membrane film is breathable.

19. The laminate of claim 16, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

20. The laminate of claim 16, wherein said monofilaments in each of said first, second and third unidirectional tape layers comprise ultra-high molecular weight polyethylene.

21. The laminate of claim 16, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45° relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90° relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90° or −90° relative to said first predetermined direction.

22. A waterproof flexible laminate comprising: (a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction; (b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer; (c) a stretchable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and (d) a stretchable tricot knit layer bonded to said second unidirectional tape layer opposite said first unidirectional tape layer, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 90° relative to said first predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+45° or −45° relative to said first predetermined direction.

23. The laminate of claim 22, wherein said stretchable urethane membrane film is non-breathable.

24. The laminate of claim 22, wherein said stretchable urethane membrane film is breathable.

25. The laminate of claim 22, wherein said monofilaments in each of said first and second unidirectional tape layers comprise ultra-high molecular weight polyethylene, and wherein said adhesive in each of said first and second unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said first and second unidirectional tape layers are waterproof and air-permeable.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

(1) FIG. 1A is an illustration of S06 where A is the fiber, B is the matrix and C is the woven material, note there is no top or bottom coating; and

(2) FIG. 1B is an illustration of S07 and S13 where A is the fiber and B is the matrix material, C in this Figure preferably comprises a waterproof non-breathable urethane film.

(3) TABLE-US-00001 TABLE (1) DETAILED DESCRIPTION Sample Delamination rank after 1/2 Sample hour wash/ weight Additional Comments Number durability translucence (gsm) Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 comments white woven S06 3 4 64 release liner #5380° WHC #53890° release liner Non-waterproof inner layer no removed 2 removed breathable outer coatings after after and natural process process color, 0/90 fibers, moderate air permeable no coating one S07 5 4 92 W2-1.0 #5380°  #5380° release liner Waterproof side, coated on removed Non-breathable the other, 0/60 after fiber, natural process color no coating one S13 4 4 90 W2-1.0 #1420° #14260° release liner Waterproof side, coated on removed Non-breathable the other, 0/60 after fiber, grey process

(4) Each of the materials of Table (1) preferably utilize Unitape layers. A preferred Unitape layers is preferably manufactured by spreading fibers and coating them with an adhesive to form a substantially continuous sheet. The preferred Unitape layers are non-woven.

(5) More specifically, each of the flexible sheet materials of Table (1) preferably utilizes Unitape layers (either applicant's #538 or #142 Unitape). Preferably, these unitape “sheets” are cut to size and laid in multiple orientations to form a preferred two directional fiber reinforced sheet. Each of the materials of Table (1) preferably utilize Unitape layers (either #538 or #142) with following preferred characteristics: About 14 gsm of non-breathable CT71 adhesive in the unitape and 14 gsm of Dyneema SK75 1760Dtex fiber, which, when cross plied, preferably creates a fiber matrix network that will bead water and will be air permeable but will allow water to pass through with significant atmospheric pressure. Unitape #142 has a small amount of light grey tint in the CT71 adhesive that makes the resulting products have a light grey color. Unitape #538 is natural colored (translucent pale yellow) so the resulting products are translucent pale yellow.

(6) As illustrated in FIGS. 1A and 1B, laminate S06 has no film or membrane on either side of the laminate but has the woven material we have coded as WHC2 (Nylon 6 ripstop, 10 d×10 d+30 d, 255×218, 26 g/sqm, C6:DWR) sandwiched between the unitape layers, the purpose of the woven is to add rip-stop performance to the laminate and add structural stability to the laminate. This material is a typical 0/90° orientation but has lower than normal modulus in the +/−45° directions because of the lack of film or membrane Laminate S07 does not have a film or membrane on one side but has a non-breathable urethane membrane film W2-1.0 on the other side so that it is waterproof-non breathable with fibers laid at about 0° and 60° so the material (through the combination of the fiber angles and stretchable film) has low modulus in the 120° direction and moderate modulus in the 30° direction Laminate S13 is same as S07 but is light grey because of the unitape used.

(7) The “membrane-free” flexible composite generally exhibits greater “stretch”, or modulus attained, or rebound ability (of the materials in the non-fiber reinforced directions), when compared to applicant's prior-disclosed embodiments (see U.S. Pat. No. 5,470,632 to Heiner Meldner et al). Applicant's new disclosed embodiments are preferably designed to have a low modulus or rebound in the off axis directions.

(8) It is noted that applicant's preferred adhesive coating (CT71) is preferably a partially thermosetting polymer that has excellent adhesion to low surface energy fibers (and films, as applicable) and forms a toughened finished product once cured that is puncture resistant and resists UV degradation. Upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as design preference, intended use, cost, structural requirements, available materials, technological advances, etc., other laminate versions, such as, for example, a non-breathable membrane applied on one or both sides of the layup assembly, which preferably could be replaced with breathable membranes.

(9) In another preferred embodiment of the present invention, materials have an engineered stretch wherein the finished material stretch and rebound and design directions may be used in designed amounts. For example, a flexible composite with a high modulus from initial strain in the X-Y plain directions 0°/180°, 90°/270°, and 45°/225° but lower strengths, from initial strain, in all other x-y plane directions.

(10) Preferably, the initial modulus of the material drops off as the direction of stress moves farther and farther from a fiber reinforced direction and increases as the load moves back towards a fiber reinforced direction. By knowing the material characteristics of each component ply and the interaction effects they have with each other a material can be manufactured with particular characteristics that may be drastically different than the constituent components.

(11) The following table discloses Unitape layers (applicant's #538 Unitape). Preferably, these unitape “sheets” are cut to size and laid in multiple orientations to form a preferred multi-directional fiber reinforced sheet. Each of the materials of Table (2) preferably utilize Unitape layers (either #538) in angular orientation (0-degrees; 45-degrees) with following preferred characteristics, as shown:

(12) TABLE-US-00002 Aprox. Product Sample weight name Number (gsm) Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 CT9BW6- S40 215 W6-2.0 #538 0° #538 45° #538 −45° W6-2.0 2.0 (45) CT9BW2- S45 163 Tricot knit #538 0° #538 45° #538 −45° W2-1.0 1.0/TR1 (45) (any

(13) Preferably, each of the materials above preferably utilize Unitape layers. Preferred Unitape layers are preferably manufactured by spreading fibers and coating them with an adhesive to form a substantially continuous sheet. The preferred Unitape layers are non woven.

(14) More specifically, each of the flexible sheet materials of the above Table 2 preferably utilizes Unitape layers (applicant's #538 Unitape). Preferably, these unitape “sheets” are cut to size and laid in multiple orientations to form a preferred three directional fiber reinforced sheet. Each of the materials of Table (1) preferably utilize Unitape layers (#538) with the following preferred characteristics: About 14 gsm of non-breathable CT71 adhesive in the unitape and 14 gsm of Dyneema SK75 1760Dtex fiber, which, when cross plied, preferably creates a fiber matrix network that will bead water and will be air permeable but will allow water to pass through with significant atmospheric pressure. Unitape #538 may include additives that cause it to become colored to inventors desire Unitape #538 is natural colored (translucent pale yellow) so the resulting products are translucent pale yellow.

(15) Additionally, as illustrated above, laminate S40 preferably has a non-breathable weldable urethane film W6-2.0 on both the bottom and top surfaces and three layers of #538 unitape. This material is a 0/+45/−45′ unitape orientation and has low modulus in 90° directions because of the lack of fiber in that direction.

(16) Laminate S45 preferably has a tricot knit on one side for added abrasion resistance and a non-breathable urethane membrane film W6-2.0 on the other side so that the laminate is waterproof-non breathable with fibers laid at about O″ +45°, and −45° so the material (through the combination of the fiber angles and stretchable film and stretchable tricot) has low modulus in the 90′ direction.

(17) Additional alternative surface coatings may include various types of knits, wovens, non-wovens, meshes, breathable films (porous and non porous), multilayered films, foams. Preferably, adding various materials, as noted, into the stack of plies in configurations other than described for instance: having a woven material between layers of unitape; having a film layer between unitape plies; having a woven material and a weldable film layer between two plies of unitape etc, may suffice.

(18) Further, other preferred alternative fiber angles could be used to drive high modulus in fiber reinforced directions and low modulus in non-fiber reinforced directions (assuming flexible matrix and other non-fiber components are also low-modulus).

(19) Upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other material arrangements such as, for example, material could be cured inside or outside an autoclave, exact material unitapes and other components may be changed to control the modulus of the material in off and on fiber axis directions, etc., may suffice.

(20) And, upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other adhesive arrangements such as, for example, removing current surface coatings and utilizing ct71 to be both the adhesive and the coating, etc., may suffice. Alternately preferably, no adhesive may be needed if the fibers are weldable to themselves and/or the surface coatings.

(21) Further, upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other materials and layering arrangements to improve performance and usability, such as those indicated below, may suffice: i. Resin 1. toughening agents 2. breathable adhesive 3. non-breathable adhesive 4. FR additives 5. No-stink additives 6. Other resins a. Water based b. PU's ii. thin films 1. breathable film 2. non breathable 3. directionally strong films iii. texture could be added iv. abrasion layers 1. woven nylon 2. woven polyester 3. non-wovens 4. super fabric v. non-woven layers 1. on outer surface 2. between plies vi. unitape fiber 1. fiber types a. aramid b. para aramid c. Liquid Crystal Polymers d. UHMEPE e. Polyesters f. Polyamides (Nylons) g. Polybenzimidazole 2. Resin content a. Increased b. Decreased 3. Amount of fiber a. Increased b. Decreased 4. Unitape Fiber hybrids a. Intra laminar b. Inter laminar vii. Ply count can change viii. Unitape per ply can change ix. Unitape directions can change

(22) And, upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other uses such as, for example, medical bracing, safety devices (fall straps), etc., may suffice.

(23) Although applicant has described applicant's preferred embodiments of this invention, it will be understood that the broadest scope of this invention includes modifications such as diverse shapes, sizes, and materials. Such scope is limited only by the below claims as read in connection with the above specification. Further, many other advantages of applicant's invention will be apparent to those skilled in the art from the above descriptions and the below claims.