Quasi-unidirectional fabrics for structural applications, and structural members having same

A structural member comprising a plurality of fabrics bonded together, each fabric comprising:

• a. a first layer of structural yarns comprising first structural yarns aligned in a first direction;
• b. a second layer of structural yarns comprising second structural yarns aligned in a second direction at an angle relative to the first direction, the second layer of structural yarns disposed on top of the first layer of structural yarns;
• c. first encapsulating yarns disposed on the second layer of structural yarns, the first encapsulating yarns being aligned with the first structural yarns;
• and
• d. second encapsulating yarns being aligned with the second structural yarns, the second encapsulating yarns being alternatively woven above one of the first encapsulating yarns and below one of the first structural yarns such that the first encapsulating yarns and second encapsulating yarns cooperate to secure the first layer of structural yarns to the second layer of structural yarns.

A rigid structural member comprising a plurality of fabrics bonded together, each fabric comprising:

• a. a first layer of structural yarns comprising first structural yarns aligned in a first direction;
• b. a second layer of structural yarns comprising second structural yarns aligned in a second direction at approximately 90 degrees relative to the first direction, the second layer of structural yarns disposed on top of the first layer of structural yarns;
• c. first encapsulating yarns disposed on the second layer of structural yarns, the first encapsulating yarns being aligned with the first structural yarns;
• and
• d. second encapsulating yarns being aligned with the second structural yarns, the second encapsulating yarns being alternatively woven above one of the first encapsulating yarns and below one of the first structural yarns such that the first encapsulating yarns and second encapsulating yarns cooperate to secure the first layer of structural yarns to the second layer of structural yarns;
• e. wherein the first and second structural yarns each have a tenacity of at least 15 grams per denier and a tensile modulus of at least 400 grams per denier, and the first and second encapsulating yarns have a denier between approximately 20 and approximately 1000, and the plurality of fabrics are bonded together by at least one of a resin and a film.