Flexible composite systems and methods
AssigneeDsm IP Assets B.V.
InventorsChristopher Michael Adams, Wesley Edward Hatcher, Keith Joel McDaniels
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Abstract
In various embodiments, an improved flexible-composite material is described that comprises at least one scrim constructed from at least two unidirectional tape layers bonded together and at least one woven fabric, non-woven fabric, or membrane bonded to the scrim. In various embodiments, the unidirectional tape layers comprise a plurality of parallel fiber bundles comprising monofilaments within an adhesive resin. In various embodiments, the fiber bundles are separated by gaps that can be filled in by adhesive or non-adhesive resin.
Claims34
A flexible-composite material comprising:
- at least one scrim, and at least one unidirectional tape layer bonded together;
- wherein said unidirectional tape layers comprise a plurality of parallel fiber bundles comprising monofilaments in an adhesive resin.
A flexible-composite material comprising:
- At least two gappy unidirectional tape layers bonded together to form a scrim;
- wherein said unidirectional tape layers comprise a plurality of parallel fiber bundles comprising monofilaments in an adhesive resin, and wherein said fiber bundles are separated by gaps.
A method of manufacturing a flexible-composite material, said method comprising:
- providing at least two gappy unidirectional tape layers bonded together to form a scrim;
- and
- bonding at least one woven fabric, oriented non-woven fabric, random oriented non-woven fabric, film, or membrane layer onto said at least one scrim layer.
A method of manufacturing a flexible-composite material, said method comprising:
- producing thin unitape layers comprising fiber bundles consisting of a plurality of monofilaments by combining said monofilaments with a polymer resin and pultruding said monofilaments through a rotary die such that said monofilaments are spread by gaps and oriented parallel to each other;
- producing a scrim layer by combining at least two of said thin unitape layers;
- and
- bonding at least one of a woven fabric, non-woven fabric, and/or membrane layer onto at least one of said scrim layers.
Dependencies are inferred from the claim text.