Multi layer fabrics for structural applications having woven and unidirectional portions and methods of fabricating same

A rigid panel for structural applications, comprising:

• a. at least one multi-layer fabric, each multi-layer fabric comprising:
• i. a first woven portion having structural warp yarns and structural weft yarns interwoven together to form a first woven layer, the structural warp yarns and weft yarns being made of aramid fibers;
• ii. a unidirectional portion that includes a first unidirectional layer having first structural unidirectional yarns, the first unidirectional layer being adjacent the first woven layer, and the first structural unidirectional yarns being made of aramid fibers;
• iii. at least one securing yarn interwoven with the first woven layer and the first unidirectional layer to secure the first unidirectional portion to the first woven portion, the at least one securing yarn being made of a polyester;
• and
• iv. encapsulating yarns interwoven with the first unidirectional yarns first woven portion to secure the first unidirectional yarns together to form the first unidirectional layer, the encapsulating yarns being made of a polyester;
• v. wherein the encapsulating yarns and the securing yarns have a diameter that is less than about 14% of the diameter of the warp yarns, weft yarns and unidirectional yarns;
• and
• b. a thermoset epoxy resin applied to the at least one multi-layer fabric, the epoxy resin selected to secure the at least one multi-layer fabric together to form the rigid panel.