Composite structures and methods of preparation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional Leno weave fabrics exhibit lower puncture resistance, tensile strength, and tear strength compared to solid woven fabrics, making them unsuitable for various applications, and the manufacturing processes for composite materials using solid fabrics are intensive, deteriorate fabric properties, and generate hazardous waste.
Innovation Solution
A composite material using a heavy Leno weave fabric with resin coatings applied on both sides, where the resin layers bond through the fabric's pore structure, eliminating the need for tie coats and maintaining fabric properties, and allowing for the use of polymers with low surface energy like PVDF.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional Leno weave fabric is used, then the fabric has good drape and flexibility, but the puncture resistance, tensile strength and tear strength are lower than solid woven fabrics
Solution Approach 1:
The patent combines Leno weave fabric with resin coatings to create a composite material that enhances mechanical strength while preserving the fabric's inherent drape and flexibility. The resin impregnation fills the open pores and binds yarns together, creating a hybrid structure that leverages both the fabric's flexibility and the resin's strength.
Solution Approach 2:
The patent utilizes the porous structure of Leno weave fabric as a beneficial feature rather than a limitation. The open pore structure is maintained and used to allow resin penetration and bonding, while the porosity itself contributes to the composite's lightweight nature and resin distribution.
2Strength
If solvent-based tie coats are used to bond thermoplastic polyurethane onto solid woven fabric, then the materials are bonded together, but the fabric properties are weakened and hazardous waste is produced
Solution Approach 1:
The patent replaces the chemical bonding mechanism (solvent-based tie coats) with a physical bonding mechanism. The resin is applied in a molten or dissolved state and then solidifies through cooling or solvent evaporation, creating a mechanical interlock within the fabric pores rather than relying on chemical adhesion promoters.
Solution Approach 2:
The patent converts the typically harmful open pore structure of Leno weave fabric, which would normally weaken the material, into a beneficial feature that facilitates resin penetration and distribution. The porosity that would normally be a weakness becomes the pathway for resin impregnation, strengthening the fabric without requiring harsh chemicals.
3Strength
If heavy Leno weave fabric with yarns of at least about 1,300 denier is used with resin coatings, then the mechanical properties are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies resin coatings to the fabric in advance of the final product formation, allowing the resin to penetrate and bond within the fabric structure before the composite is put into service. This preliminary impregnation ensures uniform distribution and strong bonding without requiring complex post-processing steps.
Solution Approach 2:
The patent merges the fabric reinforcement function with the resin bonding function into a single integrated process. The heavy Leno weave fabric provides the structural framework while the resin coatings provide both additional strength and bonding capability, eliminating the need for separate tie coat layers and simplifying the overall manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite material achieves improved mechanical and material properties, reducing production time and costs by up to 70% and avoiding solvent-based processing, while meeting or exceeding the performance of comparable composites made with solid weave fabrics.
Implementation Method 1
the heavy Leno weave fabric defining a pore structure... the first and second resin coatings are bound to each other through the heavy Leno weave fabric via the pore structure
Data Source
AI summary
A composite includes a heavy Leno weave fabric, a first resin coating, and a second resin coating. The heavy Leno weave fabric has a first side and a second side. The fabric is characterized by yarns having a denier number of at least about 1,300 in both warp and weft directions. The fabric defines a pore structure. The first resin coating is on the first side of the heavy Leno weave fabric. The second resin coating is on the second side of the heavy Leno weave fabric. The first and second resin coatings are bound to each other through the fabric via the pore structure.