Composite Twisted Elongate Element for Delamination Resistance
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Solution Overview
Problem
Existing composite thermoplastic polymer fabrics used in high-impact applications often fail due to delamination between layers when subjected to shock loads, as the bond strength is limited by the ratio of materials with different melting points, typically restricted to 1 to 30% or less, which limits their strength and durability.
Innovation Solution
A composite twisted elongate element comprising a first thermoplastic polymeric material with a lower melting point and a second molecularly-oriented thermoplastic polymeric material, capable of being autogeneously bonded, is twisted together to form a fabric that can be self-adhering and self-supporting, eliminating the need for resin matrices or adhesives, and providing enhanced impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coextruded yarns of thermoplastic polymers with different melting temperatures are used to form fabrics, then the fabrics can be formed into three-dimensional shaped articles under heat and pressure without additional adhesives, but the bond strength is limited by the material ratio restriction (1 to 30% or less)
Solution Approach 1:
The patent employs a composite structure consisting of a first thermoplastic polymer material (lower melting temperature) and a second thermoplastic polymer material (higher melting temperature) twisted together in a specific ratio (30-70% of the first material). This composite construction allows the fabric to achieve both self-bonding capability through the lower-melting material and sufficient bond strength through the optimized combination with the higher-melting material, eliminating the need for additional adhesives while overcoming the previous strength limitations.
Solution Approach 2:
The patent changes the critical parameter of material ratio from the conventional 1 to 30% or less to a new range of 30-70% for the first thermoplastic polymer material. This parameter change enables sufficient bonding strength while maintaining the self-adhering property, as the increased proportion of lower-melting material provides better bonding capability without compromising the structural integrity provided by the higher-melting material.
2Productivity
If single ribbon tapes are used as warp and weft to weave fabrics and then hot pressed, then articles can be manufactured, but delamination occurs between consolidated fabric layers when subjected to shock loads
Solution Approach 1:
The patent uses composite twisted yarns combining two thermoplastic polymer materials with different melting temperatures in a 30-70% ratio. The lower-melting material provides strong bonding between layers, while the higher-melting material maintains structural integrity under shock loads. This composite structure prevents delamination by creating a balanced system where bonding and structural properties are simultaneously optimized, unlike single-material tapes that fail under shock conditions.
Solution Approach 2:
The patent applies local quality by assigning different functional roles to different components within the twisted yarn structure. The first thermoplastic polymer material (30-70%) primarily provides bonding function between fabric layers, while the second thermoplastic polymer material (30-70%) provides structural strength and shock resistance. This functional differentiation within the composite yarn enables the fabric to resist delamination under shock loads while maintaining manufacturability.
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 solution enhances the internal bonding strength and impact resistance of the fabric, allowing it to form single-layer or laminated structures with improved lamination strength and reduced delamination risk, suitable for high-impact applications such as luggage shells and body armor without the need for additional adhesives or films.
Implementation Method 1
The melting point or softening point of the first polymeric material is at least 10°C less than the melting point or softening point of the second polymeric material, and the first and second polymeric materials are capable of being autogeneously bonded
Implementation Method 2
consolidating into single layer or multilayer shells or structures, e.g. under the action of heat and pressure without the need for additional resin or adhesive
Data Source
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AI summary
There is provided an elongate element (5; 5a to 5d), such as a composite and/or twisted elongate element or braid, comprising a plurality of elongate elements (10) twisted/braided together and which comprise at least one first elongate elements (20) and at least one second elongate element (25), the or each first elongate element (20) comprises a first polymer material A and the or each second elongate element comprises a second polymeric material B, a melting point ( MP A ) of material A is lower than the melting point ( MP B ) of material B. In a consolidated material (100) comprising at least one elongate (5; 5a to 5d), material A acts as a matrix binder/adhesive agent, and material B acts as a strengthening/integrity providing agent.