Gap-free Tape-woven Fabric via Offset Layer Nesting
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Solution Overview
Problem
Tape-woven fabrics exhibit inherent gaps or openings at the intersections of tape-like warps and wefts, which can impair the appearance and performance of composite materials, particularly in applications like ballistic mitigation and air-bag applications, and are prone to delamination due to their fragile nature and complex production processes.
Innovation Solution
A woven fabric design featuring tape-like warps and wefts arranged in mutually offset and overlapping layers, where the warps and wefts interlace to cover gaps and provide mechanical interconnection, preventing delamination and improving stability, while allowing for simpler and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tape-like warps and wefts are used to weave fabric, then the fabric has lower areal weight and improved flexibility, but inherent gaps or openings appear at the intersections of tapes
Solution Approach 1:
The patent introduces a third dimension by creating overlapping layers of tape-woven fabrics. Instead of attempting to eliminate gaps within a single plane, the solution stacks multiple fabric layers with offset patterns, causing tapes from different layers to cover gaps between tapes in adjacent layers. This dimensional transition from 2D to 3D arrangement effectively eliminates visible gaps while preserving the low areal weight benefit of using tapes instead of traditional yarns.
Solution Approach 2:
The patent implements a nested structure where multiple tape-woven fabric layers are stacked and interlocked. Each layer contains tapes that weave through and are interlocked by tapes from other layers, creating a nested configuration where fabrics are embedded within one another. This nesting arrangement ensures that gaps in any single layer are covered by tapes from surrounding layers, eliminating see-through openings while maintaining the flexibility and weight advantages of tape construction.
2Stability of the object's composition
If stabilized tapes with binder are used, then the tapes gain structural stability and resistance to disintegration, but they become less flexible and pliable
Solution Approach 1:
The patent applies different stabilization levels to different regions of the tape structure. The binder is applied selectively to provide stability where needed (at tape intersections and along edges) while leaving other portions of the tapes more flexible. This localized quality approach ensures that tapes maintain sufficient structural integrity to resist disintegration during handling and weaving, while preserving the flexibility required for the weaving process and final fabric drape.
Solution Approach 2:
The patent modifies the binder content and composition parameters to achieve optimal balance between stability and flexibility. By controlling the amount, type, and distribution of binder material, the tapes can be tuned to have just enough structural stability to prevent disintegration while maintaining the pliability needed for weaving operations. This parameter optimization allows the tapes to adapt to both handling requirements and final fabric performance needs.
3Ease of operation
If non-stabilized tapes are used, then the tapes remain more flexible and easier to handle, but they are more fragile and prone to disintegration
Solution Approach 1:
The patent applies preliminary stabilization treatments to tapes before the weaving process. Binders are applied in advance to tape surfaces to create a protective coating that prevents disintegration during subsequent handling and weaving operations. This preliminary action ensures that tapes maintain their flexibility and ease of handling during the weaving process while gaining the necessary structural stability to resist breaking and falling apart during production and application.
Data Source
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AI summary
A novel woven fabric is provided wherein preferably two unidirectional mutually offset and at least partly overlapping layers of tape-like warps interlace with tape-like wefts that are incorporated individually in either non-overlapping manner or in a mutually offset and overlapping manner relative to other weft tapes. Such a woven fabric is without see-through gaps at the areas/sites encircled by intersecting tape-like warps and wefts, and also delamination resistant. It is particularly suitable for composite material, ballistic mitigation, and similar applications.