Multilayered Textile Material for 3D Forming
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Solution Overview
Problem
Current high-performance fiber materials used in woven and non-woven configurations face issues with crimp-induced stress concentrations, lack of elasticity, and inability to form three-dimensional objects due to rigid structures, resulting in reduced strength and flexibility.
Innovation Solution
A multilayered material comprising three non-woven fiber layers with unidirectional fibers oriented at specific angles (-40°/0°/40° or -50°/0°/50°) and thermoplastic polyurethane outer layers, allowing for material deformation and elasticity to form three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high performance fibers are used in woven configuration, then tensile strength is improved, but crimp is induced causing stress concentrations and reducing long term performance
Solution Approach 1:
The material is divided into multiple non-woven layers with different fiber orientations rather than using a single woven structure. This segmentation eliminates the crimp problem by distributing fibers in separate layers at specific angles (-40°/0°/40° or -50°/0°/50°), allowing each layer to contribute to strength without the stress concentrations caused by weaving-induced crimp.
2Strength
If high performance fibers are used in non-woven configuration with unidirectional orientation, then weight is reduced and tensile strength is improved, but elasticity and stretchability are lost making it impossible to form three dimensional objects
Solution Approach 1:
The invention creates a composite material system combining multiple non-woven layers of high performance fibers oriented at different angles with an elastomeric polymer matrix. The composite structure integrates the high tensile strength of unidirectional fibers with the elasticity of the polymer matrix, enabling the material to both maintain strength and deform elastically for three dimensional forming.
3Strength
If multiple layers of UHMWPE fibers are used, then tensile strength is improved, but the material becomes rigid and lacks softness and elasticity
Solution Approach 1:
The invention changes the physical and chemical parameters of the material system by introducing an elastomeric polymer matrix and controlling the fiber orientation angles. These parameter changes transform the rigid, crinkly character of pure UHMWPE fiber laminates into a material with controlled elasticity and softness while maintaining high tensile strength through the optimized angular configuration of fiber layers.
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 material achieves a balance of low weight, high tensile strength, and elasticity, enabling the formation of three-dimensional objects without wrinkles or folds, with improved seam strength and breathability.
Implementation Method 1
a matrix material comprising at least one first outer layer adhered to a side of one of the three nonwoven fiber layers
Data Source
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AI summary
Described are multilayered materials for forming three dimensional objects. The multilayered materials include at least three nonwoven fiber layers with unidirectionally oriented fibers and a matrix material. The multilayered materials have elastic properties that allow the multilayered material to deform by stretching the multilayered material over a three dimensional mold to form a three dimensional object.