Nonwoven Flexible Composites for Lightweight Inflatable Structures
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Solution Overview
Problem
Woven substrates used in inflatable life-saving devices like evacuation slides and life rafts face challenges due to crimp effects, leading to compromised mechanical performance, increased weight, and high coating requirements, which affect their strength and air-holding capabilities.
Innovation Solution
The use of nonwoven materials with a substrate of filaments bonded by adhesives or primers and coated with gas barrier polymers to create high-strength, lightweight flexible composites that minimize crimp effects and optimize filament orientation for enhanced tensile strength and air-holding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If woven substrates are used for inflatable structures, then strength and rigidity are provided, but crimp effects occur leading to compromised mechanical performance and increased weight
Solution Approach 1:
The patent applies composite materials by combining nonwoven substrate materials with specific filament configurations and coating layers. The composite structure integrates high-strength filaments (such as aramid, carbon, or UHMWPE) with bonding agents and functional coatings, creating a multi-layer composite that achieves superior mechanical performance while minimizing weight compared to traditional woven substrates
2Strength
If woven construction is used, then fabric structure is formed, but yarn crimp leads to low strength materials and compromised tensile and compressive properties
Solution Approach 1:
The patent applies parameter changes by fundamentally altering the fabric structure from woven to nonwoven construction. This parameter change eliminates yarn crimp effects and interlacing complexity, allowing filaments to be bonded in configurations that maximize tensile strength without the structural complications of traditional weaving, thereby improving mechanical properties while simplifying the overall fabric structure
3Reliability
If multiple layers of coatings are applied to woven fabrics to achieve air holding characteristics, then gas barrier properties are achieved, but weight and cost increase
Solution Approach 1:
The patent applies porous materials by utilizing the controlled porosity of nonwoven fabric structures. The nonwoven substrate provides inherent air-trapping capabilities through its fibrous network, reducing or eliminating the need for multiple heavy coating layers required by woven fabrics, thereby achieving reliable air holding characteristics with minimal weight addition
4Weight of moving object
If nonwoven materials are used, then weight is reduced and tensile strength is improved, but coating requirements and manufacturing complexity must be managed
Solution Approach 1:
The patent applies preliminary action by pre-coating or pre-laminating the nonwoven substrate during the fabric manufacturing process rather than requiring post-manufacturing coating operations. This preliminary action integrates the coating step into the substrate production, simplifying subsequent manufacturing operations and reducing the complexity of applying multiple coating layers during device assembly
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
Nonwoven materials provide improved tensile strength, reduced weight, and efficient air-holding characteristics, allowing for the creation of lightweight, high-strength inflatable devices that meet regulatory requirements while minimizing material usage and coating thickness.
Implementation Method 1
a substrate of nonwoven material comprising a plurality of filaments; an adhesive or primer to bind the filaments
Implementation Method 2
a coating or film or both on one or both surfaces of the substrate of nonwoven material; wherein the flexible composite material is a high-strength lightweight material with a tensile strength of at least about 100 pounds per inch and a weight of about 8 ounces per square yard or less
Data Source
AI summary
Embodiments of the present invention provide systems and methods for using nonwoven materials for evacuation slides, life rafts, life vests, and other life-saving inflatable devices. The nonwoven materials have a substrate layer with continuous filaments formed in various directions. The substrate layer then has a layer (e.g., a coating or a film or both) on one or both surfaces of the substrate of nonwoven material.