Twisted Polymer Composite Fabric for Impact Resistance
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Solution Overview
Problem
Existing woven fabrics made from single ribbon tapes of co-extruded polymer are prone to delamination when subjected to shock loads, as they require lamination of multiple layers to achieve sufficient impact resistance.
Innovation Solution
A woven fabric is created using composite elongate elements, where multiple elongate elements are twisted together, comprising a polymeric base and a polymeric surface layer with a softening temperature lower than the base, allowing for self-adhesion and reduced layering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of woven fabric are laminated together to achieve sufficient impact resistance, then the impact resistance is improved, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The fabric structure is segmented into distinct functional components: a polymeric base material providing structural integrity and a separate thermoplastic surface layer providing bonding capability. This segmentation allows each component to be optimized independently while working together to achieve both impact resistance and self-adhesion in a single layer
Solution Approach 2:
The invention uses composite materials by combining a polymeric base material with a thermoplastic surface layer that has a lower melting point. This composite structure enables the fabric to achieve sufficient impact resistance through the base material while the thermoplastic layer provides self-adhesion capabilities, eliminating the need for multiple laminated layers
2Reliability
If multiple layers of woven fabric are laminated together to prevent delamination under shock loads, then the reliability is improved, but the manufacturing time and process complexity increase
Solution Approach 1:
The thermoplastic surface layer on each fabric layer serves a dual function: it provides structural protection and simultaneously acts as the bonding agent for self-adhesion. When heat is applied, the thermoplastic layer melts and bonds adjacent fabric layers together, eliminating the need for separate adhesives or complex lamination processes and significantly reducing manufacturing time
Solution Approach 2:
The invention exploits parameter changes by utilizing the temperature-dependent properties of the thermoplastic surface layer. At processing temperature, the thermoplastic layer transitions from a solid state to a molten state, enabling bonding between layers. After cooling, it returns to a solid state, providing strong adhesion and preventing delamination under shock loads
3Device complexity
If a single layer of woven fabric is used to reduce manufacturing complexity, then the device complexity is reduced, but the impact resistance and resistance to delamination deteriorate
Solution Approach 1:
The fabric structure incorporates local quality by providing different properties at different locations within the same layer: the polymeric base material provides structural integrity and impact resistance, while the thermoplastic surface layer provides bonding capability. This localized functional differentiation allows a single layer to achieve both mechanical strength and self-adhesion properties that would otherwise require multiple layers
4Strength
If adhesive materials are used to bond fabric layers together, then the bonding strength is improved, but the manufacturing process complexity and material cost increase
Solution Approach 1:
The thermoplastic surface layer on the fabric performs the bonding function that would otherwise require separate adhesive materials. When heat is applied during manufacturing, the thermoplastic layer melts and bonds adjacent fabric layers together, then solidifies to provide strong adhesion. This self-service approach eliminates the need for additional adhesives, simplifying the manufacturing process and reducing material costs
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 twisted composite elongate elements provide increased distribution of polymeric materials, enhancing the fabric's impact resistance and eliminating the need for lamination, thus simplifying the manufacturing process and preventing delamination.
Implementation Method 1
a molecularly-oriented thermoplastic polymer base having at least one thermoplastic surface polymeric layer compatibly bonded to said polymer base by molecular interspersion between the contiguous surfaces of the adjoining base and surface layers
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
Implementation Method 3
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
Implementation Method 4
said surface polymeric layer having a softening temperature lower than that of the polymer base
Data Source
Figure 1~2
Figure 3(a)~3(b)
Figure 4(a)~4(b)
AI summary
There is provided a composite elongate element (5a-5d) comprising a plurality of elongate elements (10) twisted together. At least one of the elongate elements (15) comprises a polymer base (20) and at least one polymer surface layer (25). The at least one polymer surface layer (25) has a softening temperature lower than that of the polymer base (20).