Unidirectional UHMWPE Fabric via Segmented Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing unidirectional fabrics from ultra-high molecular weight polyethylene fibers are complex and costly, prone to defects like breaking, distortion, and stress concentration, which reduce the strength and bulletproof performance of the final product.
Innovation Solution
The method involves sequentially spreading and bonding ultra-high molecular weight polyethylene thin films or strips without overlapping, using a tension regulating roller and adhesive, followed by hot-pressing to create a continuous, integral structure that eliminates the need for warping and reduces glue usage, thereby simplifying the process and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple ultra-high molecular weight polyethylene fibers are warped and bonded using traditional adhesive coating process, then unidirectional fabric can be prepared, but the warping process is complex, production cost is high, and fibers are liable to breaking, distortion, and stress concentration
Solution Approach 1:
The patent divides the fabric structure into discrete fiber segments arranged in parallel, where each fiber segment is independently positioned and bonded at its ends to adjacent segments. This segmentation approach eliminates the need for complex continuous warping while maintaining structural integrity through point-bonding, thereby simplifying manufacturing and reducing stress concentration risks.
Solution Approach 2:
The patent transitions from traditional 2D plane bonding to a 3D spatial arrangement where fibers are positioned in parallel with bonded ends extending in the same direction. This dimensional change allows for simplified processing while maintaining fabric strength through the three-dimensional bonding structure that distributes stress more effectively.
2Productivity
If traditional warping and adhesive coating process is used, then unidirectional fabric can be produced, but fibers are liable to intertwining, knotting, and non-uniform arrangement which reduce energy transfer effectiveness
Solution Approach 1:
By segmenting the fabric into discrete fiber segments with controlled bonding at ends only, the patent prevents fiber intertwining and knotting that occur in traditional continuous warping. This segmentation enables more reliable energy transfer through uniform fiber arrangement while simplifying the production process.
Solution Approach 2:
The patent applies bonding only at specific locations (fiber ends) rather than along the entire fiber length, creating local bonding zones that maintain fiber uniformity and prevent distortion. This localized bonding approach ensures reliable energy transfer through uniformly arranged fibers while improving production efficiency.
3Ease of manufacture
If multiple unidirectional fabrics are crisscross laminated at 0 degree/90 degrees with adhesive, then non-woven fabric can be prepared, but the process is complex and glue usage is excessive
Solution Approach 1:
The patent segments the lamination process by bonding only at fiber end points rather than requiring continuous adhesive coating across entire fabric surfaces. This segmentation dramatically reduces adhesive consumption while simplifying the lamination process through point-to-point bonding of crisscrossed unidirectional fabrics.
Solution Approach 2:
The patent extracts the adhesive bonding function from continuous surface coating and concentrates it only at necessary connection points (fiber ends). This extraction eliminates excessive glue usage in traditional crisscross lamination while maintaining structural integrity through targeted bonding.
4Manufacturing precision
If traditional warping process is used to arrange fibers uniformly, then parallelism and straightness can be achieved, but the process is complex and costly
Solution Approach 1:
The patent segments the fiber arrangement into discrete parallel segments that are independently positioned and bonded. This segmentation achieves uniform fiber arrangement and parallelism without requiring complex continuous warping processes, thereby maintaining manufacturing precision while reducing device complexity.
Solution Approach 2:
The patent achieves fiber uniformity by transitioning to a 3D spatial arrangement where parallel fibers are positioned and bonded at their ends. This dimensional change simplifies the arrangement process while maintaining manufacturing precision through the inherent stability of the parallel segmented structure.
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
This approach results in a unidirectional fabric with improved strength, reduced production costs, and enhanced bulletproof performance by ensuring uniform stress distribution and energy transfer, while minimizing internal injuries and processing complexities.
Implementation Method 1
spread through a tension regulating roller
Implementation Method 2
bonded with an adhesive to prepare the unidirectional fabrics
Implementation Method 3
followed by hot-pressing to create a continuous, integral structure
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a unidirectional fabric, a non-woven fabric, preparation methods thereof and a non-woven fabric product, wherein the preparation method of the unidirectional fabric comprises: sequentially and continuously spreading multiple ultra-high molecular weight polyethylene thin films or strips along a direction and connecting the multiple ultra-high molecular weight polyethylene thin films or strips into a whole to obtain the unidirectional fabric; and the non-woven fabric is prepared on the basis of the unidirectional fabric and the non-woven fabric product is prepared on the basis of the non-woven fabric.