Waterproof Breathable Composite Material for Flexible Membranes
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Solution Overview
Problem
Traditional waterproof breathable materials exhibit low strength-to-weight ratio, excessive thickness, and limited tear resistance, restricting their applicability due to heavy weight and poor rip stop properties.
Innovation Solution
A waterproof breathable composite material is developed by bonding a W/B membrane to a composite material with unidirectional fiber and polymer matrix plies, utilizing high-strength fibers like Dyneema and Vectran, and a non-W/B polymer adhesive to create a thinner, more flexible, and lighter material with enhanced strength and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional lamination process bonds W/B films to woven fabrics, then material provides strength and tear resistance, but weight increases and strength-to-weight ratio decreases
Solution Approach 1:
The patent applies composite materials by bonding W/B films to a composite fabric made of high-strength fibers (Dyneema, Vectran, Aramid) instead of traditional woven fabrics. This composite structure provides superior tear resistance and strength while maintaining lower weight, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent changes the material parameters by using high-strength-to-weight ratio fibers (Dyneema, Vectran, Aramid) with specific tensile strengths and moduli. These parameter changes in the base fabric enable the laminate to achieve higher tear resistance without proportionally increasing weight, thus improving the strength-to-weight ratio.
2Reliability
If traditional W/B materials use woven or randomly oriented non-woven structures, then material provides durability, but thickness increases and flexibility decreases
Solution Approach 1:
The patent applies local quality by using a unidirectional knit structure where fibers are oriented in specific directions to provide strength where needed. This localized fiber orientation achieves durability through targeted reinforcement rather than uniform thick construction, reducing overall thickness while maintaining reliability.
3Strength
If traditional W/B materials use heavy woven fabrics, then material provides rip stop properties, but strength-to-weight ratio decreases
Solution Approach 1:
The patent uses composite materials combining W/B film with high-strength fiber knits (Dyneema, Vectran, Aramid) that inherently provide rip stop properties through their structural characteristics. This composite approach achieves rip stop functionality without the weight penalty of traditional heavy woven fabrics.
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 resulting material achieves a higher strength-to-weight ratio and tear resistance while maintaining breathability, suitable for diverse applications such as sleeping bags, tent walls, and clothing, with optional fire retardancy and anti-microbial properties.
Implementation Method 1
they may be either waterproof but porous to gas and water vapor flow or they may be non porous but allow water vapor to move through the material via diffusion
Implementation Method 2
a first and second layer of composite material and a W/B membrane are bonded together with an adhesive to form a laminate
Data Source
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AI summary
A waterproof breathable material has a higher strength-to-weight ratio and higher tear resistance- to-weight ratio than traditional materials, and may be applied in a wide field of potential uses. A non- woven composite material comprises at least one waterproof breathable (W/B) membrane, a first unidirectional non- woven composite layer having multiple fibers enclosed by adhesive in parallel to each other, a second unidirectional non-woven composite layer having multiple fibers enclosed in adhesive in parallel to each other. The first unidirectional non-woven composite layer is positioned such that the fibers are oriented 90° relative to the fibers of the second unidirectional non- woven composite layer, and a space is formed between the first and second multiple fibers. No adhesive is present in the space.