Nonwoven flexible composites

• US 9,481,144 B1
• Filed: 03/02/2016
• Issued: 11/01/2016
• Est. Priority Date: 03/02/2015
• Status: Active Grant

• Current Assignee: Air Cruisers Company LLC (Safran SA)
• Original Assignee: Air Cruisers Company LLC (Safran SA)
• Inventors: Duggal, Deepak, Jeffers, Mark, Swierkocki, Thomas W.
• Primary Examiner(s): Randazzo, Thomas
• Application Number:
  US15/058,688
• Time in Patent Office: 244 Days
• US Class Current: 1/1
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2597/00 Tubular articles, e.g. hoses, pipes
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B63B 2231/48 Synthetic rubber, e.g. silicone rubber, Neoprene, polyurethane
• CPC Class Codes: B63C 2009/042 inflatable
• CPC Class Codes: B63C 9/04 Life-rafts
• CPC Class Codes: B63C 9/1255 inflatable
• CPC Class Codes: B64D 25/14 : Inflatable escape chutes
• CPC Class Codes: B64D 25/18 : Flotation gear aircraft alighting gear B64C

Abstract

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 filament fibers formed in various directions. The substrate layer then has a first and second layer of polyurethane. The first and second layers of polyurethane may be laminated or coated to a nonwoven substrate of the filament fibers. An isocyanate-based adhesive or primer may be particularly useful in causing cross-linking of the materials to one another.

Claims

1. An inflatable evacuation slide, life raft, life vest, or other emergency flotation or inflatable device, comprising:

a flexible composite material, comprising

a substrate of nonwoven material comprising a plurality of straight laid fibers;

an isocyanate-based adhesive or primer; and

a first layer of polyurethane on one surface of the substrate of nonwoven material and a second layer of polyurethane on a second surface 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 190 pounds per inch and a weight of about 8 ounces per square yard or less,

wherein the flexible composite material is adhered to itself to form a tubular structure or is adhered to another flexible composite material.

2. The device of claim 1, wherein the substrate of nonwoven material comprises multiple layers.

3. The device of claim 1, wherein the first or second or both layers of polyurethane comprise a coating or a lamination film.

4. The device of claim 1, wherein the substrate of nonwoven material comprises a non-inflatable part of the device.

5. The device of claim 4, wherein the substrate of nonwoven material comprises floor material of a life raft or evacuation slide.

6. The device of claim 4, wherein the substrate of nonwoven material comprises a girt material of an evacuation slide.

7. The device of claim 4, wherein the substrate of nonwoven material comprises a handle or accessory patch of a life raft or evacuation slide.

8. The device of claim 1, wherein the straight laid fibers present a flat surface without crimping or peaks and valleys.

9. The device of claim 1, wherein the straight laid fibers are non-continuous in length.

10. The device of claim 9, where in the non-continuous fibers comprise a random orientation fiber layout.

11. The device of claim 1, wherein the straight laid fibers are continuous in length.

12. The device of claim 1, wherein the continuous straight laid fibers comprise a single strand positioned according to load exhibited on the structure.

13. The device of claim 1, wherein the straight laid fibers are unidirectional.

14. The device of claim 1, wherein the straight laid fibers are multidirectional.

15. The device of claim 1, wherein the straight laid fibers comprise a random orientation.

16. The device of claim 1, wherein a seam comprises a butt seam, and overlap seam, or a prayer seam.

17. The device of claim 1, wherein the substrate of nonwoven material comprises a customized fabric comprising fibers laid in particular directions of the expected stress to be experienced by the device be manufactured.

18. The device of claim 1, wherein the device comprises a tubular structure comprising a hoop direction and a longitudinal direction, wherein there are more fibers in the hoop direction than in the longitudinal direction.

19. The device of claim 1, wherein the device comprises one or more miter seam locations, wherein there are more fibers at the miter seam location than at other areas of the device.

20. The device of claim 1, wherein the device comprises tubular structures of varying diameters, wherein structures comprising larger diameters comprise more nonwoven fibers than structures comprises smaller diameters.

21. The device of claim 1, wherein the plurality of fibers are spun bond fibers.

22. The device of claim 1, wherein a seam is formed via application of hot air, radio frequency, thermal welding, or any combination thereof.

23. The device of claim 1, wherein the isocyanate-based adhesive or primer causes cross-linking between the fibers and the first and second layer of polyurethane.

24. The device of claim 1, wherein the material comprises a tensile strength of at least about 190 pounds per inch and a weight of about 6 ounces per square yard or less.

25. A method for manufacturing an inflatable evacuation slide, raft, life vest, or other emergency flotation or inflatable device, comprising:

providing or obtaining a flexible composite material, comprising a substrate of nonwoven material comprising a plurality of straight laid fibers;

applying a first layer of polyurethane on one surface of the substrate of nonwoven material;

applying a second layer of polyurethane on a second surface of the substrate of nonwoven material;

forming the material into a tubular structure; and

applying a floor or other accessory to the tubular structure.