Engineered composite systems

• US 9,789,662 B2
• Filed: 03/13/2014
• Issued: 10/17/2017
• Est. Priority Date: 03/13/2013
• Status: Active Grant

• Current Assignee: DSM IP Assets BV (DSM-Firmenich AG)
• Original Assignee: Cubic Tech Corporation (DSM-Firmenich AG)
• Inventors: Downs, Roland Joseph, Adams, Christopher Michael, Holweger, Jon Michael, Hatcher, Wesley Edward, McDaniels, Keith Joel
• Primary Examiner(s): Singh-Pandey, Arti
• Application Number:
  US14/207,790
• Publication Number:
  US 20140308510A1
• Time in Patent Office: 1,314 Days
• Field of Search: 4282997
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• 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 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted 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: Y10T 428/249947 Polymeric fiber

Abstract

A system for providing improved engineered-composite materials, equipment, and manufacturing processes.

Claims

1. A waterproof, non-breathable flexible laminate comprising:

(a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction;

(b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer;

(c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer;

(d) a stretchable non-breathable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and

(e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer,

wherein said monofilaments have diameters less than 20 microns; and

wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

2. The laminate of claim 1, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45°

relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90°

relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90°

or −

90°

relative to said first predetermined direction.

3. The laminate of claim 1, wherein said monofilaments comprise ultra-high molecular weight polyethylene.

4. The laminate of claim 3, wherein each of said unidirectional tape layers comprises from about 12 gsm to about 16 gsm non-breathable adhesive and from about 12 gsm to about 16 gsm ultra-high molecular weight polyethylene monofilaments.

5. The laminate of claim 3 having added abrasion resistance on the side possessing the stretchable tricot knit layer.

6. The laminate of claim 1, wherein first, second and third unidirectional tape layers include smaller areas absent monofilaments.

7. The laminate of claim 6, further comprising larger areas absent monofilaments, wherein said larger areas comprise laminar overlays of said smaller areas of said unidirectional tape layers absent monofilaments.

8. The laminate of claim 1, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

9. The laminate of claim 1, wherein said monofilaments in each of said unidirectional tape layers are extruded.

10. A waterproof, non-breathable flexible laminate comprising:

(a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction;

(b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer;

(c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer;

(d) a stretchable non-breathable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and

(e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer, wherein each of said first, second and third predetermined directions are different.

11. The laminate of claim 10, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45°

relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90°

relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90°

or −

90°

relative to said first predetermined direction.

12. The laminate of claim 10, wherein said monofilaments have diameters less than 20 microns;

and wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

13. The laminate of claim 10, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

14. The laminate of claim 10, wherein said monofilaments in each of said first, second and third unidirectional tape layers comprise ultra-high molecular weight polyethylene.

15. The laminate of claim 12, further comprising larger areas absent monofilaments, wherein said larger areas comprise laminar overlays of portions of said unidirectional tape layers absent monofilaments.

16. A waterproof flexible laminate comprising:

(a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction;

(b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer;

(c) a third unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a third predetermined direction, said third unidirectional tape layer bonded to said second unidirectional tape layer;

(d) a stretchable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and

(e) a stretchable tricot knit layer bonded to said third unidirectional tape layer opposite said second unidirectional tape layer,

wherein said monofilaments have diameters less than 20 microns; and

wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to nine times the monofilament major diameter.

17. The laminate of claim 16, wherein said stretchable urethane membrane film is non-breathable.

18. The laminate of claim 16, wherein said stretchable urethane membrane film is breathable.

19. The laminate of claim 16, wherein said adhesive in each of said first, second and third unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said unidirectional tape layers are waterproof and air-permeable.

20. The laminate of claim 16, wherein said monofilaments in each of said first, second and third unidirectional tape layers comprise ultra-high molecular weight polyethylene.

21. The laminate of claim 16, wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 45°

relative to said first predetermined direction, and wherein said second and third unidirectional tape layers are oriented relative to one another such that said third predetermined direction is 90°

relative to said second predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+90°

or −

90°

relative to said first predetermined direction.

22. A waterproof flexible laminate comprising:

(a) a first unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a first predetermined direction;

(b) a second unidirectional tape layer comprising monofilaments coated in an adhesive, all of said monofilaments lying in a second predetermined direction, said second unidirectional tape layer bonded to said first unidirectional tape layer;

(c) a stretchable urethane membrane film bonded to said first unidirectional tape layer opposite said second unidirectional tape layer; and

(d) a stretchable tricot knit layer bonded to said second unidirectional tape layer opposite said first unidirectional tape layer,

wherein said first and second unidirectional tape layers are oriented relative to one another such that said second predetermined direction is 90°

relative to said first predetermined direction, and wherein said laminate exhibits low modulus when stretched in a direction+45°

or −

45°

relative to said first predetermined direction.

23. The laminate of claim 22, wherein said stretchable urethane membrane film is non-breathable.

24. The laminate of claim 22, wherein said stretchable urethane membrane film is breathable.

25. The laminate of claim 22, wherein said monofilaments in each of said first and second unidirectional tape layers comprise ultra-high molecular weight polyethylene, and wherein said adhesive in each of said first and second unidirectional tape layers comprises a partially thermosetting, waterproof breathable polymer, such that each of said first and second unidirectional tape layers are waterproof and air-permeable.