Composite fabric product and method of manufacturing the same

Abstract

Manufacturing method for a composite fabric material including: holding a bundle of fibers under tension, the fiber being continuous filaments of carbon fibers, aramid fibers, or glass fibers, etc.; placing a layer of a matrix material over and under the fiber bundle, the matrix material being a thermoplastic adhesive material such as polyamide resins, thermoplastic polyurethane, or polyester, etc.; heating the matrix material to melt it and applying a pressure on the layers while the fiber bundle is under tension; and cooling the layers, whereby the fibers are locked in place by the adhesive. Composite material layers produced by the above steps may be laminated and further processed or formed as desired. The composite fabric materials manufactured by this method have superior tensile properties, compression properties, impact properties, and impact dispersion and propagation properties compared to composite fabric materials made with conventional methods.

1 . A method for manufacturing a composite fabric material, comprising the steps of: 
 (a) holding a bundle of continuous fibers under tension;    (b) placing one or more layers of a matrix material over and/or under the fiber bundle while maintaining the fibers under tension;    (c) heating the layers of matrix material and the fiber bundle while maintaining the fibers under tension, the heating being sufficient to melt the adhesive material;    (d) applying a pressure on the heated layers of matrix material and the fiber bundle while maintaining the fibers under tension; and    (e) cooling the resulting product of step (d) while maintaining the fibers under tension, thereby imparting an internal stress in the fibers.    
   
   
       2 . The method of  claim 1 , wherein step (a) comprises providing the fibers being selected from a group consisting essentially of carbon fibers, aramid fibers, S-Glass fibers, E-Glass fibers, and hybrids thereof.  
   
   
       3 . The method of  claim 1 , wherein step (a) comprises providing the fibers as carbon fibers.  
   
   
       4 . The method of  claim 1 , wherein step (a) comprises providing the fibers in the bundle to form a unidirectional fabric.  
   
   
       5 . The method of  claim 1 , wherein step (a) comprises providing the fibers in the bundle to form a woven fabric.  
   
   
       6 . The method of  claim 1 , wherein step (b) comprises providing the matrix material as a thermoplastic adhesive material.  
   
   
       7 . The method of  claim 1 , wherein step (b) comprises providing the matrix material being selected from a group consisting essentially of polyamide resins, thermoplastic polyurethane (TPU), and polyester.  
   
   
       8 . The method of  claim 1 , wherein step (b) comprises providing the matrix material as nylon-12.  
   
   
       9 . The method of  claim 1 , wherein step (b) comprises providing the matrix material in an amount of approximately 20% to approximately 60% by volume of the matrix material to the total composite fabric material.  
   
   
       10 . The method of  claim 1 , wherein step (b) comprises providing the matrix material in an amount of approximately 5% to approximately 60% by volume of the matrix material to the total composite fabric material.  
   
   
       11 . The method of  claim 1 , 
 wherein step (b) comprises providing the matrix material as nylon-12, and    wherein step (c) comprises providing a temperature of the matrix material in a range of approximately 310 degrees C. to approximately 380 degrees C.    
   
   
       12 . The method of  claim 1 , wherein steps (c) and (d) comprise using a pair of heated pressure rollers.  
   
   
       13 . The method of  claim 1 , 
 wherein step (c) comprises using a heating element, and    wherein step (d) comprises using a pair of pressure rollers.    
   
   
       14 . The method of  claim 1 , wherein step (d) comprises applying a pressure in a range of approximately 15 psi to approximately 22 psi.  
   
   
       15 . The method of  claim 1 , wherein step (d) comprises applying a pressure of approximately 20 psi.  
   
   
       16 . The method of  claim 1 , 
 wherein step (a) comprises providing the fiber bundle as Toho™ G30-700 fibers, and    wherein step (a) comprises providing the tension in the bundle of fibers comprises a range of approximately 4 to approximately 6 lbs.    
   
   
       17 . (canceled)  
   
   
       18 . A composite fabric material product fabricated by the process of  claim 1 .  
   
   
       19 - 27 . (canceled)  
   
   
       28 . A composite fabric material product fabricated by the process of  claim 1 , 
 wherein step (a) comprises providing the fibers being selected from a group consisting essentially of carbon fibers, aramid fibers, S-Glass fibers, E-Glass fibers, and hybrids thereof,    wherein step (a) comprises providing the fibers as carbon fibers,    wherein step (a) comprises providing the fibers in the bundle to form a fabric being selected from a group consisting essentially of a unidirectional fabric and a woven fabric,    wherein step (b) comprises providing the matrix material being selected from a group consisting essentially of a thermoplastic adhesive material, polyamide resins, thermoplastic polyurethane (TPU), polyester, and nylon-12,    wherein step (b) comprises providing the matrix material in an amount of approximately 20% to approximately 60% by volume of the matrix material to the total composite fabric material,    wherein step (c) comprises providing a temperature of the matrix material in a range of approximately 310 degrees C. to approximately 380 degrees C.,    wherein step (c) comprises using a heating element,    wherein step (d) comprises using a pair of pressure rollers,    wherein step (d) comprises applying a pressure in a range of approximately 15 psi to approximately 22 psi,    wherein step (a) comprises providing the fiber bundle as Toho™ G30-700 fibers, and    wherein step (a) comprises providing the tension in the bundle of fibers comprises a range of approximately 4 to approximately 6 lbs.