Bonded composite structure

Abstract

A product made by a method for bonding fibers that includes providing a first fiber layer and a second fiber layer positioned below the first fiber layer to bond the first fiber layer with the second fiber layer. The method may also include providing a first additive layer. The first additive layer is located between the first fiber layer and the second fiber layer. Then, the method may further include activating the first additive layer by directing energy at the first additive layer.

1 . A product made by a process that comprises:
 a first fiber layer comprising a UHMWPE Dyneema fiber;   a second fiber layer located adjacent the first fiber layer, wherein the second fiber layer comprises a UHMWPE Dyneema fiber, and wherein a portion of the second fiber layer overlaps a portion of the first fiber layer to create a seam area;   a composite structure formed at the seam area by bonding the first UHMWPE Dyneema fiber layer and the second UHMWPE Dyneema fiber layer together with applied energy to the seam area.   
     
     
         2 . The product of  claim 1 , further comprising a first additive layer located between the first fiber layer and the second fiber layer in the seam area. 
     
     
         3 . The product of  claim 1 , comprising a first additive layer located adjacent a side of the first fiber layer that is opposite a side of the first fiber layer that is facing the second fiber layer in the seam area. 
     
     
         4 . The product of  claim 3 , further comprising a second additive layer adjacent a side of the first fiber layer that is opposite a side that has the first additive layer in the seam area. 
     
     
         5 . The product of  claim 4 , further comprising a third additive layer adjacent a side of the second fiber layer that is opposite a side of the second fiber layer that is facing the first fiber layer in the seam area. 
     
     
         6 . The product of  claim 5 , wherein the first, second, and third additive layers are made from at least one of polyester and polyamides. 
     
     
         7 . A product made by a process for bonding Ultra-High Molecular Weight Polyethylene (UHMWPE) Dyneema fiber to itself with an airtight seam, comprising:
 providing a first UHMWPE Dyneema fiber layer having a first side and a second side;   providing a second UHMWPE Dyneema fiber layer having a first side and a second side and positioning a portion of the first side of the second UHMWPE Dyneema fiber layer on a portion of the second side of the first UHMWPE Dyneema fiber layer to form a seam area;   providing a thermal buffer layer on the first side of the first UHMWPE Dyneema fiber layer or on the second side of the second UHMWPE Dyneema fiber layer in the seam area, or both the first side of the first UHMWPE Dyneema fiber layer and on the second side of the second UHMWPE Dyneema fiber layer in the seam area, the thermal buffer layer consisting of a silicone or polyester film; and   directing energy at the seam area to bond together the portions of the first and second UHMWPE Dyneema fiber layers and the thermal buffer layer to form an airtight seam.   
     
     
         8 . The product of  claim 7 , wherein the product further comprises a first additive layer located between the first fiber layer and the second fiber layer in the seam area. 
     
     
         9 . The product of  claim 8 , wherein the product further comprises a second additive layer adjacent a side of the first fiber layer that is not adjacent the first additive layer in the seam area. 
     
     
         10 . The product of  claim 9 , wherein the product further comprises a third additive layer adjacent a side of the second fiber layer that is not adjacent the first additive layer. 
     
     
         11 . The product of  claim 9 , wherein the first, second, and third additive layers comprise at least one of polyester and polyamides. 
     
     
         12 . The product of  claim 7 , wherein the energy consists of radio-frequency energy. 
     
     
         13 . A product, made by a process comprising:
 providing a first fiber layer consisting of an Ultra-High Molecular Weight Polyethylene (UHMWPE) Dyneema fiber, the first fiber layer having a first side and a second side;   providing a second fiber layer consisting of a UHMWPE Dyneema fiber having a first side and a second side and positioning the second fiber layer to have the first side facing the second side of the first fiber layer;   overlapping a portion of the second side of the first fiber layer and a portion of the first side of the second fiber layer to create a seam area;   providing a thermal buffer layer against the first side of the first UHMWPE Dyneema fiber layer or against the second side of the second UHMWPE Dyneema fiber layer, or both, in the seam area; and   forming a composite structure at the seam area by RF welding the first and second UHMWPE Dyneema fiber layers and the thermal buffer layer together to form an airtight seam.   
     
     
         14 . The product of  claim 13 , further comprising a first additive layer positioned between the first fiber layer and the second fiber layer in the seam area. 
     
     
         15 . The product of  claim 13 , further comprising a first additive layer positioned adjacent a side of the first fiber layer that is not adjacent the second fiber layer in the seam area. 
     
     
         16 . The product of  claim 13 , further comprising a first additive layer positioned adjacent a side of the second fiber layer that is not adjacent the first fiber layer in the seam area. 
     
     
         17 . The product of  claim 13 , further comprising a first additive layer positioned between the first fiber layer and the second fiber layer, a second additive layer positioned adjacent a side of the first fiber layer that is not adjacent the first additive layer, and a third additive layer positioned adjacent a side of the second fiber layer that is not adjacent the first additive layer in the seam area. 
     
     
         18 . The product of  claim 17 , wherein the first, second, and third additive layers are made from at least one of polyester and polyamides.