HIGH PERFORMANCE COMPOSITE FABRIC
Methods and apparatus are provided for a durable, wear resistant composite fabric. In one exemplary embodiment the composite fabric comprises an outer layer of a woven synthetic fabric, and a backing layer of a woven fabric made from high tenacity fibers. The backing layer may be consolidated with the outer layer.
1 . A durable, wear resistant composite fabric, comprising:
an outer layer of a woven synthetic fabric; and
a backing layer of a woven fabric made from high tenacity fibers, the backing layer consolidated with the outer layer.
2 . The composite material of claim 1 , wherein the outer layer is made of nylon.
3 . The composite material of claim 1 , wherein the backing layer is made of high performance polymer fibers.
4 . The composite material of claim 3 , wherein the high performance polymer fibers are selected from the group comprising aramid fibers, para-aramid fibers, high molecular weight polyethylene fibers, polybenzobisoxazole fibers, and terephthaloyl chloride fibers.
5 . The composite material of claim 3 , wherein the backing layer is formed of a puncture resistant, relatively tight weave, comprising at least 40 fibers per inch in a first, warp direction, and at least 40 fibers per inch in a second, fill direction.
6 . The composite material of claim 5 , wherein the puncture resistant backing layer is characterized by a warp yarn density in excess of 100 percent, and a fill yarn density in excess of 75 percent.
7 . The composite material of claim 5 , wherein the relatively tight weave of the backing layer comprises filament crossovers in the range of about fifty million to ninety million filament crossovers per square inch.
8 . The composite material of claim 1 , wherein the backing layer is consolidated with the outer layer through a laminating process using a thermoset adhesive.
9 . The composite material of claim 1 , wherein the backing layer is Kevlar® Correctional™ para-aramid fiber fabric.
10 . The composite material of claim 1 , wherein the fibers may have a tensile strength greater than about 2000 MPa, and an elastic modulus greater than about 60 GPa.
11 . The composite material of claim 1 , wherein the fibers have a tensile strength greater than about 7 grams per denier.
12 . A composite fabric, comprising:
a first layer of a woven synthetic fabric; and
a second layer comprising a woven fabric formed of a puncture resistant, relatively tight weave of high performance fibers, with at least 40 fibers per inch in a first, warp direction, and at least 40 fibers per inch in a second, fill direction.
13 . The composite fabric of claim 12 , wherein the puncture resistant second layer is characterized by a warp yarn density in excess of 100 percent, and a fill yarn density in excess of 75 percent.
14 . The composite fabric of claim 12 , wherein the first layer is made of nylon.
15 . The composite material of claim 12 , wherein the high performance polymer fibers are selected from the group comprising aramid fibers, para-aramid fibers, high molecular weight polyethylene fibers, polybenzobisoxazole fibers, and terephthaloyl chloride fibers.
16 . The composite fabric of claim 12 , wherein the backing layer is consolidated with the outer layer through a laminating process using a thermoset adhesive.
17 . The composite fabric of claim 16 , further comprising a third fabric layer attached to one of the first and second fabric layers.
18 . The composite fabric of claim 12 , wherein the fibers may have a tensile strength greater than about 2000 MPa, and an elastic modulus greater than about 60 GPa.
19 . The composite fabric of claim 12 , wherein the second layer comprises between about 60 and 72 fibers per inch in both the warp and fill directions.
20 . A composite fabric, comprising:
a first fabric layer of a wear resistant, synthetic material; and
a second fabric layer comprising Kevlar® Correctional™ brand woven para-aramid fiber fabric laminated to the first fabric layer.
21 . The composite fabric of claim 20 , wherein the second layer is laminated to the first layer using a thermoplastic adhesive.
22 . The composite fabric of claim 21 , wherein the second layer is laminated to the first layer using a pressure sensitive adhesive.
23 . The composite fabric of claim 20 , wherein the first layer is woven nylon.
24 . A method of manufacturing a high performance composite fabric, comprising:
providing a first woven fabric made of a synthetic fiber;
positioning a second woven fabric made from high tenacity fibers adjacent the first woven fabric; and
consolidating the first and second woven fabrics into a unitary composite.
25 . The method of manufacturing a high performance composite fabric of claim 24 , wherein the first and second woven fabrics are consolidated under heat and pressure using a thermoplastic bonding agent.
26 . The method of manufacturing a high performance composite fabric of claim 25 , wherein the second woven fabric includes high performance polymer fibers selected from the group comprising aramid fibers, para-aramid fibers, high molecular weight polyethylene fibers, polybenzobisoxazole fibers, and terephthaloyl chloride fibers.
27 . The method of manufacturing a high performance composite fabric of claim 26 , wherein the fibers of the second woven fabric have a tensile strength greater than about 2000 MPa, and an elastic modulus greater than about 60 GPa.