Three-dimensional textile composite structure and manufacture and use thereof

Abstract

A three-dimensional cellular textile composite structure with energy-absorbing capacities under multiple impacts is provided. The cellular textile composite structure includes a base, and at least one progressively collapsible projection extending from the base for absorbing energies under the multiple impacts. The projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after the first impact of the multiple impacts.

1 . A three-dimensional textile composite structure with energy-absorbing capacities under multiple impacts, comprising: 
 a base, and    at least one progressively collapsible projection extending from the base for absorbing energies under the multiple Impacts,    wherein the projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after the first impact of the multiple impacts.    
   
   
       2 . The structure of  claim 1 , wherein the projection has a grid-domed shape.  
   
   
       3 . The structure of  claim 1 , wherein the non-woven textile material is made from staple fibers with a random orientation.  
   
   
       4 . The structure of  claim 3 , wherein the staple fibers have a low level of anisotropy in mechanical properties.  
   
   
       5 . The structure of  claim 1 , wherein the thermoplastic matrix material has a melting temperature lower than the no-woven textile material.  
   
   
       6 . The structure of  claim 1 , wherein the non-woven textile material is impregnated with the thermoplastic matrix material by the following steps: 
 laminating a layer of the thermoplastic matrix material with a layer of the non-woven textile material;    heating the laminate to a processing temperature higher than the melting temperature of the thermoplastic matrix material but lower than the melting temperature of the non-woven textile material; and    applying pressure to the heated laminate for impregnating the non-woven textile material with the melted thermoplastic matrix material.    
   
   
       7 . A process for manufacturing a textile composite structure capable of retaining energy-absorption capacity at least after the first impact of multiple impacts, comprising: 
 providing a layer of non-woven textile material;    laminating a layer of thermoplastic matrix material with the non-woven textile layer, the thermoplastic matrix material melting at a lower temperature than the non-woven textile;    heating the laminate to a processing temperature higher than the melting temperature of the thermoplastic matrix material but lower than the melting temperature of the non-woven textile material;    applying pressure to the heated laminate for impregnating the non-woven textile material with the melted thermoplastic matrix material; and    molding the non-woven textile material impregnated with the thermoplastic matrix material to a desired shape with a base and a plurality of progressively collapsible projections extending from the base.    
   
   
       8 . The process of  claim 7 , wherein the heating step includes raising the processing temperature to at least five degrees higher than the melting temperature of the thermoplastic matrix material.  
   
   
       9 . The process of  claim 7 , wherein the projections have a grid-domed shape.  
   
   
       10 . The process of  claim 7 , wherein the non-woven textile material is made from staple fibers with a random orientation  
   
   
       11 . The process of  claim 10 , wherein the staple fibers have a low level of anisotropy in mechanical properties.  
   
   
       12 . The process of  claim 7 , further comprising: 
 obtaining the non-woven textile layer by processing a layer of fabrics using a process selected from needle-punching, water jet penetration, melting binding, adhesive bonding, melt-blowing and bonding by adhesive fibers.    
   
   
       13 . An energy-absorbing door, comprising: 
 inner and outer panels joined together in spaced apart relation; and    an energy absorbing structure provided on the inner panel including at least an energy-absorbing sheet of textile composite having a base and a plurality of projections extending from the base,    wherein each projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after an initial Impact.    
   
   
       14 . A safety headwear, comprising: 
 an outer shell; and    an energy-absorbing liner within said outer shell including at least an energy-absorbing sheet of textile composite having a base and a plurality of projections extending from the base,    wherein each projection Includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after an initial impact.    
   
   
       15 . A body protective gear, comprising: 
 an outer surface; and    an energy-absorbing liner within the outer surface including at least an energy-absorbing sheet of textile composite having a base and a    wherein each projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after an initial Impact.    
   
   
       16 . A protective package, comprising 
 an outer shell; and    an energy-absorbing liner within the outer shell including at least an energy-absorbing sheet of textile composite having a base and a plurality of projections extending from the base,    wherein each projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after an initial impact.    
   
   
       17 . A seat cushion, comprising 
 an outer shell; and    an energy-absorbing liner within said outer shell including at least an energy-absorbing sheet of textile composite having a base and a plurality of projections extending from the base,    wherein each projection includes a non-woven textile material supported in a thermoplastic matrix material such that the projection is capable of retaining energy-absorption capacity at least after an initial impact.