Moldable fabric with unidirectional tape yarns

Abstract

The invention relates to an impact resistant component comprising at least two composite sheets fused together, each composite sheet comprising an adhesive layer fused between two unidirectional sheets, wherein each unidirectional sheet comprises a plurality of monoaxially drawn fibers arranged substantially parallel to one another along a common fiber direction, the fibers comprising a base layer of a strain oriented polymer disposed between surface layer(s) of a heat fusible polymer, wherein the surface layer(s) are characterized by a melting temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the adhesive layer has a melting temperature below that of the base layer of the unidirectional sheet.

1 . An impact resistant component comprising:
 at least two composite sheets fused together, each composite sheet comprising two unidirectional sheets and an adhesive layer, wherein the adhesive layer fuses the unidirectional sheets to one another;   wherein each unidirectional sheet comprises a plurality of monoaxially drawn fiber elements arranged substantially parallel to one another along a common fiber direction, the fiber elements comprising a core of a strain oriented polymer and one surface layer of a heat fusible polymer that covers at least a portion of one side of the core, wherein the surface layer is characterized by a softening temperature below that of the core to permit fusion bonding upon application of heat and   wherein the adhesive layer has a softening point lower than the surface layer of the fiber elements, wherein the unidirectional sheets are oriented such that the adhesive layer adheres to the core layers of the fiber elements and the surface layers form the outer surface of the composite sheets, wherein the unidirectional sheets of each composite sheet have the same common fiber direction, and:   wherein the surface layers of the composite sheets fuse together to form the fused impact resistant component.   
   
   
       2 . (canceled) 
   
   
       3 . The impact resistant component of  claim 1 , wherein the at least one surface layer of the fiber elements comprises an olefin polymer. 
   
   
       4 . The impact resistant component of  claim 1 , wherein the core of the fiber elements comprises an olefin polymer. 
   
   
       5 - 6 . (canceled) 
   
   
       7 . The impact resistant component of  claim 1 , wherein the core is comprised of one or more fibers having a cross-sectional shape selected from the group consisting of circular, oblong, and elliptical and the at least one surface layer covers the entire surface area of the core. 
   
   
       8 . The impact resistant component of  claim 1 , wherein the adhesive layer is in an amount of between about 0.2 to 10% of the weight of the impact resistant component. 
   
   
       9 . The impact resistant component of  claim 1 , wherein the at least two composite sheets are fused together without additional adhesives. 
   
   
       10 . The impact resistant component of  claim 1 , wherein the unidirectional sheets of each composite sheet have the same common fiber direction. 
   
   
       11 . The impact resistant component of  claim 10 , wherein the common fiber direction of the unidirectional sheets of one composite sheet are perpendicular to the common fiber direction of the unidirectional sheets of the adjacent composite sheets. 
   
   
       12 . The impact resistant component  claim 1 , wherein the core, surface layer, and the adhesive layer comprise a polymer selected from the group consisting of polypropylene and polyethylene. 
   
   
       13 . An impact resistant component comprising:
 at least 10 composite sheets fused together, each composite sheet comprising two unidirectional sheets and an adhesive layer, wherein the adhesive layer fuses the unidirectional sheets to one another, wherein each unidirectional sheet comprises   a plurality of monoaxially drawn fiber elements arranged substantially parallel to one another along a common fiber direction, the fiber elements comprising a core of a strain oriented polymer and one surface layer of a heat fusible polymer that covers at least a portion of one side of the core, wherein the surface layer is characterized by a softening temperature below that of the core to permit fusion bonding upon application of heat and   wherein the adhesive layer fuses the unidirectional sheets together, where in the adhesive layer has a softening point lower than the surface layer of the fiber elements, wherein the unidirectional sheets are oriented such that the adhesive layer adheres to the core layers of the fiber elements and the surface layers form the outer surface of the composite sheets, and;   wherein the surface layers of the composite sheets fuse together to form the fused impact resistant component.   
   
   
       14 . (canceled) 
   
   
       15 . The impact resistant component of  claim 13 , wherein the at least one surface layer and the core of the fiber elements comprises an olefin polymer. 
   
   
       16 - 27 . (canceled) 
   
   
       28 . An impact resistant component comprising:
 at least two composite sheets fused together,   each composite sheet comprising two unidirectional sheets and an adhesive layer, wherein each unidirectional sheet comprises   a plurality of monoaxially drawn fiber elements arranged substantially parallel to one another along a common fiber direction, the fiber elements comprising a core of a strain oriented polymer and surface layers of a heat fusible polymer that covers at least a portion of each side of the core, wherein the surface layers are characterized by a softening temperature below that of the core to permit fusion bonding upon application of heat; and,   wherein the unidirectional sheets within each composite sheet have the same common fiber direction, wherein the adhesive layer fuses the unidirectional sheets together, wherein the adhesive layer has a softening point lower than the surface layer of the fiber elements, and wherein the surface layers of the composite sheets fuse together to form the fused impact resistant component.   
   
   
       29 . The impact resistant component of  claim 29 , wherein the unidirectional sheets of each composite sheet have the same common fiber direction. 
   
   
       30 . The impact resistant component of  claim 29 , wherein the at least two composite sheets are fused together without additional adhesives. 
   
   
       31 . The impact resistant component of  claim 29 , wherein the common fiber direction of the unidirectional sheets of one composite sheet are perpendicular to the common fiber direction of the unidirectional sheets of the adjacent composite sheets. 
   
   
       32 . An impact resistant component comprising:
 at least ten composite sheets fused together,   each composite sheet comprising two unidirectional sheets and an adhesive layer, wherein each unidirectional sheet comprises   a plurality of monoaxially drawn fiber elements arranged substantially parallel to one another along a common fiber direction, the fiber elements comprising a core of a strain oriented polymer and surface layers of a heat fusible polymer that covers at least a portion of each side of the core, wherein the surface layers are characterized by a softening temperature below that of the core to permit fusion bonding upon application of heat; and,   wherein the unidirectional sheets within each composite sheet have the same common fiber direction, wherein the adhesive layer fuses the unidirectional sheets together, wherein the adhesive layer has a softening point lower than the surface layer of the fiber elements, and wherein the surface layers of the composite sheets fuse together to form the fused impact resistant component.   
   
   
       33 . The impact resistant component of  claim 32 , wherein the at least two composite sheets are fused together without additional adhesives. 
   
   
       34 . The impact resistant component of  claim 32 , wherein the common fiber direction of the unidirectional sheets of one composite sheet are perpendicular to the common fiber direction of the unidirectional sheets of the adjacent composite sheets.