Woven mat fabric with fused layers

Abstract

A woven mat fabric with fused layers containing a plurality of woven layers, where each woven layer contains a plurality of warp elements interwoven with a plurality of weft elements. The warp and weft elements contain polymeric strips which have a core layer disposed in layered relation with at least one surface layer. The core layer contains a first strain oriented polymer composition and having a first softening point and the surface layer contains a second polymer composition having a softening point lower than the first softening point. The weft and warp elements within each layer are fused to one another, but the weft and warp elements of one layer are not consolidated to the weft and warp elements of the adjacent layers.

1 . A woven mat fabric with fused layers comprising a plurality of woven layers, each woven layer comprising:
 a plurality of warp elements comprising polymeric strips extending in a first direction, wherein said strips comprise a core layer disposed in layered relation with at least one surface layer, the core layer comprising a first strain oriented polymer composition and having a first softening point, the surface layer comprising a second polymer composition having a softening point lower than the first softening point; and   a plurality of weft elements extending transverse to the first direction in interwoven relation to the warp elements, wherein the plurality of weft elements comprise polymeric strips comprising a core layer disposed in layered relation with at least one surface layer, the core layer comprising a first strain oriented polymer composition and having a first softening point, the surface layer comprising a second polymer composition having a softening point lower than the first softening point,   wherein the weft and warp elements within each layer are fused to one another, and wherein the weft and warp elements of one layer are not consolidated to the weft and warp elements of the adjacent layers.   
     
     
         2 . The woven mat fabric with fused layers of  claim 1 , wherein at least a portion of the weft elements comprise a material having a softening point at least 10° C. different than the softening point of the at least one surface layer. 
     
     
         3 . The woven mat fabric with fused layers of  claim 1 , wherein at least a portion of the weft elements comprise a material having a chemical composition different the surface layer of the polymeric strips. 
     
     
         4 . The woven mat fabric with fused layers of  claim 3 , wherein the material is selected from the group consisting of polyolefin tapes, monofilament fibers, and multifilament yarns. 
     
     
         5 . The woven mat fabric with fused layers of  claim 3 , wherein the material comprises cotton yarns. 
     
     
         6 . The woven mat fabric with fused layers of  claim 3 , wherein the material comprises anti-ballistic multifilament yarns. 
     
     
         7 . The woven mat fabric with fused layers of  claim 3 , wherein the tenacity of the material is greater than 10 grams per denier. 
     
     
         8 . The woven mat fabric with fused layers of  claim 3 , wherein the material comprises a nonolefin material. 
     
     
         9 . The woven mat fabric with fused layers of  claim 1 , wherein at least a portion of the warp elements comprise a material having a softening point at least 10° C. different than the softening point of the at least one surface layer. 
     
     
         10 . The woven mat fabric with fused layers of  claim 1 , wherein at least a portion of the warp elements comprise a material having a chemical composition different the surface layer of the polymeric strips. 
     
     
         11 . The woven mat fabric with fused layers of  claim 10 , wherein the material is selected from the group consisting of polyolefin tapes, monofilament fibers, and multifilament yarns. 
     
     
         12 . The woven mat fabric with fused layers of  claim 10 , wherein the material comprises cotton yarns. 
     
     
         13 . The woven mat fabric with fused layers of  claim 10 , wherein the material comprises anti-ballistic multifilament yarns. 
     
     
         14 . The woven mat fabric with fused layers of  claim 10 , wherein the tenacity of the material is greater than 10 grams per denier. 
     
     
         15 . The woven mat fabric with fused layers of  claim 10 , wherein the material comprises a nonolefin material. 
     
     
         16 . The woven mat fabric with fused layers of  claim 1 , wherein the warp and weft elements comprise tapes, wherein the tapes comprise a core layer surrounded by a first surface layer and a second surface layer. 
     
     
         17 . The woven mat fabric with fused layers of  claim 1 , wherein the warp and weft elements comprise a polyolefin. 
     
     
         18 . The woven mat fabric with fused layers of  claim 17 , wherein the warp and weft elements comprise a core layer comprising polypropylene and at least one surface layer comprising a propylene copolymer.