Systems and method for producing three-dimensional articles from flexible composite materials

Abstract

The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.

What is claimed is: 
     
         1 . A method of producing a flexible composite material, the method comprising:
 providing a male tool having an outer three-dimensional shape;   creating a fiber-reinforced scrim by sticking together two unitape layers, each unitape layer comprising a single fiber-reinforced direction provided by monofilaments spread side-by-side and embedded in an adhesive resin, the two unitape layers having an intersecting relative orientation in the scrim whereby one unitape layer has a different fiber direction than the other unitape layer, and the elastic polymer allowing the uncured scrim to stretch in non-fiber reinforced bias directions not aligned with the fiber directions;   molding the fiber-reinforced scrim over the male tool; and   curing the fiber-reinforced scrim on the male tool to form the flexible composite material cured in the outer three-dimensional shape,   wherein the single direction monalament alignment within each unitape layer is stabilized and maintained by reinforcement provided by the intersecting unitape layers.   
     
     
         2 . The method of  claim 1 , wherein the fiber-reinforced scrim is pre-cured prior to molding the fiber-reinforced scrim over the male tool. 
     
     
         3 . The method of  claim 2 , wherein a film or surface layer is applied on one or both sides of the fiber-reinforced scrim prior to pre-curing. 
     
     
         4 . The method of  claim 1 , wherein the monofilaments in each of the unitape layers comprise ultra-high molecular weight polyethylene (UHMWPE). 
     
     
         5 . The method of  claim 1 , wherein the flexible composite material thus cured is configured to be gas inflatable. 
     
     
         6 . The method of  claim 1 , further comprising integrating the flexible composite material within a bag to form an inflatable structure. 
     
     
         7 . The method of  claim 1 , wherein the intersecting relative orientation of the unitape fiber directions in the scrim is 0°/90°. 
     
     
         8 . The method of  claim 1 , further comprising adding directional fiber reinforcement over the fiber-reinforced scrim after molding the fiber-reinforced scrim over the male tool and prior to curing. 
     
     
         9 . The method of  claim 1 , further comprising shaping additional unitape layers over the fiber-reinforced scrim after molding the fiber-reinforced scrim over the male tool and prior to curing so as to limit stretch of the cured flexible composite along specific load paths. 
     
     
         10 . The method of  claim 1 , wherein sticking together two unitape layers further comprises adding an interlayer of elastomer between each unitape layer to allow the two unitape layers to rotate or hinge slightly upon deformation of the cured flexible composite from the outer three-dimensional shape.