Flexible composite systems and methods

Abstract

In various embodiments, an improved flexible-composite material is described that comprises at least one scrim constructed from at least two unidirectional tape layers bonded together and at least one woven fabric, non-woven fabric, or membrane bonded to the scrim. In various embodiments, the unidirectional tape layers comprise a plurality of parallel fiber bundles comprising monofilaments within an adhesive resin. In various embodiments, the fiber bundles are separated by gaps that can be filled in by adhesive or non-adhesive resin.

What is claimed is: 
     
         1 . A flexible-composite material comprising:
 at least two unidirectional tape layers bonded together to form a scrim, wherein each of said unidirectional tape layers comprise a plurality of parallel fiber bundles comprising monofilaments in an adhesive resin, and wherein said fiber bundles are separated by gaps; and   at least one of a woven fabric, a random or oriented non-woven fabric, a membrane or a film.   
     
     
         2 . The flexible-composite material of  claim 1 , wherein said at least one scrim is bonded to at least one woven fabric. 
     
     
         3 . The flexible-composite material of  claim 2 , wherein said woven fabric is any one of knits, imaginable square weave, basket weave, warp knit, and fleece. 
     
     
         4 . The flexible-composite material of  claim 1 , wherein said at least one scrim is bonded to at least one random or oriented non-woven fabric. 
     
     
         5 . The flexible-composite material of  claim 1 , wherein said at least one scrim is bonded to at least one membrane or film. 
     
     
         6 . The flexible-composite material of  claim 1 , wherein one non-woven fabric is bonded between two of said scrims or between unidirectional tape layers within one of said scrims. 
     
     
         7 . The flexible-composite material of  claim 1 , wherein one woven fabric is bonded between two of said scrims or between unidirectional tape layers within one of said scrims. 
     
     
         8 . The flexible-composite material of  claim 1 , wherein one membrane is bonded between two of said scrims or between unidirectional tape layers within one of said scrims. 
     
     
         9 . The flexible-composite material of  claim 1 , wherein said gaps are at least partially filled with breathable or non-breathable adhesive. 
     
     
         10 . The flexible-composite material of  claim 1 , further comprising at least one plastic film. 
     
     
         11 . The flexible-composite material of  claim 10 , wherein said plastic film is any one of PET, PEN, Nylon, fluoropolymer, and urethane. 
     
     
         12 . The flexible-composite material of  claim 10 , comprising two plastic films laminated to both sides of said flexible-composite material. 
     
     
         13 . The flexible-composite material of  claim 10 , wherein said plastic film is (a) disposed between said unidirectional tape layers, or (b) disposed between said woven fabric, non-woven fabric or membrane and said scrim. 
     
     
         14 . The flexible-composite material of  claim 1 , further comprising at least one non-impregnated fabric, said non-impregnated fabric (a) laminated to one or both sides of said flexible-composite material, (b) disposed between two of said at least two unidirectional tape layers, or (c) disposed between said woven fabric, non-woven fabric or membrane and said scrim.