High Tensile Strength Fabric Seams, Weldable Fabric Tabs and the Preparation of Reduced Weight Inflatables

Abstract

The present disclosure provides high tensile strength FCL seams, as well as methods for forming high tensile strength FCL seams by laser welding. The present disclosure also provides weldable FCL tabs for the reinforcement of both linear and curved sections of seams, as well as methods for reinforcing linear and curved sections of seams with weldable FCL tabs.

1 . A seam having a length of at least one inch comprising:
 a weld formed between a first base flexible composite laminate (FCL) ( 110 ) and a second base FCL ( 120 ),
 each of the first base FCL ( 110 ) and the second base FCL ( 120 ) comprising a plurality of stacked, unidirectionally oriented polyethylene fibers arranged in cross-plied monolayers ( 101  and  102 ) and embedded in a plastic matrix ( 103 ), wherein each base FCL is coated on at least one face with a meltable layer ( 104 ) or ( 105 ); 
 the weld comprising a homogeneous, fused monolayer ( 106 ) formed from the meltable layers ( 104 ) and ( 105 ) from each of the first base FCL ( 110 ) and the second base FCL ( 120 ), wherein the relative orientation of each pair of the plurality of unidirectionally oriented polyethylene fibers within the cross-plied monolayers ( 101 ) and ( 102 ) adjacent to the fused monolayer ( 106 ) is
 (i) perpendicular or having an oblique angle of no less than 75 degrees; or 
 (ii) parallel or having an oblique angle of no more than 15 degrees. 
 
   
     
     
         2 . The seam of  claim 1 , wherein one or both of the meltable layers ( 104 ) and ( 105 ) is no more than 55 microns (μM) thick, and no more than 90% of the thickness of the first base FCLs ( 110 ) or the second base FCL ( 120 ). 
     
     
         3 . The seam of  claim 1 , wherein the unidirectionally oriented polyethylene fibers are selected from the group consisting of Ultra High Density Polyethylene (UHMWPE) fibers, High Density Polyethylene (HDPE) fibers, Medium-Density Polyethylene (MDPE) fibers, Low-Density Polyethylene (LDPE) fibers, Very Low-Density Polyethylene (VLDPE) fibers, and Cross-Linked Polyethylene (PEX) fibers. 
     
     
         4 . (canceled) 
     
     
         5 . The seam of  claim 1 , wherein
 i. the density of each of the first base FCL ( 110 ) and the second base FCL ( 120 ) is between 0.40 grams per cubic meter (g/m 3 ) and 3.0 g/m 3 ;   ii. the weight of each of the first base FCL ( 110 ) and the second base FCL ( 120 ) is between 35 grams per square meter (g/m 2 ) and 140 g/m 2 ; or   iii. both i and ii.   
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . The seam of  claim 1 , wherein the relative orientation of each pair of the plurality of unidirectionally oriented polyethylene fibers within the cross-plied monolayers ( 101 ) and ( 102 ) adjacent to the fused monolayer ( 106 ) is perpendicular. 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . The seam of  claim 1 , wherein the relative orientation of each pair of the plurality of unidirectionally oriented polyethylene fibers within the cross-plied monolayers ( 101 ) and ( 102 ) adjacent to the fused monolayer ( 106 ) is parallel. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . The seam of  claim 1 , wherein the unidirectionally oriented polyethylene fibers of the first base FCL ( 110 ) or the second base FCL ( 120 ) of the seam in an area of at least 0.05 square centimeters (cm 2 ) show less than 10% damage from overheating as visualized by scanning-electron microscopy (SEM). 
     
     
         16 . (canceled) 
     
     
         17 . The seam of  claim 1 , wherein at least 90% of the seam in a sampled length of at least 20 square centimeters (cm 2 ) is free of discoloration, rippling, bubbling, deformation, and tearing. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . The seam of  claim 1 , wherein the seam shows no visible discontinuous weld lines oriented perpendicular to the direction of the seam when sampled along a length of at least 10 centimeters (cm). 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . The seam of  claim 1 , wherein less than 5% by weight of the polyethylene fibers of each of the first base FCL ( 110 ) and the second base FCL ( 120 ) of the seam are melt recrystallized as determined by differential scanning calorimetry (DSC; 10° C./min). 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . The seam of  claim 1 , wherein the seam has an average tensile strength that is at least 15% of the base tensile strength of the weaker of the first FCL ( 110 ) and the second FCL ( 120 ), wherein the average tensile strength is an average shear tensile strength or an average peel tensile strength. 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . The seam of  claim 1 , wherein each of the cross-plied monolayers ( 101 ) and ( 102 ) has a thickness that is between 30 microns (μM) and 120 μM. 
     
     
         32 . (canceled) 
     
     
         33 . The seam of  claim 1 , wherein the plastic matrix ( 103 ) comprises a thermoset, a thermoplastic, or a combination thereof. 
     
     
         34 . The seam of  claim 1 , wherein the plastic matrix ( 103 ) is an epoxy matrix or an elastomer. 
     
     
         35 . (canceled) 
     
     
         36 . (canceled) 
     
     
         37 . The seam of  claim 1 , wherein
 i. the homogeneous, fused monolayer ( 106 ) further comprises an absorption modifier ( 163 ); or   ii. one or both of the meltable layers ( 104 ) and ( 105 ) further comprises an absorption modifier ( 163 ), optionally wherein the absorption modifier ( 163 ) is selected from the group consisting of Clearweld™ MLD940A, Clearweld™ LD940B, Clearweld™ LD940C, Clearweld™ LD940E, and Clearweld™ LD940F.   
     
     
         38 . (canceled) 
     
     
         39 . (canceled) 
     
     
         40 . (canceled) 
     
     
         41 . (canceled) 
     
     
         42 . The seam of  claim 1 , wherein one or both of the meltable layers ( 104 ) and ( 105 ) further comprises a light-absorbing polymer that absorbs light having a wavelength that is between 700 nanometers (nm) and 1400 nm. 
     
     
         43 . (canceled) 
     
     
         44 . (canceled) 
     
     
         45 . (canceled) 
     
     
         46 . The seam of  claim 42 , wherein the light-absorbing polymer is selected from the group consisting of thermoplastic polyurethane (TPU), thermoplastic polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene, ABS, and Mylar®. 
     
     
         47 . The seam of  claim 1 , wherein one or both of the meltable layers ( 104 ) and ( 105 ) has a melting temperature of 140° C. or less. 
     
     
         48 . The seam of  claim 1 , wherein each of the first base FCL ( 110 ) and the second base FCL ( 120 ) are gas impermeable, and wherein the weld is gas impermeable. 
     
     
         49 . The seam of  claim 1 , wherein the unidirectionally oriented polyethylene fibers are Ultra High Density Polyethylene (UHMWPE) fibers selected from the group consisting of Dyneema®, Spectra®, and Dynex®. 
     
     
         50 .- 220 . (canceled)