Patent ID: 9718237
Date: 2017-08-01
CPC Classifications: B29B,B29C,B29K,B29L,B32B,C08J,D03D,F41H,Y10T

Claim:
1. A method of forming a fibrous composite comprising at least two adjoined fiber layers, each fiber layer comprising fibers having surfaces that are at least partially covered with a polymeric material, and wherein less than 50% of the fiber surface area is covered by a fiber surface finish, which fiber surface finish is between the fiber surface and said polymeric material; said composite having a stress at yield of at least 7.50 ksi (˜51.71 MPa) as measured by ASTM D790 for a composite having an areal density of about 1.5 lb/ft 2 (7.32 kg/m 2 ) or less, the method comprising providing a plurality of polymeric fibers wherein less than 50% of the fiber surface area of said fibers is covered by a fiber surface finish; optionally treating the fiber surfaces to enhance the surface adsorbability, bonding or adhesion of a subsequently applied polymeric material to the fiber surfaces; applying a polymeric material onto at least a portion of said fibers, thereby adsorbing, bonding or adhering the polymeric material on or to the fiber surfaces; producing a plurality of fiber layers from said fibers either before or after applying said polymeric material to said fibers; and consolidating said plurality of fiber layers to produce a fibrous composite.