Patent ID: 9643382
Date: 2017-05-09
CPC Classifications: B32B,Y10T

Claim:
1. A fiber reinforced structural element comprising: a) a first thermoplastic fiber reinforced member, wherein the thermoplastic fiber reinforced member comprises at least one layer of thermoplastic fibers, wherein at least some of the thermoplastic fibers within each layer are fused to other thermoplastic fibers within the same layer, and wherein at least some of the thermoplastic fibers within each layer are fused to thermoplastic fibers within adjacent layers; b) a first non-thermoplastic fiber reinforced member, wherein the non-thermoplastic fiber reinforced member comprises at least one layer of non-thermoplastic fibers and a hardened matrix at least partially surrounding the non-thermoplastic fibers, c) a first multi-layer woven tie layer having an upper surface and a lower surface and comprising at least a first woven ply and a second woven ply, each of the woven plies comprising warp yarns in the warp direction and weft yarns in a weft direction perpendicular to the warp direction interwoven with the warp yarns, wherein at least some of the warp or weft yarns in the first woven ply comprise thermoplastic fibers, wherein at least some of the warp or weft yarns in the second ply comprise non-thermoplastic fibers, wherein the woven plies are integrated through combined portions formed by interlacing warps or wefts of adjacent woven plies, wherein the upper surface of the multi-layer woven tie layer is predominately thermoplastic fibers and the lower surface of the multi-layer woven tie layer is predominately non-thermoplastic fibers, wherein the upper surface of the multi-layer woven tie layer is adjacent the thermoplastic fiber reinforced member, wherein the lower surface of the multi-layer woven tie layer is adjacent the non-thermoplastic fiber reinforced member, wherein at least some of the thermoplastic fibers of the thermoplastic fiber reinforced thermoplastic member are fused to the thermoplastic fibers on the upper surface of the multi-layer woven tie layer and wherein the hardened matrix of the non-thermoplastic fiber reinforced member at least partially extends around the non-thermoplastic fibers in the lower surface of the multi-layer woven tie layer.