Patent ID: 7378359
Filing Date: 2008-05-27
Classification: B32B,D03D,D04H,D10B,Y10T

Abstract:
1. A multi-layer moldable fibrous composite construction, the fibrous composite construction comprising: at least one layer of non-woven construction comprising a plurality of monoaxially drawn staple fiber elements of tape geometry characterized by an aspect ratio of length divided by width in the range of about 3 to about 150, wherein said staple fiber elements are fusion bonded to one another, at least a portion of the staple fiber elements within the non-woven construction comprising a staple fiber base layer of a strain oriented polymer disposed in layered relation between two staple fiber covering layers of a heat fusible polymer, wherein said staple fiber covering layer is characterized by a softening temperature below that of the staple fiber base layer to permit fusion bonding upon application of heat; and a mat structure disposed in covering relation across at least one surface of the non-woven construction, the mat structure comprising a plurality of monoaxially drawn interwoven fiber elements, said interwoven fiber elements comprising an interwoven fiber base layer of a strain oriented polymer disposed in layered relation between two interwoven fiber covering layers of a heat fusible polymer, wherein said interwoven fiber covering layer is characterized by a softening temperature below that of the interwoven fiber base layer to permit fusion bonding upon application of heat, and wherein the polymer forming said interwoven fiber covering layer is adapted for melt fusion bonding to the polymer forming said staple fiber covering layer upon application of temperatures below the softening temperatures of both the staple fiber base layer and interwoven fiber base layer, and wherein the composite of the mat structure and the non-woven construction is adapted for three-dimensional molding.