Patent ID: 8877109

Claim:
A method for producing a reinforced multi-layered fabric system, said method comprising the steps of: providing a first set of coated yarns with a first nonmetallic coating with the first coating having a thickness and used as a circumference of the first set of coated yarns; providing a first set of uncoated yarns; weaving a first fabric layer with the first set of coated yarns and the first set of uncoated yarns; providing a second set of coated yarns with a second nonmetallic coating with the second coating having a thickness and used as a circumference of the second set of coated yarns; providing a second set of uncoated yarns; weaving a second fabric layer with the second set of coated yarns and the second set of uncoated yarns; positioning the first fabric layer in planar contact with the second fabric layer; providing a third set of uncoated yarns; providing a fourth set of uncoated yarns; weaving a third fabric layer with the third set of uncoated yarns and the fourth set of uncoated yarns; positioning the second fabric layer in planar contact with the third fabric layer; providing a fifth set of uncoated yarns; providing a sixth set of uncoated yarns; weaving a fourth fabric layer with the fifth set of uncoated yarns and the sixth set of uncoated yarns; and positioning the third fabric layer in planar contact with the fourth fabric layer; attaching the first fabric layer with the second fabric layer; attaching the second fabric layer with the third fabric layer; attaching the third fabric layer with the fourth fabric layer; removing the first and second nonmetallic coating to maintain a layer geometry of the first fabric layer, the second fabric layer, the third fabric layer and the fourth fabric layer; and integrating a matrix material into the reinforced multi-layered fabric system; wherein a diameter of the first set of coated yarns is approximately 188 percent of an uncoated diameter of the first set of coated yarns; wherein a diameter of the second set of coated yarns is approximately 150 percent of an uncoated diameter of the second set of coated yarns.