Abstract: A wearable container containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of less than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A protective garment containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of greater than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A wearable container containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of less than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A wearable container containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of less than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A wearable container containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of less than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A vehicle containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of less than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A vehicle containing a composite which has an alternating pattern containing groupings of woven fabric and groupings of biaxially oriented thermoplastic films. The composite has a thickness of greater than about 5 mm. Each grouping of woven fabric contains at least one woven fabric layer, each woven fabric layer containing tape elements having a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. Each grouping of biaxially oriented thermoplastic films contain at least one biaxially oriented thermoplastic film which has a core layer of thermoplastic disposed between covering layers of a thermoplastic able to bond to polypropylene.

Abstract: A fiber reinforced structural element comprising a thermoplastic fiber reinforced member, a non-thermoplastic fiber reinforced member, and a multi-layer woven tie layer. The thermoplastic fiber reinforced member contains at least one layer of thermoplastic fibers and the non-thermoplastic fiber reinforced member contains at least one layer of non-thermoplastic fibers. The multi-layer woven tie layer contains at least a first woven ply and a second woven ply, where the woven plies are integrated through combined portions formed by interlacing warps or wefts of adjacent woven plies. The multi-layer woven tie layer is oriented such that the upper surface of the multi-layer woven tie layer which is predominately thermoplastic fibers is adjacent the thermoplastic fiber reinforced member and the lower surface of the multi-layer woven tie layer which is predominately non-thermoplastic fibers is adjacent the non-thermoplastic fiber reinforced member.

Abstract: A fiber reinforced structural element comprising a thermoplastic fiber reinforced member, a non-thermoplastic fiber reinforced member, and a multi-layer woven tie layer. The thermoplastic fiber reinforced member contains at least one layer of thermoplastic fibers and the non-thermoplastic fiber reinforced member contains at least one layer of non-thermoplastic fibers. The multi-layer woven tie layer contains at least a first woven ply and a second woven ply, where the woven plies are integrated through combined portions formed by interlacing warps or wefts of adjacent woven plies. The multi-layer woven tie layer is oriented such that the upper surface of the multi-layer woven tie layer which is predominately thermoplastic fibers is adjacent the thermoplastic fiber reinforced member and the lower surface of the multi-layer woven tie layer which is predominately non-thermoplastic fibers is adjacent the non-thermoplastic fiber reinforced member.

Abstract: A winder liner for unvulcanized rubber material comprising a first woven layer, a second woven layer, and a polymer layer. The first and second woven layers each contain a plurality of warp tape elements in a warp direction interwoven with a plurality of weft tape elements in a weft direction and a plurality of interstices between the warp and weft tape elements. The polymer layer is disposed on the inner surfaces of the first woven layer and the second woven layer and in the interstices of the first woven layer and the second woven layer. The polymer layer contains a first polymer comprising a co-polymer having at least 50% ?-olefin units and is characterized by a number-average molecular weight of about 7,000 to 500,000 g/mol, and a viscosity of between about 2,500 and 150,000 cP measured at 170° C.

Abstract: An energy absorbing panel containing a pair of generally parallel spaced apart rigid end plates having a stiffness of at least about 200 N-m and a plurality of fabric layers extending between the rigid end plates oriented in a z-axis direction defined as being perpendicular to the rigid end plates. Each fabric layer contains a plurality of monoaxially drawn, thermoplastic fibers. The plurality of fabric layers are fused together forming a bonded structure. Methods of making the energy absorbing panel are also disclosed.

Abstract: An energy absorbing panel containing a pair of generally parallel spaced apart rigid end plates having a stiffness of at least about 200 N-m and a plurality of fabric layers extending between the rigid end plates oriented in a z-axis direction defined as being perpendicular to the rigid end plates. Each fabric layer contains a plurality of monoaxially drawn, thermoplastic fibers. The plurality of fabric layers are fused together forming a bonded structure. Methods of making the energy absorbing panel are also disclosed.

Abstract: A method of consolidating thermoplastic fibrous layers by providing a plurality of fibers having a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core containing at least 70% alpha-olefin units which is formed into a first fibrous layer. A second fibrous layer is applied to the first fibrous layer which second layer contains a second polymer being a co-polymer having at least 50% alpha-olefin units which is characterized by a number-average molecular weight of about 7,000 to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C. and a melting temperature lower than the melting temperature of the exterior surface of the core. Heat and optionally pressure are applied to the assembly to consolidate the layers.

Abstract: A woven mat fabric with fused layers containing a plurality of woven layers, where each woven layer contains a plurality of warp elements interwoven with a plurality of weft elements. The warp and weft elements contain polymeric strips which have a core layer disposed in layered relation with at least one surface layer. The core layer contains a first strain oriented polymer composition and having a first softening point and the surface layer contains a second polymer composition having a softening point lower than the first softening point. The weft and warp elements within each layer are fused to one another, but the weft and warp elements of one layer are not consolidated to the weft and warp elements of the adjacent layers.

Abstract: The invention relates to an impact resistant component comprising at least two composite sheets fused together, each composite sheet comprising an adhesive layer fused between two unidirectional sheets, wherein each unidirectional sheet comprises a plurality of monoaxially drawn fibers arranged substantially parallel to one another along a common fiber direction, the fibers comprising a base layer of a strain oriented polymer disposed between surface layer(s) of a heat fusible polymer, wherein the surface layer(s) are characterized by a melting temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the adhesive layer has a melting temperature below that of the base layer of the unidirectional sheet.

Abstract: A method of consolidating thermoplastic fibrous layers. The method begins with providing a plurality of fibers, where the fibers have a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core. The first layer contains a first polymer, where the first polymer contains at least 70% ?-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core. These fibers are formed into a fibrous layer. Next, a second layer is applied to the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers. The second layer contains a second polymer being a co-polymer having at least 50% ?-olefin units which is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C.

Abstract: A flexible knife resistant composite incorporating a stack of at least five knife resistant textile layers, where each knife resistant textile layer comprises monoaxially drawn tape elements. The tape elements contain a base layer strain oriented olefin polymer with at least one covering layer of a heat fusible olefin polymer on the base layer and the covering layer is characterized by a softening temperature below that of the base layer. The tape elements within each layer are consolidated to one another by the covering layer and the tape elements of one layer are not consolidated to the tape elements of the adjacent layers.

Abstract: The invention relates to an impact resistant component comprising at least two composite sheets fused together, each composite sheet comprising an adhesive layer fused between two unidirectional sheets, wherein each unidirectional sheet comprises a plurality of monoaxially drawn fibers arranged substantially parallel to one another along a common fiber direction, the fibers comprising a base layer of a strain oriented polymer disposed between surface layer(s) of a heat fusible polymer, wherein the surface layer(s) are characterized by a melting temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the adhesive layer has a melting temperature below that of the base layer of the unidirectional sheet.

Abstract: A three dimensional molded article with a compound curvature having a composite wall with at least one contour having a depth to width ratio of at least about 0.2. The composite wall is formed of highly drawn thermoplastic tapes with thermoplastic films disposed on the outside of the tapes. The tapes have a highly drawn interior layer and exterior layers with a peak melting temperature below the peak melting temperature of the inner layer. The composite wall has a thickness of at least eight tapes which can be formed in layers of woven fabrics. The tapes are fused together and the film layers are fused to the exterior of the tapes. The films have inner surfaces that can fuse together, and outer surfaces that can fuse together. In this manner, when the film folds over itself in the molding process, the outer surface of the film bonds to itself and against the tapes to provide a smooth continuous layer.

Abstract: The invention relates to an impact resistant component comprising at least two composite sheets fused together, each composite sheet comprising an adhesive layer fused between two unidirectional sheets, wherein each unidirectional sheet comprises a plurality of monoaxially drawn fibers arranged substantially parallel to one another along a common fiber direction, the fibers comprising a base layer of a strain oriented polymer disposed between surface layer(s) of a heat fusible polymer, wherein the surface layer(s) are characterized by a melting temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the adhesive layer has a melting temperature below that of the base layer of the unidirectional sheet.