TW200844291A - Microwave processing of ballistic composites - Google Patents

Abstract

The present invention relates to the production of ballistic resistant articles. Prior to molding, the ballistic resistant fabrics are heated with microwave energy as an alternative to conventional preheating heating methods, reducing heating time and increasing production efficiency.

Description

200844291 IX. Description of the invention: [Technical field to which the invention pertains] The present invention relates to a moldable impact resistant article dream garment & ° as part of a molding process, using microwave energy as a substitute for a conventional preheating heating method Heat the impact resistant fabric to reduce heating. j and & plus production efficiency [prior art]

An impact resistant article containing high strength fibers having excellent properties against high speed projectiles is known. Articles such as bulletproof vests, guard panels, vehicle panels, and military equipment structural members are typically made from fabrics containing high strength fibers. Conventional high strength fibers include polyethylene fibers, para-aramid fibers (diphenylene terephthalamide), graphite fibers, nylon fibers, glass fibers, and the like. For many applications such as vest or vest components, the fibers can be used as a knit or knit. For many other applications, the fibers are enclosed or embedded in a matrix material to form a rigid or flexible fabric. Various impact resistant constructions are known which are suitable for forming articles such as helmets, panels and vests. For example, U.S. Patents 4,403,012, 4,457,985, 4,613,535, 4,623,574, 4,650,710, 4,737,402, 4,748,064, 5,552,208, 5,587,230, 6'642'159, 6,841,492, ό, 846, 758 are incorporated herein by reference. An impact resistant composite of high strength fibers made of a material such as an extended chain ultra high molecular weight polyethylene. These composites exhibit varying degrees of resistance to high velocity impact penetration of projectiles such as bullets, shells, grenades and the like. For example, U.S. Patent Nos. 4,623,574 and 4,748,064 disclose inter-early composite structures comprising a high-intensity wrap-around in the elastomeric matrix embedded in 126806.doc 200844291. U.S. Patent No. 4,650,710 discloses a flexible article of manufacture comprising a painful child, a viscous viscous shield composed of a local strength stretch chain polyolefin (ECP) fiber. The fibers of the web are coated with a low modulus elastomer (4). U.S. Pat. U.S. Patent No. M42, i59 discloses an impact resistant rigid composite having a plurality of fibrous layers comprising a long wire mesh disposed in a matrix, wherein the elastomeric layer is between the long wire mesh and the substrate. Haifu & and the hard board combine to increase protection against armor-piercing projectiles. Typically, the combination is molded in the desired configuration to form an impact resistant article by subjecting the combination of fibers, any matrix composition, and any other polymeric layer to heat and pressure for a particular molding cycle time. In the molding process, it is extremely important that the molding temperature is low enough to avoid damage to the fibers of the component of the impact fabric. In other words, it is extremely important that the molding temperature is lower than the melting point of the polymer forming the fiber or the temperature at which the fiber breakage occurs. For example, σ for stretch chain polyethylene fibers, such as by Honeywell International,

The SPECTRA® fibers manufactured by Inc. are generally acceptable for molding temperatures from about 68°F (20°C) to about 293°F (145 C). However, the fiber is affected after prolonged exposure to heat at 265 F (129 ° C) and the SPECTRA 8 fiber melts at 30 (TF (149 ° C). Temperatures above 265 ° F can cause fiber layer filaments Deformation, thereby reducing its impact resistance. Other fiber types can withstand higher molding temperatures. For example, the upper limit of the temperature range of the aromatic polyamide fiber is generally about 2 higher than the upper limit of the temperature range of the extended chain polyethylene fiber. (rc to approx. 126806.doc 200844291 30〇C. /匕,纟—Efficient method, it is also desirable to maximize the molding temperature to minimize molding time.” Use common convection heating at about 176卞 ( 8〇C) to about 293 卞 (145. 温度 temperature range and about 1 〇 (four) (called to about 1 〇, _ psi (69,000 coffee) under the dust force standard molding time is about 2 〇 to the bell In addition, f see convection heating requires (four) machine to preheat for at least U) minutes before molding. Therefore, in this technology, the species can be relative

There is a need for more efficient fabric molding methods that effectively form impact resistant articles over relatively short molding times at low temperatures. This month provides a solution to this need in this technology. The present invention provides a method of forming an impact resistant article wherein the heating time for molding the articles during preparation is reduced. Impact resistant fabrics, such as the spectra shieid8 fabric manufactured by Honeywell Internati〇nal, Inc., are undesirable 'hot bodies. The purpose is to have a warm-up time in which the fabric is hot enough to be molded into an impact-resistant mouth ij. By reducing this warm-up time, it is possible to produce k-plane production efficiency. * This 'X month provides a method of molding an impact resistant article comprising: heating the impact resistant fabric with microwave energy; and then molding the heated fabric. By using microwave energy to heat, the total heating and molding time is significantly reduced. The method of the invention is more effective than the conventional heating technique, and the productivity is remarkably improved. When a conventional heat source is used, it takes a long time to expose to a high temperature to cause good adhesion between the enamels and may cause fiber degradation. Microwave processing avoids this problem by allowing for hot times and due to the uniform distribution of microwave energy (four) and uniform heating to avoid significant temperature gradients within the mouth. 126806.doc 200844291 SUMMARY OF THE INVENTION The present invention provides a method of forming an article comprising: a) providing a fabric comprising a plurality of fibers arranged in a matrix having about 7 grams per denier (g/denier) Or higher dilatability and a tensile modulus of about (9) g/danier or higher; the fibers have optional microwave reactive compositions thereon,

b) heating the fabric in a microwave oven by subjecting the fabric to microwave energy sufficient to thereby heat the fiber or optional microwave reactive composition to at least about the softening temperature of the fiber or the softening temperature of the optional microwave reactive composition;将When the fabric has a softening temperature of at least about the softening temperature of the fiber or the softening temperature of the optional microwave reactive composition due to the application of microwave energy, the heated fabric is molded into an article; and d) is molded The fabric is cooled. The present invention also provides a method of forming a compacted fibrous web comprising a plurality of fibrous layers, each fibrous layer comprising a plurality of tenacities having a basis weight of about 7 grams per denier or more and about 15 inches per gram / Daniel or higher tensile modulus fibers; and the fibers have a polymeric matrix group thereon; the compacted fibrous web is compacted under heat and pressure, wherein the compacted 2 heat is used Microwave energy sufficient to thereby heat the polymeric matrix composition to a temperature of at least about the softening temperature of the polymeric matrix composition is applied. The present invention further provides an impact resistant article comprising an impact resistant fabric comprising a plurality of fibers arranged in an array having a tenacity of about 7 grams/denier or higher and about 15 gram/denier or higher. Tensile modulus; the fibers have a composition of dry microwave reactivity 126806.doc 200844291 coated thereon, which has been heated to above its softening point temperature by application of microwave energy. [Embodiment] The fulcrum furnace provides an effective way of uniformly heating a plurality of non-conductive materials such as impact resistant fabrics. Microwave treatment of impact resistant fabrics provides the desired benefits, including economic benefits through energy savings and time, and increased method yields and yields. The materials produced in this paper have other heating methods on the outside.

A unique uniform microstructure is achieved, which is uniform in energy distribution from the microwave and uniform in heating. / /, OBJECT OF THE INVENTION A fabric having superior impact penetration resistance describes a fabric exhibiting excellent properties against high-speed projectiles. For example, the "fiber" is an elongated shape having a length dimension much larger than the transverse dimension of the width and thickness. The cross section of the fibers used in the present invention can vary widely. ^ Two = rectangular. Thus, the term fiber includes filaments, tapes, strips and the like having a regular cross section. Irregular or ruled more than 截 截 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截 截Regular or irregular leaves. The stalks are single-leaf and the right-handed shackles have a substantially circular cross-section. The "yarns" used herein are interlocking fiber strands. The line of the ancient skins is ordered in a 'description, ordered parallel arrangement. The fiber "layer" describes the flat, flat, or non-woven dimension or yarn layer of the t-fiber or yarn. The fiber is a number of interconnected fibers. Or the yarn may be formed, for example, as a web, a fiber, or another braid, non-wound or by any other, white or white method of forming a fabric. 126806.doc is In addition, "Weaving 10 - 200844291 its combination. The inclusion of a plurality of fibers before or after the procedure as used herein may refer to a woven or non-woven material or a "woven fabric" that describes the structure in which the composite layer is molded.

The change in tenacity expressed by gyr (g/d) versus the fraction expressed as the initial fiber length, as used herein, is a 'strength, high tensile modulus fiber,' which is preferably at least about 7 mils or more. Leu, at least about ι 〇 gram / denier or the same preferred tensile modulus (both measured by astm DU%) and at least about 8 Å / g or higher of the preferred fracture energy fiber. The term "denier" as used herein refers to a unit of linear density, a being equal to the grams of fiber per side of the metric fiber or yarn. The term "lux" as used herein refers to tensile stress, expressed as the force per unit linear density (denier) of an unstressed sample (grams). The "initial modulus" of the fiber is a material property indicating the resistance of the material to deformation. The term 'tensile modulus' refers to the ratio of stress changes per denier. The particularly suitable high strength, high tensile modulus fiber materials include stretch-bonded polyolefin fibers such as highly oriented, high. Molecular weight polyethylene fibers, especially ultra high molecular weight polyethylene fibers and ultra high molecular weight polypropylene fibers. Also suitable are extended chain polyethylene fibers, extended chain polyacrylonitrile fibers, para-aramid fibers, polybenzoes. Fibrillary fibers (such as polybenzoxazole (pB) and polybenzothiazole (PBT) fibers) and liquid crystal copolyester fibers. Each of these fiber types is generally known in the art. Preferably, in the case of polyethylene, the fibers are extended chain polyethylene having a molecular weight of at least 5 Å, 〇〇〇, preferably at least 1 million and more preferably between 2 and 5 million. Stretch-stranded polyethylene (ECPE) fibers can be grown by solution spinning 126806.doc -11 - 200844291, such as described in U.S. Patent No. 4,137,394, the disclosure of which is incorporated herein to Glue structure Yi Yi incorporated by reference in the U.S. Patent No. 4,551,296 and 5,006,390, herein the. BEST polyethylene fibers of the present invention is a polyethylene fiber from Honeywell International Inc · sold by the trademark Spectra®.

Spectra® fibers are well known in the art and are described in U.S. Patent Nos. 4,623,547 and 4,748,064, the entire disclosures of which are incorporated herein by reference. At ounces to ounces, Spectra® high-performance fibers are 1 times stronger than steel and are light enough to float on water. These fibers also have other important characteristics including impact resistance, moisture, abrasive chemicals and puncture properties. Suitable polypropylene fibers include highly oriented extended chain polypropylene (ECPP) fibers, as described in U.S. Patent 4,413,110, incorporated herein by reference. Suitable polyvinyl alcohol (PV-OH) fibers are described, for example, in U.S. Patent Nos. 4,440,711 and 4,599,267, the disclosures of which are incorporated herein by reference. Suitable polyacrylonitrile (PAN) fibers are disclosed, for example, in U.S. Patent 4,535,027, which is incorporated herein by reference. Each of these fiber types is generally known and widely available. Suitable aromatic aramids (aromatic polyamides) or aramid fibers are commercially available and are described, for example, in U.S. Patent 3,671,542. For example, suitable poly(p-phenylenediamine-p-xylylene) filaments are commercially available from Dupont under the trademark KEVLAR®. Also suitable for use in the practice of the present invention is the poly(m-phenylenediamine meta-xylamine) fiber manufactured by Dup〇nt under the trademark NOMEX®. 126806.doc -12 - 200844291 A suitable polybenzoxanthromeric fiber for use in the present invention is commercially available, for example, in U.S. Patent Nos. 5,296,185, 5,356,584, 5,534,205, each incorporated herein by reference. And 6,040,050. Preferably, the polybenzopyrrole fiber is a ZYL〇N@ brand fiber from T〇y〇b〇 c〇·. Suitable liquid crystal copolyester fibers for use in the present invention are commercially available and are disclosed, for example, in U.S. Patents 3,975,487, 4,118,372 and 4,161,470 each incorporated herein by reference. Other suitable fiber types for use in the present invention include glass fibers, fibers formed from carbon, fibers formed from basalt or other minerals, M5® fibers, and combinations of all of the above, all of which are commercially available. M58 fiber system

Magellan Systems International of Richmond (Virginia) is manufactured and described, for example, in U.S. Patents 5,674,969, 5,939,553, 5,945,537 and 6, G4G,478, each of which is incorporated herein by reference. As described above, the 'strength, tensile modulus fiber is a preferred tenacity of about 7 gram/denier or higher as measured by ASTM D2256, preferably about 15 gram/denier or higher. A modulus of fiber and a fiber of about 8 j/g or higher which is preferably the energy required for fracture. For greater impact resistance, the fiber breech should be about 15 grams/denier or higher, preferably about 2 gram/denier or higher, more preferably about 25 gram/denier or higher and preferably about 3 〇. G/denier or higher; the fiber preferably also has about 300 g/denier or higher, more preferably about 400 g/denier or higher, more preferably about 5 g/denier or higher, more preferably about 1, 000 grams / Daniel or higher and best about}. ^ gram / Daniel or higher tensile modulus. The fiber having an increased impact protection property also preferably has a height of about 15 J/g or more, more preferably about 25 J/g or more, more preferably about 126806.doc -13 - 200844291 30 J/g or more. The energy required for the fracture, and preferably the energy required for the fracture of about 4 Torr or higher. The high strength properties of such combinations can be obtained by using well known methods of growth or gelling. US Patent Nos. 13,11, 4,440, 711, 4, 535, G27, 4, 457, 985, 4, 623, 547, 4, 650, 710, and 4, 748, G64 generally discuss preferred high strength stretch bond polyethylene fibers for use in the present invention and disclose the disclosure by way of citation. And this article. ί The impact resistant fabric may comprise - or a plurality of woven or non-woven fibrous layers or combinations thereof. Woven and non-woven fibrous layers can be formed using techniques generally known in the art. Suitable non-woven fibrous layers include fibers comprising a fiber or a plurality of fibers or yarns arranged in a substantially parallel array, the non-woven fibrous layer of the present invention is in an elastomer Or a rigid polymer composition (referred to in the art as a matrix composition) comprises a monolayer of solid fiber web. In general, "polymeric matrix composition" is a binder that bonds the fibers after the compacting or lamination step. "Compacted mesh" describes a compacted combination of a plurality of fibrous layers and a matrix composition. As used herein, "soap" structure refers to a structure that has been compacted into a single unitary structure - or a plurality of layers of individual fibers, wherein compaction can occur via drying, (d) H pressure, or a combination thereof. The compacted web may also comprise a plurality of yarns coated with the matrix composition, formed into a plurality of layers, and (d) formed into a single fabric layer. In a random or parallel non-woven parallel orientation, the individual fibers forming the fabric layer may or may not be coated with a base negative composition, impregnated with a base & 4 shell, using techniques well known in the art. The baiquibe composition, embedded in the matrix composition or otherwise coated with the matrix composition. The matrix composition can be applied to the high strength fibers either before or after the formation of the layers 126806.doc - 14 - 200844291. The matrix material combinations are then compacted together to form a multilayer composite. Most particularly, the non-woven fiber layer of the present invention comprises: a plurality of layers, each layer comprising a plurality of parallel fibers arranged in an orientation, wherein the layers are at an angle relative to a longitudinal fiber direction of each adjacent fiber. And the strands; and wherein the fibers have a polymeric matrix composition thereon; or ... or a plurality comprising: a plurality of randomly arranged fibers; and wherein the fibers are optionally combined with the matrix composition . ^ ^ As for this technical towel, it is generally known that when a fiber bundle is stranded and twisted, the fiber arrangement direction of the j-layer is rotated relative to the fiber arrangement direction of the other layer, and the non-woven fabric achieves excellent impact resistance. The fiber layer is a fiber layer of the moon, and the longitudinal fiber of the other layer is wide: the longitudinal fiber direction is perpendicular, and in the other example of the second layer, five layers of the layer are formed to rotate... 5. The layer and the fifth layer of the phase material ^ the purpose of the invention, the adjacent layer can be two:: order). To achieve the original direction of about 〇. and about 90. / relative to the other layer of longitudinal fiber square fiber pile It is ... which angle is arranged, but about 〇. and about 9 〇. 义, 义, 隹疋 is preferred. Although the fabric of the fiber layer... the example of the next month includes two or five layers individually through a variety of well-known - Γ 加以 加以 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 非 非 非 非 非 非 非 非 非 非 非 非 非 非 非 非 非 非 非. Any number of intersections required for the application are twisted by 20 to about 40 or more layers. 126806.doc 200844291 Any fabric weaving method can be used with the technique known in the art, such as flat, woven, woven, satin weave, basket weave, satin weave, twill weave, and the like. To form a woven fiber layer. Plain weave is most common. Before weaving, each woven fiber may or may not be coated with a polymeric matrix composition using a matrix composition similar to that of a non-woven fibrous layer. Individual fibers of the material. Alternatively, the fabric may comprise alternating or non-intercalating layers of woven and non-woven fibers, such as non-woven/woven/non-woven or woven/non-woven/woven structures. Any number of combined woven and/or non-woven layers are included, and each non-woven layer may comprise a single laminated solid web having a plurality of constituent layers. Optionally, adjacent layers may be attached to the intermediate adhesive layer In particular, each woven layer is preferably attached to an adjacent layer via an adhesive layer. Suitable adhesives include non-exclusively elastomeric materials such as polyethylene, parent polyethylene, chlorosulfonated polyethylene, Ene copolymer, polypropylene, propylene copolymer, polybutadiene, polyisoprene, natural rubber, ethylene-propylene co-I, ethylene propylene-diuret ternary copolymer, polythioether polymer Polyurethane elastomer, polychloroprene, polyvinyl chloride, butadiene plasticized using one or more plasticizers well known in the art (such as dioctyl phthalate) Acrylonitrile elastomer, poly(isobutylene-co-isoprene), polyacrylate, polyester, unsaturated polyester, polyether, fluoroelastomer, polyoxyxene elastomer, ethylene copolymer, thermoplastic elastomer, Phenolic resin, polybutyral, epoxy polymer, styrenic block copolymer (such as styrene-isoprene-styrene or styrene-butadiene-styrene type) and generally used in the art Other suitable adhesive compositions are known. Particularly preferred adhesive compositions 126806.doc -16- 200844291 include methacrylate adhesive, cyanoacrylic adhesive, uv cured adhesive, urethane adhesive Agent, epoxy resin adhesive, ethylene vinyl acetate adhesive Sowing above compound materials. The adhesive is best composed of a thermoplastic polymer, especially ethyl acetoacetate. These adhesives can be applied, for example, in the form of a hot melt, a film, a paste or a spray or in the form of a two-component liquid adhesive. 1 A woven or non-woven fibrous layer of the present invention can be prepared using a variety of matrix materials, including low modulus elastomeric matrix materials and high f' turns rigid matrix materials. The suitable matrix material non-exclusively includes a low modulus elastomeric material having an initial tensile modulus of less than about 6, 〇〇〇3 MPa) and an initial tensile modulus of at least about 300.000 psi (2068 MPa). High modulus rigid materials (each measured by ASTM D638 at 37 ° C). As used throughout the text, the term tensile modulus means the modulus of elasticity as measured by ASTM 2256 for fibers and by ASTM D63 8 for matrix materials. The elastomeric matrix composition can comprise a variety of polymeric and non-polymeric materials. Preferably, the elastomeric matrix composition comprises a low modulus elastomeric material. For the purposes of the present invention, the low modulus elastomeric material has a tensile modulus of about 6,000 psi (41.4 MPa) or less than 6,000 psi as measured by ASTM D638 Test Procedure. The tensile modulus of the elastomer is preferably about 4, 〇〇〇 psi (27.6 MPa) or less than 4.000 Psi, more preferably about 2400 psi (i6.5 MPa) or less than 2400 psi, more preferably about 1200 psi ( 8.23 MPa) or less than 1200 psi, and most preferably about 5 psi (3.45 MPa) or less than 500 pSi. The glass transition temperature (Tg) of the elastomer is preferably less than about 0 ° C, more preferably less than about _4 ° C, and most preferably less than about _50 ° C. The elastomer also has an elongation at break of preferably at least about 5%, more preferably at least about 1%, and preferably has an elongation at break of at least about 300%. A variety of matrix materials and formulations having a low modulus can be used as the matrix. Representative examples include polybutadiene, polyisoprene, natural rubber, ethylene/propylene copolymer, ethylene-propylene-diene terpolymer, polythioether polymer, polyurethane elastomer , chlorosulfonated polyethylene, polychloroprene, plasticized polystyrene, butadiene acrylonitrile elastomer, poly(isobutylene-co-isoprene), polyacrylate, polyester, polyether, fluorine Elastomers, polyoxyxides, ethylene copolymers, and combinations thereof, and other low modulus polymers and copolymers that are curable below the melting point of polyolefin fibers. Also preferred are blends of different elastomeric materials or blends of elastomeric materials with one or more thermoplastics. Particularly suitable are block copolymers of a total of a diene and an ethyl fluorene aromatic monomer. Butadiene and isoprene are preferred conjugated diene elastomers. Astyrene, vinyltoluene and t-butylstyrene are preferred conjugated aromatic monomers. The block copolymer of polyisoprene can be hydrogenated to produce a thermoplastic elastomer having a saturated hydrocarbon elastomer segment. The polymer may be an ABA type simple trisole copolymer, (AB)I^(n=2-10) multiblock copolymer or R_(BA)XS (X=3-150) radial configuration copolymer; Wherein a is from the later stage of the polyethylene aromatic monomer and B is the block from the co-diene elastomer. Many of these polymers are commercially produced by Kraton Polymers of Houston (TX) and are described in the publication f'Kraton Thermoplastic Rubber,, SC-68-81. The preferred matrix polymer comprises a styrenic block copolymer commercially available from Kraton Polymers under the trademark KRATON®. The preferred low modulus matrix composition comprises a polystyrene-polyisoprene-polystyrene-block copolymer. 126806.doc -18- 200844291 Preferred high modulus rigid matrix materials suitable for use herein include, for example, ethylene-based polymers or styrene-butadiene block copolymers and such as vinyl esters and phthalic acid A material of a polymer mixture of allyl ester or phenol furfural and polyvinyl butyral. A particularly preferred rigid matrix material for use in the present invention is a thermoset polymer, preferably soluble in a carbon-carbon saturated solvent such as methyl ethyl ketone and having at least about ΐχΐ〇6 as measured by ASTM D638 when cured. High tensile modulus of pS1 (6895 MPa). Particularly preferred rigid matrix material is

The matrix material described in U.S. Patent No. 6,642,159, incorporated herein by reference. The stiffness, impact and impact properties of articles formed from the fabric composites of the present invention are affected by the tensile modulus of the matrix polymer. For example, U.S. Patent No. 4,623,574 discloses the use of a fiber reinforced composite constructed with a tensile modulus of less than about 6000 psi (41,300 kPa) and a composite of a higher modulus polymer. It has superior impact properties compared to the same fiber structure as the matrix. However, low tensile modulus matrix polymers also produce lower stiffness: raw gargle. In addition, 'in some applications, especially in applications where the compound must act in a resistive and structural mode, the impact resistance and rigidity are required. Therefore, the most suitable type of matrix polymer used by slaves will be slaves. It is a function of the type of article formed by the fabric of the present invention. To achieve both properties: Hiring: Sigma-adapted matrix compositions can combine low modulus and high modulus materials to form an earlier matrix composition. Impact resistant fabrics are used in a variety of applications. For example, one or more of the fabrics of the present month may be arranged together, such as from the north, to form a flexible article, including clothing, such as a moon, pants, a hat, or other clothing 126806 as is well known in the art. Doc 200844291 w ° The fabric of the present invention may also form other personal protective articles such as helmets, or may form a shield, cover or felt, if desired. Other common structures include flat, flat panels or custom shaped panels. Molded fabrics can be used, for example, to strengthen armored civilian vehicles for NIJ Class I, Class IIA, Class II, Class IIIA, and Class III protection; for use as doors and roofs for police patrol cars and other vehicles; Used as a traumatic pad or chest insert for NIJ Class I, Class IIA, Class II, inA, and in class shock resistant vests; for NIJ Class I, Class IIA, Class I, Class IIIA, and Class M Protected hand-held shield or used in explosive treatment devices. Multiple fabrics can be stacked or aligned in a bonded or non-bonded array. Bonding can be carried out using any of the conventional means of the art, such as by bonding or bonding together with an adhesive material, other thermoplastic material or non-thermoplastic fibers or materials. These desired articles are made from self-impacting fabrics and subjected to fabrics known in the art as molding processes. In a typical molding process, a fabric that can include any number of woven and/or non-woven layers (also referred to as "plies") is heated or preheated to the molding temperature required to allow the fabric to form a shaped article or panel. The heated fabric is typically formed or compressed under pressure in a suitable molding apparatus. The molding pressure is in the range of from about 5 〇 pSi to about 5 〇〇〇 pSi, more typically in the range of from 200 psi to about 15 psi. The molding step can take from about & seconds to about 45 minutes. According to the invention, the fabric is heated in a microwave oven rather than by any other transfer, heating first. Microwave heating is a more effective alternative to conventional heating because it effectively produces volumetric heat. Volume heating is defined as the overall heating, as opposed to transferring heat from the surface inward. The microwave causes the internal heating of the material by generating an excitation score 126806.doc -20- 200844291. Any molecule of "polar" and having a = terminal and a negative terminal will rotate back and forth to align with the changing electric field of the waves in the oven. This rotation produces energy in the form of heat. Unlike conventional heating, this effect occurs simultaneously throughout the entire process of the material through the microwave. The microwave is an electromagnetic wave in a frequency band of 300 MHZ (3xl 〇 8 cycles/second) to 300 GHz (3xl〇n weeks)/& These two frequencies correspond to ^(f) and 1 mm wavelengths, respectively. All domestic microwave ovens and laboratory microwave processors operate at 2.45 GHz corresponding to a wavelength of approximately 12.2 cm. Industrial microwaves can operate at "GHz" frequencies and can operate at lower frequencies such as 9 〇〇 MHZ2 or at lower frequencies such as 10 GHz, and typically range from 1 watt to 3 watts. The invention is not limited to any particular microwave frequency. In general, the microwave processing system consists of a microwave source, an applicator that transmits power to the sample, and a system that controls heating. The microwave generator is typically a vacuum tube or solid state device. In microwave ovens, the tubes are rated at 15 kW. These officers require a magnetic field to operate and the magnetic field is provided by permanent magnets or electromagnets. Magnetrons are the most common source of microwaves for material handling applications. In contrast, microwave energy is applied to the material via a multimode or single mode microwave applicator, and temperature control is typically achieved by varying the input power or via a pulse source. The invention contemplates the use of any special microwave, including microwave ovens, industrials sufficient for use at home. Microwave ovens and other unique microwave ovens with or without the unique wavelengths that are uniquely used. Limiting the potential of microwaves for processing materials An important factor in the use is the ability of the material to absorb microwave radiation (essentially high frequency radio waves). Unlike conventional heating, 126806.doc -21 - 200844291, microwaves use penetrating radiation through the material. The specific dielectric properties of the material itself are mosquitoes, such as material ^ dielectric = and dielectric loss tangent.

In most materials, microwave power absorption is proportional to the water content of the material. However, when processing materials, unlike microwave processing of foods, the light energy of microwave energy is directed to atoms or radicals other than water. As is generally known, many polymeric materials are not capable of absorbing microwave radiation. In particular, while certain types of high strength fibers suitable for forming fabrics having superior impact resistance may be capable of absorbing microwave radiation, others are not capable of absorbing microwave radiation. However, it has been found that blending a microwave absorbing additive with a polymeric matrix composition or otherwise applying a microwave reactive composition to the material allows for additional fabrics that are absorbing microwave radiation to be suitable for treatment with microwave radiation. . As used herein, a microwave reactive composition" is a composition that absorbs sufficient microwave radiation to separately heat a fiber or polymeric matrix composition to at least the softening temperature of the fiber or polymeric matrix composition. As discussed above, 'many polymeric materials are not capable of Absorbing microwave radiation. For example, it has been found that aromatic polyamide fibers sufficiently absorb microwave radiation, but polyethylene fibers do not sufficiently absorb microwave radiation to heat the fabric to at least the softening temperature of the fibers or, more specifically, to at least About 6〇〇c. In particular, Spectra® polyethylene fibers have been found to be substantially transparent to microwave radiation. Nylon, polyester and polyethylene naphthalate fibers also absorb at least partially microwaves. When the irradiated fibers are formed, the fibers must be at least partially coated or contacted with a material that sufficiently absorbs the microwaves to achieve a softening of the fibers or polymeric matrix composition at a temperature of 126806.doc -22-200844291. For example, a combination of microwave absorbing polymeric matrices The microwave absorbing material can be applied to the surface of the fabric. The matrix composition itself is condensed. It may have microwave absorbability or may be microwave absorptive by blending with a microwave reactive additive. The microwave reactive additive will converge the microwave energy and transfer it to the fiber. The polar material is especially microwave reactive, including polar Polymeric fibers, polar polymeric matrix compositions, and polar additives. Conductive materials have microwave reactivity, such as conductive fibers (eg, carbon fibers) and conductive polymeric matrix compositions (polystyrene, polypyrrole, etc.). The absorbent fiber type in combination with one or more polar polymers, conductive polymers or microwave reactive additives provides a good face for microwave energy. Suitable microwave reactive additives non-exclusively include metal particles (including but not limited to) magnetic properties Particles and metal powders, dielectric particles and dielectric powders, insoluble microwave absorbing polymeric particles and non-dispersible microwave absorbing polymeric particles. Although solid metals are known to reflect microwave radiation, powdered metals absorb microwave radiation and can be heated. Dielectric and polymeric powders include conventional polymeric matrix materials Dielectric and polymeric powders in a furnace that are heated to at least the softening point of the polymeric matrix material. Non-exclusive examples of suitable materials are described in the literature incorporated herein by reference. Micr〇wave pr〇cessing of Materials III? Ronald L. Beatty, Willard H. Sutton and Magdy F. Iskander, ed., Materials Research s〇ciety, vol. 269 (October 1992). Also suitable are materials described in U.S. Patents 5,349,168 and 6,066,375. The disclosures of these patents are incorporated herein by reference. Examples of suitable microwave reactive materials that are capable of absorbing electrical and magnetic portions of microwave field energy and converting the energy of 126806.doc -23-200844291 into heat include metals Powder, such as powdered nickel,! Brother, copper, molybdenum, cyanum, iron, steel, chromium, tin, zinc, silver, gold, cobalt, tungsten, titanium, aluminum (including flake aluminum powder) and their alloys. Other suitable additives are conductive materials such as carbon black, carbon fiber, gold i fibers and metals, flakes, spheres or needles (typically in the range of about 〇2 to (10) μηη). These microwave reactive additives are especially useful when blended with polymeric matrix compositions.

Other conductive materials such as graphite and a semiconducting material such as carbon carbide and a magnetic material such as a metal oxide (if used in the form of particles) may also be utilized. Such materials are non-exclusive and generally can be used with any other additive material that allows the polymeric matrix material or polymeric fibers to be heated to a substrate or to a V-human temperature in a conventional microwave oven at Μ GHz. The materials used are in the form of granules and may be flakes or powders. The size of the particles varies depending on a number of factors including the particular material selected, the amount of heat to be produced, the manner in which the coating composition is to be applied, and the like. Other suitable microwave reactive additives include oils such as watch oils and glycerin, carbon carbide, nitriding and ing. Other suitable additives include the addition of a high degree of freedom of rotation, oscillating or translational motion, such as organic salts and inorganic salts, to the addition of non-volatile additives, including metal oxides and metal dioxides. t One flavor: - titanium oxide, cobalt oxide, iron oxide, oxidized cerium oxide, suitable organic salts include sulphate monosodium (MSG), potassium citrate, calcium carbonate, wine ^ # 酉石I potassium, ammonium citrate, Sodium bicarbonate, carbonic acid and many other organic salts. Suitable inorganic salts include sulfuric acid • disodium, ferrous ferrous sulfate, manganese sulfate, sulfuric acid, coke 126806.doc -24- 200844291 sodium sulfite and combinations thereof, and many other inorganic salts. Also suitable is the material disclosed in U.S. Patent No. 4,219,361, the disclosure of which is incorporated herein by reference. These microwave reactive additives are excited by microwaves at a frequency of 2 45 and convert microwave energy into heat due to molecular friction. Other suitable materials that can be applied to the fabric or blended into the matrix composition further include polyacrylic acid vinegar solution, polyamidamine solution, polyvinyl methyl ether solution, polyamidamide hot melt adhesive, and based on polyvinyl methyl The heat melts the adhesive. It may also be suitable to immerse the fabric in a treatment fluid capable of converting at least a portion of the incident microwave energy into heat and transferring the heat to the fabric, such as water, isopropanol or ethanol. Such materials can be applied by any means known in the art. ^ The amount of additive can vary depending on the type of polymeric matrix and the type of additive. Typically, the microwave reactive additive will comprise from about 1 weight per gram of the polymeric matrix composition, a force of 10% by weight, more typically from about 3% by weight to about 3% by weight and most typically It is a G G1 wt% to about 1 () wt% of the polymeric matrix composition. A larger amount can be used if it is determined by those skilled in the art. However, when the additive is blended with the matrix resin, a greater amount of the additive will not reside in the matrix resin mixture and will precipitate in the mixing tank. Depending on the composite raw material: temperature = sensitivity and the temperature required to achieve compaction or reaction, the rate at which the extreme temperature I complex reaches this temperature may need to be adjusted. Each particular combination has its own preferred additive concentration and this concentration can vary greatly. In general, metals are more effective than polymers, salts and other materials in reacting with microwave radiation and absorbing microwave radiation. Thus, a relatively small amount of metal radicals is typically required. 126806.doc 25- 200844291 Different materials that are subjected to the microwave energy of phase g i are heated at different rates. For example, asymmetric polar molecules are susceptible to rotation by microwave energy and rapid heating. The main mechanism of the microwave radiation is the reversal of the electric field through the dipole. In particular, materials having a high concentration of strong dipoles are considered to be active absorbers of microwave energy and are particularly effective. Occasionally, there is a chemical arrangement in which positive and negative charges are kept at a fixed distance from each other. When the reaction of the material with microwave radiation is carried out, the dipole moment type and concentration change and a phase change occurs, thereby changing the dipole activity. The dipole moment is formed by adjacent groups having different electron withdrawing/electron pushing properties such that the net charge or partial charge is positioned on one atom or group and can be regarded as a small weak strip magnet. Typical groups forming such dipoles include hydroxyl groups, amine groups, cyanate groups, and the like. The efficiency of this coupling depends on a number of factors, including dipole intensity, dipole activity, and dipole. The small strong dipole seems to be the most effective coupling of microwave radiation and the liquid coupling is strongest, followed by rubber, glassy polymers and crystalline materials. έ There are dipole water-based resins and solvent bases and 1 〇〇〇/. Solid materials absorb microwave radiation at a certain degree of privacy. The strength of their dipoles combined with their dipole concentration and polymer motion freedom (which allows the dipole to align itself with the oscillating magnetic field, causing friction and heat) will determine how much energy will be converted to heat $. For example, the urethane linkage (-NH-coo-) is a strong dipole and the polyurethane resin has such a high concentration of such groups. Therefore, the matrix polymer containing the polyaminomethyl & C ester is extremely effective. A ruthenium containing a carboxylic acid group which is also a dipolar group is also preferred. Other preferred polymers include polyelectrolytes, ionic polymers, polyvinyl alcohol, polyvinyl butyral, polyoxymethylene, and polyamidamine. Other suitable polymers having a weaker dipole or lower dipole concentration are non-exclusive. 126806.doc -26- 200844291 r The raw material includes acrylic resin, ethylene vinyl acetate and ethylene acrylic acid. These materials have some degree of activity, with the magnitude of the temperature rise being related to the intensity and concentration of the dipole. Also suitable is a blend of matrix polymers, such as a two-phase matrix in which an inert resin is dispersed in an inert resin to subject the non-reactive resin to microwave energy treatment.

U The choice of the most effective microwave reactive additive will generally depend on the frequency, power and duration of the microwave energy to be absorbed. Heating is known to be accelerated by the ion effect and the specific heat of the composite. For example, oils are suitable materials that have a low specific heat. Many factors also contribute to the minimization of the amount of microwave reactive additive required. Highly active materials generally require a lower weight or percentage of the valley. Synergistic compositions (some of the other components of the complex absorb free water, induce dipoles, etc.) reduce the amount of active ingredient required. Lower target treatment temperatures also require lower levels of highly active components or higher levels of lower yield materials. Generally, the minimum amount of microwave reactive additive required will be less than about 10% by weight of the fabric, more preferably less than 10% by weight of the polymer matrix composition. More preferably, the amount of microwave reactive additive is from about 1% to about 6%, more preferably from about 3% to about 6% by weight of the polymer matrix composition or fabric (if the substrate is not present). If the microwave reactive additive is dispersed in a solvent in the form of a mixture, the mixture typically comprises from about 70% by weight to about 8% by weight of solvent. In the method of the present invention, the fabric is placed in a microwave oven by subjecting the fabric to microwave energy sufficient to thereby heat the fiber or optional microwave reactive composition to at least about the softening temperature of the fiber or optional microwave reactive composition. heating. Prior to microwave heating, the impact resistant fabric and optional microwave reactive combination 126806.doc -27- 200844291 are preferably completely dry and free of volatile materials. The material should be heated to a temperature below the temperature at which the material degrades or burns. Immediately after heating or during heating, the fabric is molded or compacted into articles when the fabric has a temperature of at least about the softening temperature of the fibers or the softening temperature of the optional microwave reactive composition (if present). The term as used herein, immediately thereafter, means that the fabric is molded or compacted when the fabric is still at a softening temperature or above a softening temperature due to heat generated by the microwave. Accordingly, the fabric is molded into articles when the heated fabric has a temperature of at least about the softening temperature of the fibers or the softening temperature of the optional microwave reactive composition (if present). Alternatively, the fabric can be continuously heated and molded in a single multi-function device that combines heating and molding capabilities. While it is foreseen that the heated fabric may be transferred from the microwave to the separate molding apparatus as the case may result in some loss of heat from the fabric, the process is performed such that when the fabric retains sufficient heat generated by the microwaves, molding begins to mold the fabric into any desired Form (4) and keep the fabric in shape (if so intended). Finally, the molded fabric is allowed to cool. As described herein, the fabric of the present invention must be heated until it reaches a temperature suitable for molding. The minimum molding temperature of the fabric is typically determined by the softening temperature point of the polymeric matrix composition or the softening temperature point of the fiber (if no matrix composition is present). As is generally the case in the art, the softening point of the plastic can be measured by the ASTM D1525 δ*- Tempemure testing methQd, which covers the measurement when the sample is in the specified (four) test condition. Specify the degree at which the needle penetration occurs. More specifically, in this test method, the flat end needle (4) loaded with the specified substance is placed with the sample material. (4) Product and needle 126806.doc -28· 200844291 The rate is heated, and the needle penetrates to (4) The temperature at which the depth of the mm is recorded is the Vicat softening temperature. A suitable minimum molding temperature is typically in the range of from about 6 Torr to about 18 Torr, but varies depending on the particular fiber type and may be outside of this range. For example, Spectra8 polyethylene fiber is affected after prolonged exposure to 265 卞 (129.4. ^ heat) and melts at 300 卞 (148.9. (:). Therefore, Spectra® polyethylene fiber is preferably heated above About 2 〇〇卞 (93 3. 〇) but less than about 257 F (125. 〇. When heated by convection, the heating step is usually added for another 10 to 30 minutes to the fabric treatment time and requires a preheated convection oven. The heating time is substantially reduced by treating the fabric with microwaves. The time of exposure to microwave energy should be sufficient to sufficiently heat the fabric to the desired temperature, and should be short enough to avoid fiber degradation. Optimally, the fabric can be in a microwave oven at three Heating to 200 °F or higher in minutes. The finished molded fabric of the present invention comprises a combination of fibers, an optional matrix composition, an optional intermediate bonding layer, and an optional microwave sensitive material. Generally, for manufacturing A fabric having sufficient impact resistance, preferably having a fiber ratio of from about 45% by weight to about 95% by weight of the fabric, more preferably from about 6% by weight to about 90% by weight of the fabric, and preferably from about 65 weight percent of the composite. ./( > to about 85% by weight. As is generally known in the art, the matrix composition and/or optional adhesive may also include other additives, such as fillers, such as carbon black or cerium oxide, which can be incorporated into oils. Alternatively, it may be vulcanized by sulfur, a peroxide, a metal oxide or a radiation curing system well known in the art. Depending on the desired structure and impact properties of the article formed from the fabric of the present invention, the number of fabric layers may be controlled. And the type and type of matrix of various types of 126806.doc -29- 200844291. For example, the formation of a low-cost trauma liner for reducing the deformation of the impact resistant vest preferably includes two fabric layers, namely two woven fibers a layer or two single layer compacted non-woven unidirectional fiber webs each formed of two fiber layers of 〇./90. cross-stranded with a rubber layer on each outer surface of the combined fabric In addition, for an impact resistant panel having a degree of impact protection of π or nA grade, a fabric comprising 14 fabric layers and 1 fabric layer respectively is preferred. Whether the component fibers of the non-woven fabric can absorb Microwave radiation or whether or not a microwave reactive composition is required, the fabric of the present invention can be heated in a microwave oven by microwave radiation to a temperature of at least about 6 (rc). The microwave oven can operate at any frequency and any microwave power setting. The fabric of the present invention is heated in a microwave oven to 2 Torr (93 〇 or higher) in three minutes. The following non-limiting examples are illustrative of the invention. Examples 1-6 (Comparative) Spectra® fiber (1300-denier, 1〇〇〇 type) and kraton® styrene-isoprene-styrene (SIS) polymeric matrix resin (KrAt〇n@ D_ 1161 : 40% by weight of solids provided) , diluted to 16% by weight solids content 'applied to fabrics' or SANCURE® 12929 polyurethane urethanes (available from Noveon, Inc., a subsidiary of Lubrizol) Spectra shield® ("ss") non-woven samples were subjected to microwave heating tests. In each case, the sample was prepared to have a resin content of 20 ± 2 wt% and a non-woven cross-stranded Spectra Shield® material (〇, 90. construction). Each will include two 〇. /90. Ten attachments for cross-stranded and compacted layers 126806.doc -30- 200844291 Test strips (2''χ2Μ) (5·08 cmx5.08 cm) were cut from each sample, stacked and exposed to varying degrees The microwave energy (using a standard 2.45 GHz 1500 watt domestic microwave oven) lasts for a variety of durations. The temperature of the heated fabric was measured. The results are summarized in Table 1A.

Table 1A Example (Comparative) Polymer Matrix Composition Microwave Power (%) Microwave Time (min) Maximum Temperature (°F) 1 Kraton® SIS Rubber 70 1 113 (45°〇2 Kraton® SIS Rubber 70 2 113 (45°〇) 3 Kraton® SIS rubber 70 5 113 (45°〇4 Kraton® SIS rubber 100 1 113 (45°〇5 Kraton® SIS rubber 100 2 113 (45°〇6 Kraton® SIS rubber 100 5 113 (45°〇 in the example) In each of Examples 1-6, the KRATON® polymeric matrix material failed to reach a temperature of about 113 °F when subjected to microwave radiation under specified conditions, well below the softening point of the KRATON8 polymer. Therefore, KRATON8 polymer alone Failure to adequately absorb microwaves to produce the minimum amount of heat required to mold Spectra Shield® materials. Examples 7-10 For Spectra® Fibers (1300-Daniel, Model 1000) and SANCURE® 12929 Polyurethane Matrix Resin ( Samples of Spectra Shield 8 (''SS'') non-woven fabrics, available from Noveon, Inc., a subsidiary of Lubrizol, Ohio Cleveland, were subjected to microwave heating tests. In each case, the samples were prepared to have a weight of 20 ± 2 % resin Spectra Shield® (0., 90°) construction with non-woven cross-stranding. Ten specimens (2Mx2M) each comprising two 〇°/90° cross-stranded and compacted plies (5.08 cmx5.08 cm) cut from each sample, stacked and exposed to 126806.doc -31 - 200844291 exposed to varying degrees of microwave energy (using a standard 2.45 GHz 1500 watt household microwave oven) for various durations. The temperature of the fabric. The results are summarized in Table 1B.

Table 1B Example Polymer Matrix Composition Microwave Power (%) Microwave Time (min) Maximum Temperature (°F) 7 Sancure 8 12929 70 1 175 (79.44°〇8 Sancure® 12929 70 2 213 (100.6°〇9 Sancure® 12929 100 1 213 (100.6 ° C) 10 Sancure® 12929 100 2 213 (100.6 ° 〇 The above example shows Sancure® 12929 Polymer Matrix Resin providing microwave heating capability to Spectra Shield 8 for preheating. Examples 11-16 (Comparative) Similar to Example 1_1〇 For the use of Spectra® fiber (1300-Daniel, Model 1000) and Good-Rite 8SB-1168 styrene-butadiene styrene (SBS) rubber polymer matrix resin (available from Ohio Cleveland Noveon, Inc.) Spectra Shield® non-woven samples were subjected to microwave heating tests. In each case, the samples were prepared with a Spectra Shield® (0., 90°) configuration with a resin content of 20 ± 2 wt% and non-woven cross-strand. Ten attached test pieces (2Mx2'') (5.08 cm x 5.08 cm) each comprising two 0°/90° cross-stranded and compacted plies were cut from each sample, stacked and exposed to varying degrees Microwave energy (using standard 2.45 GH z 1500 watts for household microwave ovens, for various durations. The temperature of the heated fabric was measured. The results are summarized in Table 2. 126806.doc • 32- 200844291 Table 2 Examples (Comparative) Polymer Matrix Composition Microwave Power (%) Microwave Time (min) Maximum melting temperature (T) 11 Good-Rite® SB-1168 SBS rubber 70 1 113 (45°〇12 Good-Rite® SB, 1168 SBS rubber 70 2 113 (45°〇13 Good-Rite® SB -1168 SBS rubber 70 5 113 (45°〇14 Good-Rite® SB-1168 SBS rubber 100 1 113 (45°〇15 Good-Rite® SB-1168 SBS rubber 100 2 113 (45°〇16 Good-Rite8 SB -1168 SBS rubber 100 5 113 (45°〇 above shows that Good-Rite SB-1168 SBS rubber polymer matrix resin does not provide Spectra Shi eld® with microwave heating capability for preheating. Examples 17-32 Similar to Examples 1-16, a Microwave heating test was performed on Spectra Shield® non-woven fabric samples formed from Spectra 8 fibers (1300-Daniel, Model 1 000) and various polymeric matrix polymers. In each case, the sample was prepared to have a non-woven cross-stranded Spectra Shield® material (0., 90° configuration) with a resin content of 20 ± 2 wt%. The polymeric matrix polymer tested was: Example 17: Airflex® 4500, a guanamine-modified ethylene-vinyl chloride copolymer available from Air Products and Chemicals, Inc. 〇 Example 18: PermaxTM 230, polyamine hydrazine The ester resin was obtained from Noveon, Inc. 〇 Example 19: Hycar 826523, Acrylic Tree, available from Noveon, Inc. Example 20: Hycar 826-1475, acrylic resin, available from Noveon, 126806.doc -33- 200844291

Inc. 实例 Example 21: Hycar® 26-1199, acrylic, available from Noveon, Inc. Example 22: Sancure 820023, Polyaminophthalate Resin, available from Noveon, Inc. Example 23: Good-Rite SB-1168, carboxy-modified styrene-butadiene-styrene copolymer, obtained from No veon, Inc. Example 24: Daran® SL112, PVdC Polymer, available from WR Grace & Co. 〇 Example 25: PermaxTM 803, Acrylic-PVdC Copolymer, available from Noveon, Inc. Example 26: Sancure® 777, Polyamine Hydrazine Acid Resin, available from Noveon, Inc. 〇 Example 27: Sancure® 843, Polyurethane Resin, available from Noveon, Inc. 〇 Example 28: Dispercoll 8U53, Polyurethane Tree From Bayer AG. 〇 Example 29: Vycar 8 460X251, PVC copolymer available from Noveon, Inc. ° Example 30: Sancure 820025, polyurethane resin, available from Noveon, Inc. Example 31 ·· Butvar® RS- 261, polyvinyl butyral, available from Solutia, Inc. Example 32: Sancure 82026, a polyamine phthalate resin, obtained from Noveon, Inc., will include ten 126806.doc-34- each of two 〇°/90° cross-stranded and compacted plies. 200844291 The test piece (2''χ2") (5·08 cmx5.08 cm) was cut from each sample, stacked and exposed to microwave energy (using a standard 2.45 GHz microwave oven with 5〇% power) for 60 second. Measure the highest fabric temperature after microwave treatment! minutes, measure the temperature reached after simmering in the microwave forcibly dried in a conventional oven, and evaluate each sample to reach 5 〇% power in a 2·45 GHz microwave oven. 175 °F time. The results are summarized in Table 3. In row 4, a column with a short line indicates that the highest fabric temperature after one minute in the microwave has not been measured. For each example, the sample was heated in an oven to remove any water or other volatile components of the resin dispersion prior to subjecting the sample to microwave radiation. The samples were initially dried in an oven at 15 (ΓΕΓ·65·56〇 for 5 days. After the start of the microwave test, some samples gave a popping sound indicating the presence of residual water or other volatiles. Then the samples were returned to the oven card. Dry for another 5 days at 200 F (93.33 C) to complete any removal of water and/or volatiles. For each example, the response to microwave radiation was evaluated according to the following procedure: 1. Round thickness of STYROFOAMTM Partially placed on a 1500 watt microwave oven disc drive. This STYr〇f〇AMtm is used to isolate any heat generated by the evaluated sample from any heat generated by the ceramic disc drive plate. Samples of the materials evaluated were placed on the styr〇f〇amtm section. These samples were placed at the edges of styr〇f〇AmTM at 12:00, 3:〇〇, 6:00 and 9··00 4 samples are spaced apart from each other by 3, (7.62 cm) 〇 3. Then 'use 126806.doc -35- 200844291 manufactured by iiiinoisij, n〇is T〇〇1 w〇rks Inc.

The Tempilstik® temperature indicator is used to evaluate the temperature threshold. 4. Test the required temperature range using two Tempilstik crayons with a nominal temperature below the target temperature and two crayons with an activation range above the target temperature. 5 • Mark each of the four compacted fabric samples with one of four temperatures using an indelible pen. Scrape scraped from one of the crayons is scraped onto a fabric sample having a suitable temperature written on its surface. Also here are the other three crayon and three other samples. 6. Turn off the microwave oven, set to the desired power level, set the duration and start microwave heating. 7. Thereafter, it was determined which wax melted onto the surface of the fabric sample. table 3

The example polymeric matrix composition is heated in the microwave for 1 minute and heated to 175 °F or above 175 °F. The maximum fabric temperature (°F) after 1 minute in the microwave is the temperature reached in the microwave after drying in a conventional oven (°) F) Estimated time to reach I75°F in the microwave (seconds) 23 Airflex® 4500 is 175+ 30 24 PermaxTM 230 is 175+ 20 25 Hycar® 26523 No - 125-150 N/A 26 Hycar® 26-1475 No 113 <125 N/A 27 Hycar® 26-1199 is 175+ 175+ 45 28 Sancure® 20023 is - 175+ 30 29 Good-Rite® SB-1168 No 113 <125 N/A 30 Daran® SL112 is 175 + 175+ 44 31 PermaxTM 803 No - <125 N/A 32 Sancure® 777 is 175+ 175+ 19 126806.doc -36- 200844291 33 Sancure® 843 is 175+ 175+ 30 34 Dispercoll® U53 is 175+ 175+ 25 35 Vycar® 460X251 is 175+ 175+ 40 36 Sancure® 20025 is - 175+ 27 37 Butvar® RS-261 is 175+ 175+ 45 38 Sancure® 2026 is - 175+ 5 Example 7-3 8 All polymeric matrix resins tested were water based resins

Loose liquid. Some successes and others have been unsuccessful in absorbing microwave radiation. The Keaton 8D-1161 resin tested in Examples 1-6 was a solvent based resin and was unsuccessful in absorbing microwave radiation. However, other solvent based resins are expected to be successful and aqueous polymeric matrix compositions are not desired. While the invention has been shown and described with reference to the preferred embodiments of the embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the spirit and scope of the invention. The scope of the patent application is intended to cover the disclosed embodiments, the alternatives discussed above, and all equivalents thereof.

126806.doc 37-

Claims (1)

200844291 X. Patent Application Range: 1 . A method of forming an article comprising: a) providing a fabric comprising a plurality of fibers arranged in an array having a tenacity of about 7 grams per denier or higher. And a tensile modulus of about 15 gram/denier or higher; the fibers having an optional microwave reactive composition thereon; and b) by subjecting the fabric to a microwave oven sufficient to thereby Or heating the fabric by heating the microwave reactive composition to a softening temperature of at least about the softening temperature of the fibers or the softening temperature of the optional microwave reactive composition; C) ^ the fabric is applied by application of microwave energy Forming the heated fabric into an article at a temperature of at least about the softening temperature of the fibers or the softening temperature of the optional microwave reactive composition; and d) cooling the molded fabric. 2. The method of claim 1, wherein the microwave-reactive composition is present and heated by subjecting the fabric to microwave energy sufficient to thereby heat the microwave-reactive composition to at least about its softening temperature. The fabric; and when the fabric has a temperature of at least about the softening temperature of the microwave reactive composition, the heated fabric is molded into an article. • The method of claim 2 wherein the microwave reactive composition comprises a polymeric matrix composition coated on the fibers. The method of claim 1 wherein the fabric is heated to at least about a temperature. The method of claim 1, wherein the fabric comprises a plurality of fibers, wherein 126806.doc 200844291 one of the fibers Many are capable of absorbing microwave radiation sufficient to heat the fibers to a temperature of at least about 60 ° C; wherein the fabric is heated by subjecting the fabric to microwave energy sufficient to thereby heat the fibers to at least about the softening temperatures of the fibers. The fabric; and thereafter thereafter, the heated fabric is molded into an article at a temperature at which the fabric has a softening temperature of at least about the fibers. 6. The method of claim 1, wherein the microwave-reactive composition comprises a dipolar-containing polymer. 7. The method of claim 1, wherein the microwave-reactive composition comprises a polyurethane, a polyelectrolyte, an ionic polymer, a polyvinyl alcohol, a polyvinyl butadiene, a polyoxo, a polyamine, Acrylic resin, ethylene vinyl acetate, ethylene acrylic acid or a combination thereof. The method of item 1, wherein the microwave-reactive composition comprises a polymer comprising a microwave-reactive additive capable of absorbing a foot-bearing medium, AJ wave radiation to heat the fiber to at least about 60 °C temperature. 9. The method of claim &&lt;RTIgt; </ RTI> wherein the microwave reactive additive comprises a polar composition. 1 0. The method of claim 8, wherein the microwave reactive additive comprises an organic salt, an inorganic s..., a metal powder, a dielectric powder, an insoluble microwave absorbing polymer powder, a 'dispersible microwave absorbing polymer powder or Its combination. 11. For example, the δ green item 1 Λ 10,000 method, wherein the plurality of fibers comprise polyolefin fiber, aromatic extract, +-doped amine fiber, polybenzopyrrole fiber, polyvinyl alcohol fiber, 隹t acid amine Paper dimension, polyethylene terephthalate fiber, polynaphthalene fiber 126806.doc 200844291 = bismuth fiber, polyacrylonitrile fiber, liquid crystal copolymer fiber, glass fiber, quasi-carbon fiber, rigid rod fiber or combination. The method of claim 1 wherein the fabric comprises a plurality of polyethylene fibers: a seat: or a medium of the polyethylene fibers, or a plurality of microwave-reactive compositions thereon, wherein the microwave reactive composition is capable of Sufficient microwave radiation is absorbed to heat the fiber to a temperature of at least about 60 °C. The method of item 1, wherein the heating step comprises subjecting the fabric to microwave energy at a frequency of at least about 2.45 GHz. The use of East member 1 is wherein the heating step involves subjecting the fabric to microwave energy at a frequency of at least about 10 GHz. 15. The method of claim </ RTI> wherein the molding step c) is performed after the heating step b). 16. The method of claim 1, wherein the molding step e) is performed in succession of the heating step μ. 17. A method of forming a compacted fibrous web comprising a plurality of fibrous layers - each fibrous layer comprising a plurality of tenacities having a basis weight of about 7 grams per denier or more and about 15 inches / Daniel or higher tensile modulus fibers; and the fibers have a polymeric matrix composition thereon; the 疋κ fiber network is compacted under heat and pressure, wherein the compaction heat is Microwave energy is generated sufficient to thereby heat the polymeric matrix composition to a temperature of at least about the softening temperature of the polymeric matrix composition. 18. The method of claim 17, wherein the softening temperature of the polymeric matrix composition is at least about 6 Torr as measured by ASTM D1525. Hey. 19. The method of claim 17, wherein the compacted fibrous web comprises a plurality of 126806.doc 200844291 cross-stranded nonwoven layers, each fibrous layer comprising a plurality of fibers arranged in a substantially parallel array. 20. An impact resistant article comprising an impact resistant fabric comprising a plurality of fibers arranged in an array having a tenacity of about 7 grams per denier or greater and about 150 grams per denier or higher. The tensile modulus of the fibers has a dry microwave reactive composition applied thereto that has been heated to above its softening point temperature by the application of microwave energy. 21. The impact resistant article of claim 20, which has been heated above its softening point temperature by application of microwave energy, and at or below the softening temperature of the fibers due to the application of microwave energy or the optional microwave reactive combination At the same time as the temperature at which the softening temperature of the article is reached, 'an article 22' is produced by the method of claim. 126806.doc 200844291 VII. Designated representative map: (1) The representative representative of the case is: (none) (2) The symbol of the symbol of the representative figure is simple: 8. If there is a chemical formula in this case, please reveal the best indication of the characteristics of the invention. Chemical formula: (none) 126806.doc