Barrday Inc.

Kevin Rayner

Shekoufeh Shahkarami

Joseph Krummel

Nirmala Singh

Laura Pritchard

Jonathan MacNeil

According to one aspect, a method of forming foam composites. The method includes providing a plurality of microspheres in contact with a fiber pre-form having a plurality of fibers, inserting at least one penetrating element into the fiber pre-form, and repeatedly moving the at least one penetrating element within the fiber pre-form so as to encourage the plurality of microspheres to disperse within the fiber pre-form. The fiber pre-form with the microspheres dispersed therein is then heated, causing the microspheres to expand and fuse together to form the foam composite.

Methods and apparatus for making foam composites reinforced with fibers and fiber pre-forms having particles therein

According to some aspects, a method of manufacturing a coated multi-threat fabric, including providing a first fabric layer having a first surface, the first fabric layer having a plurality of high performance fibers, applying a first polymeric material onto the first surface of the first fabric layer, the polymeric material having a melt flow index of between about 0.7 to 1400 g/10 min, a Shore D hardness of between about 36 and 75, and ultimate tensile strength of between about 5 and 75 MPa, spreading the first polymeric material onto the first surface of the first fabric layer so as to form a raw coated fabric having a first coating layer, and heating the raw coated fabric to bond the first coating layer to the first fabric layer, wherein the first polymeric material is selected such that the coated multi-threat fabric is flexible enough to be stored on a roll of a predetermined size. In some aspects, a coated multi-threat fabric includes at least one layer of fabric, each layer having a plurality of high performance fibers, and at least one coating of polymeric material bonded to the at least one layer of fabric, the polymeric material comprising an ethylene acrylic acid copolymer selected to allow the coated multi-threat fabric to be stored on a roll of a predetermined size.

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Cambridge, Canada

Kevin Rayner