CA2500733A1 - Bi-directional and multi-axial fabrics and fabric composites - Google Patents

Bi-directional and multi-axial fabrics and fabric composites Download PDF

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Publication number
CA2500733A1
CA2500733A1 CA 2500733 CA2500733A CA2500733A1 CA 2500733 A1 CA2500733 A1 CA 2500733A1 CA 2500733 CA2500733 CA 2500733 CA 2500733 A CA2500733 A CA 2500733A CA 2500733 A1 CA2500733 A1 CA 2500733A1
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CA
Canada
Prior art keywords
yarns
fabric
sets
composite
recited
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2500733
Other languages
French (fr)
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CA2500733C (en
Inventor
Ashok Bhatnagar
Elizabeth S. Parrish
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honeywell International Inc
Original Assignee
Honeywell International Inc.
Ashok Bhatnagar
Elizabeth S. Parrish
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Application filed by Honeywell International Inc., Ashok Bhatnagar, Elizabeth S. Parrish filed Critical Honeywell International Inc.
Publication of CA2500733A1 publication Critical patent/CA2500733A1/en
Application granted granted Critical
Publication of CA2500733C publication Critical patent/CA2500733C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/006—With additional leno yarn
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D11/00—Double or multi-ply fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D03D1/0035—Protective fabrics
    • D03D1/0052—Antiballistic fabrics
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/41—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific twist
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/56—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads elastic
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/573—Tensile strength
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C3/00—Stretching, tentering or spreading textile fabrics; Producing elasticity in textile fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0478—Fibre- or fabric-reinforced layers in combination with plastics layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0485—Layered armour containing fibre- or fabric-reinforced layers all the layers being only fibre- or fabric-reinforced layers
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D10B2201/02—Cotton
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D10B2201/08—Ramie
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/20—Cellulose-derived artificial fibres
    • D10B2201/28—Cellulose esters or ethers, e.g. cellulose acetate
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2211/00—Protein-based fibres, e.g. animal fibres
    • D10B2211/01—Natural animal fibres, e.g. keratin fibres
    • D10B2211/02—Wool
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/06—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated alcohols, e.g. polyvinyl alcohol, or of their acetals or ketals
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/10—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/10—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyurethanes
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/14—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensates of cyclic compounds, e.g. polyimides, polybenzimidazoles
    • D—TEXTILES; PAPER
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    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
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    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/024—Fabric incorporating additional compounds
    • D10B2403/0241—Fabric incorporating additional compounds enhancing mechanical properties
    • D10B2403/02412—Fabric incorporating additional compounds enhancing mechanical properties including several arrays of unbent yarn, e.g. multiaxial fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10S139/00—Textiles: weaving
    • Y10S139/01—Bias fabric digest
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    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/911—Penetration resistant layer
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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2615—Coating or impregnation is resistant to penetration by solid implements
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    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
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    • Y10T442/2623—Ballistic resistant
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

Bi-directional and multi-axial fabrics, fabric composites, ballistically resistant assemblies thereof, and the methods by which they are made. The fabrics are comprised of sets of strong, substantially parallel, unidirectional yarns lying in parallel planes, one above the other, with the direction of the yarns in a given plane rotated at an angle to the direction of the yarns in adjacent planes; and one or more sets of yarns having lower strength and higher elongation interleaved with the strong yarns. The fabrics of the invention provide superior ballistic effectiveness compared to ordinary woven and knitted fabrics but retain the ease of manufacture on conventional looms and knitting machines.

Claims (43)

1. A woven fabric comprising:
a) a first set of continuous filament unidirectional yarns lying in a first plane;
b) a second set of continuous filament unidirectional yarns lying in a second plane above said first plane and arranged transversely to said first set of yarns;
c) a third set of yarns arranged transversely to said first set of yarns and interlaced with said first set of yarns, each yarn of the third set lying above some and below the remaining yarns of said first set;
d) a fourth set of yarns arranged transversely to said second set and said third set of yarns and interlaced with said second and thirds sets of yarns, each yarn of the fourth set lying above some and below the remaining yarns of said second and third sets of yarns;
wherein each of said first and second sets of yarns have tenacity's equal to or greater than about 15 g/d, initial tensile moduli equal to or greater than about 400 g/d and energies-to-break equal to or greater than about 22 J/g as measured by ASTM D2256; and wherein each of said first and second sets of yarns, in proportion to the yarns comprising each of said third and fourth sets of yarns have at least twice the breaking strength, and half the elongation to break.
2. The woven fabric of claim 1, wherein the yarns of said first and second sets are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyolefins, aramids, polybenzazoles and blends thereof.
3. The woven fabric of claim 1, wherein the yarns of said first and second sets of yarns are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyethylene, polyp-phenylene terephthalamide, poly(m-phenylene isophthalamide), poly(benzobisoxazole, poly(benzobisthiazole), poly(benzobisimidazole) and blends thereof.
4. The woven fabric of claim 1, wherein the yarns said third and fourth sets are each selected independently from the group consisting of polyamide, polyester, polyvinyl alcohol, polyolefin, polyacrylonitrile, polyurethane, cellulose acetate, cotton, wool, and copolymers and blends thereof.
5. The woven fabric of claim 1, wherein the yarns of at least one of said third and fourth sets of yarns is comprised of an elastomeric fiber.
6. The woven fabric of claim 1, wherein the yarns of at least one of said third and fourth sets of yarns is comprised of staple fibers.
7. The woven fabric of claim 1, wherein the yarns of each of said first and second sets of yarns, in proportion to the yarns comprising each of said third and fourth sets of yarns, have at least three times the breaking strength, and one-third the elongation to break.
8. The woven fabric of claim 1, wherein the yarns of each of said first and second sets of yarns, in proportion to the yarns comprising each of said third and fourth sets of yarns, have at least three times the breaking strength, and one-tenth the elongation to break.
9. The woven fabric of claim 1, wherein the spacing of each of said first, second, third, and fourth sets of yarns is independently from about 5 ends/in (1.97 ends/cm) to about 50 ends/in (19.7 ends/cm).
10. The woven fabric of claim 1, wherein the spacing of each of said first second, third, and fourth sets of yarns is independently from about 8 ends/in (3.15 ends/cm) to about 20 ends/in (7.87 ends/cm).
11. The woven fabric of claim 1, wherein said woven fabric has been calendered.
12. A knitted fabric comprising:
a) a first set of continuous filament unidirectional yarns lying in a first plane;
b) a second set of continuous filament unidirectional yarns lying in a second plane above said first plane, and arranged transversely to said first set of yarns; and c) a third set of yarns forming interlocking loops interlaced with said first and said second set of yarns, each yarn of the third set lying above some and below the remaining yarns of said first set and said second set of yarns;

wherein the yarns of said first and second sets have tenacity's equal to or greater than about 15 g/d, initial tensile moduli equal to or greater than about 400 g/d and energies-to-break equal to or greater than about 22 J/g as measured by ASTM D2256; and wherein the yarns of each of said first and second sets, in proportion to the yarns comprising said third set of yarns have at least about twice the breaking strength, and about one-half the elongation to break.
13. A knitted fabric comprising:
a) a set of continuous filament unidirectional yarns in a bottom plane;
b) a plurality of intermediate planes above said bottom plane each defined by a set of continuous filament unidirectional yarns;
c) a set of continuous filament unidirectional yarns in a top plane;
d) a set of interlacing yarns forming interlocking loops, said loops binding the unidirectional yarns of all planes;
wherein the set of unidirectional yarns in each said plane is rotated at an angle relative to the set of unidirectional yarns in adjacent planes;
wherein the yarns of each set of unidirectional yarns have tenacity's equal to or greater than about 15 g/d, initial tensile moduli equal to or greater than about 400 g/d and energies-to-break equal to or greater than about 22 J/g, all as measured by ASTM D2256; and wherein the yarns of each set of unidirectional yarns, in proportion to the yarns comprising said interlacing yarns, have at least about twice the breaking strength and, at most, about one-half the percent elongation to break.
14. The knitted fabric of either claim 12 or 13, wherein each of said sets of continuous filament unidirectional yarns is selected independently from the group consisting of continuous filament highly oriented high molecular weight polyolefins, aramids, polybenzazole and blends thereof.
15. The knitted fabric of either claim 12 or 13, wherein each of said sets of continuous filament unidirectional yarn is selected independently from the group consisting of continuous filament highly oriented high molecular weight polyethylene, poly(p-phenylene terephthalamide, poly(m-phenylene isophthalamide), poly(benzobisoxazole), poly(benzobisthiazole), poly(benzobisimidazole) and blends thereof.
16. The knitted fabric of either claim 12 or 13, wherein said interlacing set of yarns is selected from the group consisting of polyamide, polyester, polyvinyl alcohol, polyolefin, polyacrylonitrile, polyurethane, cellulose acetate, cotton, wool, and copolymers and blends thereof.
17. The knitted fabric of either claim 12 or 13, wherein said interlacing set of yarns is comprised of an elastomeric fiber.
18. The knitted fabric of either claim 12 or 13, wherein said interlacing set of yarns is comprised of staple fibers.
19. The knitted fabric of either claim 12 or 13, wherein each of said sets of continuous filament unidirectional yarns, in proportion to the yarns comprising said interlacing set of yarns, has at least three times the breaking strength, and one-tenth the elongation to break.
20. The knitted fabric of either claim 12 or 13, wherein the spacing of each of said sets of continuous filament unidirectional yarns is independently selected from a range of about 5 ends/in (1.97 ends/cm) to about 50 ends/in (19.7 ends/cm).
21. The knitted fabric of either claim 12 or 13, wherein the range is about 8 ends/in (3.15 ends/cm) to about 20 ends/in (7.87 ends/cm).
22. The knitted fabric of either claim 12 or 13, wherein the fabric has been calendered.
23. A fabric composite comprising a fabric selected from the group consisting of a woven fabric having the characteristics as recited in claim 1, a knitted fabric having the characteristics as recited in claim 12, and a knitted fabric having the characteristics as recited in claim 13, embedded in a matrix selected from the group consisting of an elastomeric matrix having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa) as measured by ASTM D638.
24. The fabric composite of claim 23, wherein said matrix is a rigid matrix having an initial tensile modulus of at least about 300,000 psi (2068 MPa) as measured by ASTM D638, and wherein coated on at least a portion of one surface of said fabric composite is an elastomeric material having an initial tensile modulus less than about 6,000 psi (41.3 MPa) as measured by ASTM D638.
25. The fabric composite of claim 23, wherein the fabric is calendered.
26. The fabric composite of claim 25, wherein a plastic film is bonded to at least a portion of one of the surfaces of said fabric composite.
27. The fabric composite of claim 25, wherein an elastomer is coated on at least a portion of at least one surface of said fabric, said elastomer having an initial tensile modulus equal to or less than about 6,000 psi (41.3 MPa), as measured by ASTM D638; and a plastic film is bonded to at least a portion of said elastomer coated surface.
28. A fabric composite comprising a fabric selected from the group consisting of a calendered woven fabric having the characteristics as recited in claim 11 and a calendered knitted fabric having the characteristics as recited in claim 22 with a plastic film bonded to at least a portion of at least one of said fabric surfaces.
29. A ballistically resistant article comprised of a plurality of fabric sheets plied together in stacked array, wherein at least a majority of said fabric sheets are selected from the group consisting of a woven fabric having the characteristics as recited in claim 1, a knitted fabric having the characteristics as recited in claim 12, and a knitted fabric as recited in claim 13.
30. The ballistically resistant article of claim 29, wherein the fabric has been calendered.
31. The ballistically resistant article of claim 30, wherein at least a portion of said fabric sheets are fabric composite sheets embedded in a matrix selected from the group consisting of an elastomeric matrix having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638.
32. The ballistically resistant article of claim 31, wherein the matrix is a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638, and coated on at least a portion of one surface of said fabric composite sheets is an elastomeric material having an initial tensile modulus less than about 6,000 psi (41.3 MPa), as measured by ASTM D638.
33. The ballistically resistant article of claims 27 to 32 additionally comprising a hard face member selected from the group consisting of a metal, a ceramic, a glass, a metal filled composite, a ceramic filled composite or a glass filled composite.
34. A method of producing a ballistically resistant article comprising the steps of: weaving a fabric with the characteristics as recited in claim 1; and plying sheets of said fabric in a stacked array.
35. A method of producing a ballistically resistant article comprising the steps of: weaving a fabric with the characteristics as recited in claim 11; and plying sheets of said fabric in a stacked array.
36. A method of producing a ballistically resistant article comprising the steps of: weaving a fabric with the characteristics as recited in claim 22; and plying sheets of said fabric in a stacked array.
37. The method recited in any of claims 34 to 36 additionally comprising the step of joining said fabric sheets together by joining means.
38. A method of producing a ballistically resistant article comprising the steps of:
a) weaving a fabric with the characteristics as recited in claim 11;
b) embedding the fabric in a matrix selected from the group consisting of an elastomer having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid resin having an initial tensile modulus at least 300,000 psi (2068 MPa), as measured by ASTM D638, to produce a fabric composite;
d) plying sheets of said fabric composite in a stacked array; and e) bonding and curing said sheets of said fabric composite together to form a unitary article.
39. A method as recited in claim 38 additionally including the step of bonding a plastic sheet to at least a portion of one surface of said fabric composite prior to plying sheets of said fabric composite in stacked array.
40. A method of producing a ballistically resistant article comprising the steps of:
a) weaving a fabric with the characteristics as recited in claim 11;

b) bonding a plastic film to at least a portion of at least one of said fabric surfaces to produce a fabric composite;
c) plying sheets of said fabric composite in a stacked array; and d) bonding said sheets of said fabric composite together to form a unitary article.
41. A method of producing a ballistically resistant article comprising the steps of:
a) knitting a fabric with the characteristics as recited in claim 22;
b) embedding the fabric in a matrix selected from the group consisting of an elastomer having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid resin having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638, to produce a fabric composite;
c) plying sheets of said fabric composite in a stacked array;
d) bonding and curing said sheets of said fabric composite together to form a unitary article.
42. A method of producing a ballistically resistant article comprising the steps of:
a) knitting a fabric with the characteristics as recited in claim 22;
b) bonding a plastic film to at least a portion of at least one of said fabric surfaces to produce a fabric composite;
c) plying sheets of said fabric composite in a stacked array;
d) bonding said sheets of said fabric composite together to form a unitary article.
43. A method of producing a ballistically resistant article comprising the steps of:
a) weaving a fabric with the characteristics as recited in claim 11;
b) embedding the fabric in a matrix consisting essentially of a rigid resin having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638, to produce a fabric composite;
c) applying to the surface of said fabric composite an elastomeric material having a tensile modulus less than about 6000 psi (41.3 MPa), as measured by ASTM D638, to produce an elastomeric coated fabric composite;

d) plying sheets of said elastomeric coated fabric composite in a stacked array; and e) bonding and curing said sheets of said elastomeric coated fabric composite together to form a unitary article.
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US60/387,201 2002-06-07
US10/179,715 US6841492B2 (en) 2002-06-07 2002-06-25 Bi-directional and multi-axial fabrics and fabric composites
US10/179,715 2002-06-25
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US20040048538A1 (en) * 2002-09-05 2004-03-11 Safeboard Ab Penetration resistant article
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