U.S. patent application number 14/268437 was filed with the patent office on 2015-10-08 for high performance same fiber composite hybrids by varying resin content only.
This patent application is currently assigned to HONEYWELL INTERNATIONAL INC.. The applicant listed for this patent is HONEYWELL INTERNATIONAL INC.. Invention is credited to BRIAN D. ARVIDSON, ASHOK BHATNAGAR, DAVID A. HURST, LORI L. WAGNER.
Application Number | 20150283785 14/268437 |
Document ID | / |
Family ID | 39738954 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150283785 |
Kind Code |
A1 |
ARVIDSON; BRIAN D. ; et
al. |
October 8, 2015 |
HIGH PERFORMANCE SAME FIBER COMPOSITE HYBRIDS BY VARYING RESIN
CONTENT ONLY
Abstract
Multi-panel ballistic resistant articles formed from woven
and/or non-woven fibrous panels, each panel including varying
quantities of a polymeric composition based on the total weight of
the fibers and the polymeric composition. The hybrid structures
provide excellent ballistic penetration resistance while
maintaining a low weight. The ballistic resistant articles may be
strategically positioned to dial in different levels of desired
ballistic resistance for various applications.
Inventors: |
ARVIDSON; BRIAN D.;
(CHESTER, VA) ; HURST; DAVID A.; (RICHMOND,
VA) ; BHATNAGAR; ASHOK; (RICHMOND, VA) ;
WAGNER; LORI L.; (RICHMOND, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HONEYWELL INTERNATIONAL INC. |
Morristown |
NJ |
US |
|
|
Assignee: |
HONEYWELL INTERNATIONAL
INC.
MORRISTOWN
NJ
|
Family ID: |
39738954 |
Appl. No.: |
14/268437 |
Filed: |
May 2, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12565071 |
Sep 23, 2009 |
|
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14268437 |
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11527924 |
Sep 26, 2006 |
7622405 |
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12565071 |
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Current U.S.
Class: |
428/219 ;
428/221; 442/330 |
Current CPC
Class: |
B32B 2262/0246 20130101;
B32B 2262/14 20130101; B32B 27/36 20130101; Y10T 442/291 20150401;
Y10T 442/603 20150401; Y10T 442/2984 20150401; B32B 2605/00
20130101; B32B 5/22 20130101; B32B 27/32 20130101; B32B 2307/746
20130101; B32B 2262/0261 20130101; B32B 2262/106 20130101; B32B
2262/0253 20130101; B32B 2255/26 20130101; B32B 5/08 20130101; B32B
2307/50 20130101; B32B 2307/54 20130101; Y10T 442/2623 20150401;
B32B 5/26 20130101; B32B 2260/046 20130101; B32B 5/024 20130101;
B32B 2270/00 20130101; B32B 2262/0276 20130101; B32B 5/022
20130101; B32B 2255/02 20130101; B32B 2571/02 20130101; Y10T
442/2893 20150401; B32B 27/322 20130101; B32B 27/30 20130101; B32B
27/34 20130101; B32B 27/40 20130101; B32B 2262/02 20130101; B32B
2307/718 20130101; Y10T 428/249921 20150401; B32B 2262/101
20130101; Y10T 442/2861 20150401; B32B 5/06 20130101; Y10T 442/2615
20150401; B32B 27/304 20130101; F41H 5/0485 20130101; B32B 7/02
20130101; B32B 2262/0269 20130101; B32B 27/12 20130101; Y10T
442/2992 20150401; B32B 2260/021 20130101 |
International
Class: |
B32B 5/02 20060101
B32B005/02; B32B 5/26 20060101 B32B005/26 |
Claims
1. A ballistic resistant material comprising: a first panel and a
second panel, each comprising a plurality of fibrous layers, said
plurality of fibrous layers being consolidated; each of the fibrous
layers comprising a plurality of fibers, said fibers in each of
said fibrous layers being the same in each panel and having a
tenacity of 7 g/denier or more and a tensile modulus of 150
g/denier or more; each of said fibers having a surface, wherein the
surfaces of the fibers of said first panel are coated with a
polymeric matrix composition; and wherein the second panel
comprises fibers that are not coated with a polymeric matrix
composition.
2. The ballistic resistant material of claim 1 wherein both the
first panel and the second panel comprise a plurality of non-woven
fibrous layers.
3. The ballistic resistant material of claim 1 wherein the second
panel is polymeric matrix-free, wherein the second panel consists
of fibers that are not coated with a polymeric matrix composition,
and wherein the first panel and the second panel are juxtaposed
with each other in a non-bonded array.
4. The ballistic resistant material of claim 1 further comprising
at least one rigid plate attached to an outer surface of the first
panel, said rigid plate comprising a ceramic, glass, a metal-filled
composite, a ceramic-filled composite, a glass-filled composite, a
cermet, high hardness steel, an armor aluminum alloy, titanium or a
combination thereof.
5. The ballistic resistant material of claim 1 wherein the first
panel and the second panel are juxtaposed with each other in a
non-bonded array.
6. The ballistic resistant material of claim 1 wherein the material
consists of the first panel and the second panel, wherein the first
panel and the second panel are juxtaposed with each other in a
non-bonded array, and wherein the second panel consists of fibers
that are not coated with a polymeric matrix composition.
7. A hard armor article comprising the ballistic resistant material
of claim 1, wherein the article is a helmet or a vehicle panel.
8. A ballistic resistant material comprising, in order: a) a first
panel comprising a plurality of fibrous layers, said plurality of
fibrous layers being consolidated; each of the fibrous layers
comprising a plurality of fibers, said fibers having a tenacity of
7 g/denier or more and a tensile modulus of 150 g/denier or more;
each of said fibers having a surface, and the surfaces of said
fibers being coated with a polymeric matrix composition; and b) a
second panel attached to the first panel, which second panel is
different than the first panel, and which second panel comprises a
plurality of fibrous layers, said plurality of fibrous layers being
consolidated; each of the fibrous layers comprising a plurality of
fibers, said fibers having a tenacity of 7 g/denier or more and a
tensile modulus of 150 g/denier or more; each of said fibers having
a surface, and the surfaces of said fibers being coated with a
polymeric matrix composition; and said first panel containing a
greater percentage by weight of the polymeric matrix composition in
the first panel, based on the total weight of the first panel, than
a percentage by weight of the polymeric matrix composition in said
second panel, based on the total weight of the second panel; and c)
one or more additional panels attached to said second panel,
wherein at least one of said additional panels comprises fibers
that are not coated with a polymeric matrix composition; wherein
said one or more additional panels comprises a plurality of fibers
having a tenacity of 7 g/denier or more and a tensile modulus of
150 g/denier or more; wherein said first panel is positioned closer
to a potential ballistic threat relative to the second panel.
9. The ballistic resistant material of claim 8 wherein all of the
panels are interconnected to form a series of interconnected
ballistic resistant panels, and wherein each consecutive panel in
the series contains a lower percentage by weight of the polymeric
matrix composition than the previous panel in the series to which
it is connected, based on the total weight of each panel, and
wherein said ballistic resistant material has an areal density of
from about 0.25 lb/ft.sup.2 (1.22 kg/m.sup.2) to about 2.0
lb/ft.sup.2 (9.76 kg/m.sup.2).
10. The ballistic resistant material of claim 8 wherein at least
one of said additional panels consists of fibers that are not
coated with a polymeric matrix composition, wherein all of said
panels are juxtaposed with each other in a non-bonded array.
11. The ballistic resistant material of claim 8 comprising a series
of three interconnected panels, the panels having respective
polymeric matrix composition quantities, in order, of 20%, 10% and
0% by weight of the combined weight of its fibers and polymeric
matrix composition.
12. The ballistic resistant material of claim 8 further comprising
at least one rigid plate attached to an outer surface of the first
panel, said rigid plate comprising a ceramic, glass, a metal-filled
composite, a ceramic-filled composite, a glass-filled composite, a
cermet, high hardness steel, an armor aluminum alloy, titanium or a
combination thereof.
13. The ballistic resistant material of claim 8 wherein more than
one additional panel is present, wherein at least one of said
additional panels comprises fibers that are not coated with a
polymeric matrix composition.
14. The ballistic resistant material of claim 13 wherein at least
one of said additional panels consists of fibers that are not
coated with a polymeric matrix composition, wherein all of said
panels are juxtaposed with each other in a non-bonded array, and
wherein said ballistic resistant material has an areal density of
from about 0.25 lb/ft.sup.2 (1.22 kg/m.sup.2) to about 2.0
lb/ft.sup.2 (9.76 kg/m.sup.2).
15. The ballistic resistant material of claim 13 wherein more than
one additional panel comprises fibers that are not coated with a
polymeric matrix composition.
16. The ballistic resistant material of claim 13 wherein more than
one additional panel consists of fibers that are not coated with a
polymeric matrix composition, wherein all of said panels are
juxtaposed with each other in a non-bonded array, and wherein said
ballistic resistant material has an areal density of from about
0.25 lb/ft.sup.2 (1.22 kg/m.sup.2) to about 2.0 lb/ft.sup.2 (9.76
kg/m.sup.2).
17. The ballistic resistant material of claim 13 further comprising
one or more additional panels attached to said first panel, wherein
at least one of said additional panels comprises fibers that are
not coated with a polymeric matrix composition; wherein said one or
more additional panels comprises a plurality of fibers having a
tenacity of 7 g/denier or more and a tensile modulus of 150
g/denier or more, and wherein all of said panels are juxtaposed
with each other in a non-bonded array.
18. The ballistic resistant material of claim 17 wherein at least
one additional panel consisting of fibers that are not coated with
a polymeric matrix composition is attached to the first panel and
at least one additional panel consisting of fibers that are not
coated with a polymeric matrix composition is attached to the
second panel, wherein all of said panels are juxtaposed with each
other in a non-bonded array, and wherein said ballistic resistant
material has an areal density of from about 0.25 lb/ft.sup.2 (1.22
kg/m.sup.2) to about 2.0 lb/ft.sup.2 (9.76 kg/m.sup.2).
19. A ballistic resistant material comprising: a first panel
comprising a plurality of fibrous layers, said plurality of fibrous
layers being consolidated; each of the fibrous layers comprising a
plurality of fibers, said fibers having a tenacity of about 7
g/denier or more and a tensile modulus of about 150 g/denier or
more; each of said fibers having a surface, and the surfaces of
said fibers being coated with a polymeric composition; and a second
panel attached to the first panel, which second panel is different
than the first panel, and which second panel comprises a plurality
of fibrous layers, said plurality of fibrous layers being
consolidated; each of the fibrous layers comprising a plurality of
fibers, said fibers having a tenacity of about 7 g/denier or more
and a tensile modulus of about 150 g/denier or more; each of said
fibers having a surface, and the surfaces of said fibers optionally
being coated with a polymeric composition; wherein the first panel
and the second panel are juxtaposed with each other in a non-bonded
array; and wherein when the surfaces of the fibers of the second
panel are coated with a polymeric composition, said first panel
contains a greater percentage by weight of the polymeric
composition in the first panel, based on the total weight of the
first panel, than a percentage by weight of the polymeric
composition in said second panel, based on the total weight of the
second panel.
20. The ballistic resistant material of claim 19 wherein both the
first panel and the second panel consist of a plurality of
non-woven fibrous layers, wherein the fibers of the second panel
are coated with a polymeric composition and wherein the polymeric
composition consists of from about 7% to about 20% by weight of the
second panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of co-pending application
Ser. No. 12/565,071 filed Sep. 23, 2009, which is a division of
Ser. No. 11/527,924 filed Sep. 26, 2006, now U.S. Pat. No.
7,622,405, the entire disclosure of which is incorporated by
reference herein.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] This invention relates to multi-panel ballistic resistant
articles formed from woven and/or non-woven fibrous panels, each
panel includes varying quantities of a polymeric composition
coating based on the total weight of the fibers and the polymeric
composition.
[0004] 2. Description of the Related Art
[0005] Ballistic resistant articles containing high strength fibers
that have excellent properties against projectiles are well known.
Articles such as bullet resistant vests, helmets, vehicle panels
and structural members of military equipment are typically made
from fabrics comprising high strength fibers. High strength fibers
conventionally used include polyethylene fibers, aramid fibers such
as poly(phenylenediamine terephthalamide), graphite fibers, nylon
fibers, glass fibers and the like. For many applications, such as
vests or parts of vests, the fibers may be used in a woven or
knitted fabric. For other applications, the fibers may be
encapsulated or embedded in a polymeric matrix material to form
non-woven rigid, semi-rigid or flexible fabrics.
[0006] Various ballistic resistant constructions are known that are
useful for the formation of hard or soft armor articles such as
helmets, panels and vests. For example, U.S. Pat. Nos. 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, 6,846,758, all of which
are incorporated herein by reference, describe ballistic resistant
composites which include high strength fibers made from materials
such as extended chain ultra-high molecular weight polyethylene.
These composites display varying degrees of resistance to
penetration by high speed impact from projectiles such as bullets,
shells, shrapnel and the like.
[0007] For example, U.S. Pat. Nos. 4,623,574 and 4,748,064 disclose
simple composite structures comprising high strength fibers
embedded in an elastomeric matrix. U.S. Pat. No. 4,650,710
discloses a flexible article of manufacture comprising a plurality
of flexible layers comprised of high strength, extended chain
polyolefin (ECP) fibers. The fibers of the network are coated with
a low modulus elastomeric material. U.S. Pat. Nos. 5,552,208 and
5,587,230 disclose an article and method for making an article
comprising at least one network of high strength fibers and a
matrix composition that includes a vinyl ester and diallyl
phthalate. U.S. Pat. No. 6,642,159 discloses an impact resistant
rigid composite having a plurality of fibrous layers which comprise
a network of filaments disposed in a matrix, with elastomeric
layers there between. The composite is bonded to a hard plate to
increase protection against armor piercing projectiles.
[0008] Hybrid ballistic resistant structures, in and of themselves,
are known. For example, U.S. Pat. Nos. 5,179,244 and 5,180,880
teach soft or hard body armor utilizing a plurality of plies made
from dissimilar ballistic materials, joining aramid and non-aramid
fiber plies into a combined structure and utilizing polymeric
matrix materials that deteriorate when exposed to liquids. U.S.
Pat. No. 5,926,842 also describes hybridized ballistic resistant
structures utilizing polymeric matrix materials that deteriorate
when exposed to liquids. Further, U.S. Pat. No. 6,119,575 teaches a
hybrid structure containing a first section of aromatic fibers, a
second section of a woven plastic and a third section of polyolefin
fibers.
[0009] The present invention provides new hybrid structures that
provide excellent ballistic penetration resistance while
maintaining a low weight. Particularly, the invention provides
articles wherein ballistic performance and article weight may be
customized by manipulating the content of a polymeric matrix
composition coating the fiber layers within an armor construction.
The inventive construction allows the ballistic articles to be
strategically positioned to dial in different levels of desired
ballistic resistance for varying applications.
SUMMARY
[0010] The invention provides a ballistic resistant material
comprising, in order:
a) a first panel comprising a plurality of fibrous layers, said
plurality of fibrous layers being consolidated; each of the fibrous
layers comprising a plurality of fibers, said fibers having a
tenacity of about 7 g/denier or more and a tensile modulus of about
150 g/denier or more; each of said fibers having a surface, and the
surfaces of said fibers being coated with a polymeric composition;
and b) a second panel attached to the first panel, which second
panel is different than the first panel, and which second panel
comprises a plurality of fibrous layers, said plurality of fibrous
layers being consolidated; each of the fibrous layers comprising a
plurality of fibers, said fibers having a tenacity of about 7
g/denier or more and a tensile modulus of about 150 g/denier or
more; each of said fibers having a surface, and the surfaces of
said fibers being coated with a polymeric composition; and c) said
first panel containing a greater percentage by weight of the
polymeric composition in the first panel, based on the total weight
of the first panel, than a percentage by weight of the polymeric
composition in said second panel, based on the total weight of the
second panel.
[0011] The invention also provides a method of forming a ballistic
resistant material which comprises a series of ballistic resistant
panels, the method comprising:
a) providing a first panel comprising a plurality of fibrous
layers, said plurality of fibrous layers being consolidated; each
of the fibrous layers comprising a plurality of fibers, said fibers
having a tenacity of about 7 g/denier or more and a tensile modulus
of about 150 g/denier or more; each of said fibers having a
surface, and the surfaces of said fibers being coated with a
polymeric composition; and b) attaching at least one additional
ballistic resistant panel, wherein at least one additional
ballistic resistant panel is different from the first panel, to
said first panel to thereby form a series of interconnected
ballistic resistant panels; the at least one additional panel
comprising a plurality of fibrous layers, said plurality of fibrous
layers being consolidated; each of the fibrous layers comprising a
plurality of fibers, said fibers having a tenacity of about 7
g/denier or more and a tensile modulus of about 150 g/denier or
more; each of said fibers having a surface, and the surfaces of
said fibers being coated with a polymeric composition; said first
panel containing a greater percentage by weight of the polymeric
composition in the first panel, based on the total weight of the
first panel, than a percentage by weight of the polymeric
composition in at least one additional ballistic resistant panel,
based on the total weight of the at least one additional ballistic
resistant panel.
[0012] The invention further provides a ballistic resistant article
formed from a ballistic resistant material, the ballistic resistant
material comprising:
a) a first panel comprising a plurality of fibrous layers, said
plurality of fibrous layers being consolidated; each of the fibrous
layers comprising a plurality of fibers, said fibers having a
tenacity of about 7 g/denier or more and a tensile modulus of about
150 g/denier or more; each of said fibers having a surface, and the
surfaces of said fibers being coated with a polymeric composition;
and b) a second panel attached to the first panel, which second
panel is different than the first panel, and which second panel
comprises a plurality of fibrous layers, said plurality of fibrous
layers being consolidated; each of the fibrous layers comprising a
plurality of fibers, said fibers having a tenacity of about 7
g/denier or more and a tensile modulus of about 150 g/denier or
more; each of said fibers having a surface, and the surfaces of
said fibers being coated with a polymeric composition; and c) said
first panel containing a greater percentage by weight of the
polymeric composition in the first panel, based on the total weight
of the first panel, than a percentage by weight of the polymeric
composition in said second panel, based on the total weight of the
second panel; and d) at least one additional panel attached to the
first panel, to the second panel, or to both the first panel and to
the second panel, the at least one additional panel comprising a
plurality of fibrous layers, said plurality of fibrous layers being
consolidated; each of the fibrous layers comprising a plurality of
fibers, said fibers having a tenacity of about 7 g/denier or more
and a tensile modulus of about 150 g/denier or more; each of said
fibers having a surface, and the surfaces of said fibers optionally
being coated with a polymeric composition.
DETAILED DESCRIPTION
[0013] The invention provides a ballistic resistant material and
articles that have superior ballistic penetration resistance
against high energy ballistic threats, including bullets and high
energy fragments, such as shrapnel. The material includes two or
more individual attached panels, each panel comprising high
strength fibers having a tenacity of about 7 g/denier or more and a
tensile modulus of about 150 g/denier or more. Most broadly, a
ballistic resistant material of the invention comprises a first
panel attached to a second panel, each panel comprising a plurality
of fibrous layers, said plurality of fibrous layers being
consolidated; each of the fibrous layers comprising a plurality of
fibers, said fibers having a tenacity of about 7 g/denier or more
and a tensile modulus of about 150 g/denier or more; each of said
fibers having a surface, and the surfaces of said fibers being
coated with a polymeric composition. As described herein, the first
panel contains a greater percentage by weight of the polymeric
composition in the first panel, based on the total weight of the
first panel, than a percentage by weight of the polymeric
composition in said second panel, based on the total weight of the
second panel. As described herein, the total weight of a panel is
the weight of the fibers plus the weight of the polymeric
composition that form the panel. The ballistic resistant material
and articles of the invention may further include additional
panels, preferably forming a series of interconnected ballistic
resistant panels, wherein consecutive panels in the series contains
a lower percentage by weight of the polymeric composition than the
previous panel in the series to which it is connected, based on the
total weight of each panel, and wherein each panel may comprise
woven fibers or non-woven fibers, or a combination thereof.
[0014] For the purposes of the present invention, a "fiber" is an
elongate body the length dimension of which is much greater than
the transverse dimensions of width and thickness. The
cross-sections of fibers for use in this invention may vary
widely.
[0015] They may be circular, flat or oblong in cross-section.
Accordingly, the term fiber includes filaments, ribbons, strips and
the like having regular or irregular cross-section. They may also
be of irregular or regular multi-lobal cross-section having one or
more regular or irregular lobes projecting from the linear or
longitudinal axis of the fibers. It is preferred that the fibers
are single lobed and have a substantially circular
cross-section.
[0016] As used herein, a "yarn" is a strand consisting of multiple
filaments. An "array" describes an orderly arrangement of fibers or
yarns, and a "parallel array" describes an orderly parallel
arrangement of fibers or yarns. A fiber "layer" describes a planar
arrangement of woven or non-woven fibers or yarns. A fiber
"network" denotes a plurality of interconnected fiber or yarn
layers. As used herein, the term "interconnected" describes a
reciprocal connection of the multiple layers or multiple panels of
the invention, such that the structure functions as a single unit.
A "consolidated network" describes a consolidated (merged)
combination of fiber layers with a polymeric composition. As used
herein, a "single layer" structure refers to monolithic structure
composed of one or more individual fiber layers that have been
consolidated into a single unitary structure. In general, a
"fabric" may relate to either a woven or non-woven material.
[0017] The invention presents various embodiments that include two
or more ballistic resistant panels, where each panel may comprise
non-woven fibrous layers, woven fibrous layers, or a combination
thereof. In the preferred embodiments of the invention, a panel of
non-woven fibrous layers preferably comprises a single-layer,
consolidated network of fibers and an elastomeric or rigid
polymeric composition, which polymeric composition is also referred
to in the art as a polymeric matrix composition. The terms
"polymeric composition" and "polymeric matrix composition" are used
interchangeably herein. More particularly, a single-layer,
consolidated network of fibers comprises a plurality of fibrous
layers stacked together, each fibrous layer comprising a plurality
of fibers coated with the polymeric composition and
unidirectionally aligned in an array so that they are substantially
parallel to each other along a common fiber direction.
[0018] As is conventionally known in the art, excellent ballistic
resistance is achieved when individual fiber layer are cross-plied
such that the fiber alignment direction of one layer is rotated at
an angle with respect to the fiber alignment direction of another
layer. Accordingly, successive layers of such unidirectionally
aligned fibers are preferably rotated with respect to a previous
layer. An example is a two layer (two ply) structure wherein
adjacent layers (plies) are aligned in a 0.degree./90.degree.
orientation, where each individual non-woven ply is also known as a
"unitape". However, adjacent layers can be aligned at virtually any
angle between about 0.degree. and about 90.degree. with respect to
the longitudinal fiber direction of another layer. For example, a
five ply non-woven structure may have plies at a
0.degree./45.degree./90.degree./45.degree./0.degree. orientation or
at other angles. In the preferred embodiment of the invention, only
two individual non-woven plies, cross-plied at 0.degree. and
90.degree., are consolidated into a single layer network, wherein
one or more of said single layer networks make up a single
non-woven panel. However, it should be understood that the
single-layer consolidated networks of the invention may generally
include any number of cross-plied (or non-cross-plied) plies. Most
typically, the single-layer consolidated networks include from 1 to
about 6 plies, but may include as many as about 10 to about 20
plies as may be desired for various applications. Such rotated
unidirectional alignments are described, for example, in U.S. Pat.
Nos. 4,457,985; 4,748,064; 4,916,000; 4,403,012; 4,623,573; and
4,737,402. Likewise, a "panel" is a monolithic structure that may
include any number of component fiber layers or plies, and
typically includes 1 to about 65 fiber layers or plies, and each
panel may comprise a plurality of fibrous layers which comprise
non-woven fibers, a plurality of fibrous layers which comprise
woven fibers, or a combination of woven fibrous layers and
non-woven fibrous layers. A ballistic resistant material of the
invention may also comprise at least one panel which comprises a
plurality of fibrous layers which comprise non-woven fibers and at
least one panel which comprises a plurality of fibrous layers which
comprise woven fibers.
[0019] The stacked fibrous layers are consolidated, or united into
a monolithic structure by the application of heat and pressure, to
form the single-layer, consolidated network, merging the fibers and
the polymeric composition of each component fibrous layer. The
non-woven fiber networks can be constructed using well known
methods, such as by the methods described in U.S. Pat. No.
6,642,159. The consolidated network may also comprise a plurality
of yarns that are coated with such a polymeric composition, formed
into a plurality of layers and consolidated into a fabric. The
non-woven fiber networks may also comprise a felted structure which
is formed using conventionally known techniques, comprising fibers
in a random orientation embedded in a suitable polymeric
composition that are matted and compressed together.
[0020] For the purposes of the present invention, the term "coated"
is not intended to limit the method by which the polymeric
composition is applied onto the fiber surface or surfaces. The
application of the polymeric composition is conducted prior to
consolidating the fiber layers, and any appropriate method of
applying the polymeric composition onto the fiber surfaces may be
utilized. Accordingly, the fibers of the invention may be coated
on, impregnated with, embedded in, or otherwise applied with a
polymeric composition by applying the composition to the fibers and
then optionally consolidating the composition-fibers combination to
form a composite. As stated above, by "consolidating" it is meant
that the polymeric composition material and each individual fiber
layer are combined into a single unitary layer. Consolidation can
occur via drying, cooling, heating, pressure or a combination
thereof. The term "composite" refers to consolidated combinations
of fibers with the polymeric matrix composition. The term "matrix"
as used herein is well known in the art, and is used to represent a
polymeric binder material that binds the fibers together after
consolidation.
[0021] The woven fibrous layers of the invention are also formed
using techniques that are well known in the art using any fabric
weave, such as plain weave, crowfoot weave, basket weave, satin
weave, twill weave and the like. Plain weave is most common. Prior
to weaving, the individual fibers of each woven fibrous material
may or may not be coated with a polymeric composition in a similar
fashion as the non-woven fibrous layers using the same polymeric
compositions as the non-woven fibrous layers.
[0022] As described herein, each panel of woven or non-woven
fibrous layers preferably comprises a plurality of fibrous layers,
where the greater the number of layers translates into greater
ballistic resistance, but also greater weight. A non-woven fibrous
panel, in particular, preferably comprises two or more layers that
are consolidated into a monolithic panel. A woven fibrous panel may
also comprise a plurality of consolidated woven fibrous layers,
which are consolidated by molding under pressure. In a preferred
structure of the invention, a first panel which comprises ten
consolidated layers of a woven fibrous material is attached one
surface of a second panel which comprises ten non-woven fibrous
layers consolidated into a single layer network, and a third panel
comprising ten consolidated layers of a woven fibrous material is
attached to an opposing surface of the second panel.
[0023] The number of layers forming a single panel, and the number
of layers forming the non-woven composite vary depending upon the
ultimate use of the desired ballistic resistant article. For
example, in body armor vests for military applications, in order to
form an article composite that achieves a desired 1.0 pound per
square foot areal density (4.9 kg/m.sup.2), a total of at 22
individual layers (or plies) may be required, wherein the plies may
be woven, knitted, felted or non-woven fabrics formed from the
high-strength fibers described herein, and the layers may or may
not be attached together. In another embodiment, body armor vests
for law enforcement use may have a number of layers based on the
National Institute of Justice (NIJ) Threat Level. For example, for
an NIJ Threat Level IIIA vest, there may also be a total of 22
layers. For a lower NIJ Threat Level, fewer layers may be
employed.
[0024] The invention is characterized in particular by combining
multiple panels that contain different quantities of a polymeric
composition, as measured by the total weight of the fibers plus the
polymeric composition forming the panel. Articles of the invention
may include as few as two panels, wherein each panel comprises a
monolithic structure, and wherein each of the two panels includes a
different quantity amount of a polymeric composition. More
preferably, articles of the invention include three or more
monolithic panels, where each panel preferably includes a different
quantity amount of a polymeric composition. It is further within
the scope of the invention that each of the multiple monolithic
panels of the invention may be attached by further consolidating
(merging, preferably by molding) the panels to form another
monolithic structure, said another monolithic structure
incorporating multiple panels having differing amounts of the
polymeric matrix composition, and accordingly having different
sections which have different amounts of the polymeric matrix
composition representing the location of each of the different
panels.
[0025] In each embodiment of the invention, some panels may include
identical quantities of a polymeric matrix composition. However,
the total polymeric matrix composition content of at least two
panels forming an article must differ. In an alternate embodiment
of the invention, a ballistic resistant article comprises at least
one ballistic resistant panel wherein the fibers forming the panel
are not coated with a polymeric composition. If present, such an
uncoated, polymeric matrix-free panel is preferably part of a
series of interconnected ballistic resistant panels wherein at
least one panel of the series includes a polymeric composition.
Methods of attaching or interconnecting multiple panels are well
known in the art, and include stitching, quilting, bolting,
adhering with adhesive materials, and the like. Multiple panels may
also be attached by molding under the molding conditions herein
described. Preferably, said plurality of panels forming a series
are interconnected by stitching together at edge areas of the
panels.
[0026] In the preferred embodiments of the invention, each panel
comprises a fiber content of at least about 65% by weight, more
preferably at least about 70% by weight, more preferably at least
about 75%, and most preferably at least about 80% by weight of the
total weight of the panel. Preferably, the proportion of the
polymeric composition making up each panel preferably comprises
from about 1% to about 35% by weight based on the total weight of
each panel composite, more preferably from about 3% to about 30% by
weight, more preferably from about 5% to about 25% by weight and
most preferably from about 7% to about 20% by weight of the panel,
based on the total weight of the fibers and polymeric composition
of each panel. These weight ranges apply to panels formed with the
same polymeric composition or different polymeric compositions.
Preferably, each panel has the same polymeric composition coating.
Examples of preferred embodiments non-exclusively include: 1) a
two-panel article wherein the first panel has a polymeric
composition content of approximately 20% by weight of the combined
weight of its fibers and the polymeric composition, and the second
panel has a polymeric composition content of approximately 10% by
weight of the combined weight of its fibers and polymeric
composition; 2) a series of four interconnected panels, the panels
having respective polymeric composition quantities, in order, of
20%, 15%, 10% and 7%, said panels preferably being stitched
together; and 3) a three-panel article similar to the two-panel
article described above, but having a matrix-free third panel
attached to the 10% matrix-containing panel.
[0027] The woven or non-woven fibrous layers of the invention may
be prepared using a variety of polymeric composition (polymeric
matrix composition) materials, including both low modulus,
elastomeric materials and high modulus, rigid materials. Suitable
polymeric composition materials non-exclusively include low
modulus, elastomeric materials having an initial tensile modulus
less than about 6,000 psi (41.3 MPa), and high modulus, rigid
materials having an initial tensile modulus at least about 300,000
psi (2068 MPa), each as measured at 37.degree. C. by ASTM D638. As
used herein throughout, the term tensile modulus means the modulus
of elasticity as measured by ASTM 2256 for a fiber and by ASTM D638
for a polymeric composition material.
[0028] An elastomeric polymeric composition may comprise a variety
of polymeric and non-polymeric materials. The preferred elastomeric
polymeric composition comprises a low modulus elastomeric material.
For the purposes of this invention, a low modulus elastomeric
material has a tensile modulus, measured at about 6,000 psi (41.4
MPa) or less according to ASTM D638 testing procedures. Preferably,
the tensile modulus of the elastomer is about 4,000 psi (27.6 MPa)
or less, more preferably about 2400 psi (16.5 MPa) or less, more
preferably 1200 psi (8.23 MPa) or less, and most preferably is
about 500 psi (3.45 MPa) or less. The glass transition temperature
(Tg) of the elastomer is preferably less than about 0.degree. C.,
more preferably the less than about -40.degree. C., and most
preferably less than about -50.degree. C. The elastomer also has a
preferred elongation to break of at least about 50%, more
preferably at least about 100% and most preferably has an
elongation to break of at least about 300%.
[0029] A wide variety of materials and formulations having a low
modulus may be utilized as the polymeric composition.
Representative examples include polybutadiene, polyisoprene,
natural rubber, ethylene-propylene copolymers,
ethylene-propylene-diene terpolymers, polysulfide polymers,
polyurethane elastomers, chlorosulfonated polyethylene,
polychloroprene, plasticized polyvinylchloride, butadiene
acrylonitrile elastomers, poly(isobutylene-co-isoprene),
polyacrylates, polyesters, polyethers, fluoroelastomers, silicone
elastomers, copolymers of ethylene, and combinations thereof, and
other low modulus polymers and copolymers curable below the melting
point of the polyolefin fiber. Also preferred are blends of
different elastomeric materials, or blends of elastomeric materials
with one or more thermoplastics. The polymeric composition may also
include fillers such as carbon black or silica, may be extended
with oils, or may be vulcanized by sulfur, peroxide, metal oxide or
radiation cure systems as is well known in the art.
[0030] Particularly useful are block copolymers of conjugated
dienes and vinyl aromatic monomers. Butadiene and isoprene are
preferred conjugated diene elastomers. Styrene, vinyl toluene and
t-butyl styrene are preferred conjugated aromatic monomers. Block
copolymers incorporating polyisoprene may be hydrogenated to
produce thermoplastic elastomers having saturated hydrocarbon
elastomer segments. The polymers may be simple tri-block copolymers
of the type A-B-A, multi-block copolymers of the type (AB).sub.n
(n=2-10) or radial configuration copolymers of the type
R-(BA).sub.x (x=3-150); wherein A is a block from a polyvinyl
aromatic monomer and B is a block from a conjugated diene
elastomer. Many of these polymers are produced commercially by
Kraton Polymers of Houston, Tex. and described in the bulletin
"Kraton Thermoplastic Rubber", SC-68-81. The most preferred
polymeric composition polymer comprises styrenic block copolymers
sold under the trademark Kraton.RTM. commercially produced by
Kraton Polymers. The most preferred low modulus polymeric matrix
composition comprises a polystyrene-polyisoprene-polystrene-block
copolymer.
[0031] Preferred high modulus, rigid polymeric composition
materials useful herein include materials such as a vinyl ester
polymer or a styrene-butadiene block copolymer, and also mixtures
of polymers such as vinyl ester and diallyl phthalate or phenol
formaldehyde and polyvinyl butyral. A particularly preferred rigid
polymeric composition material for use in this invention is a
thermosetting polymer, preferably soluble in carbon-carbon
saturated solvents such as methyl ethyl ketone, and possessing a
high tensile modulus when cured of at least about 1.times.10.sup.6
psi (6895 MPa) as measured by ASTM D638. Particularly preferred
rigid polymeric composition materials are those described in U.S.
Pat. No. 6,642,159, which is incorporated herein by reference.
[0032] In addition to the non-woven fibrous layers, the woven
fibrous layers are also preferably coated with the polymeric
composition. Preferably the fibers comprising the woven fibrous
layers are at least partially coated with a polymeric composition,
followed by a consolidation step similar to that conducted with
non-woven fibrous layers. However, coating the woven fibrous layers
with a polymeric composition is not required. For example, a
plurality of woven fibrous layers forming a panel of the invention
do not necessarily have to be consolidated, and may be attached by
other means, such as with a conventional adhesive, or by stitching.
Generally, a polymeric composition coating is necessary to
efficiently merge, i.e. consolidate, a plurality of fibrous layers.
In the preferred embodiment of the invention, a matrix-free panel,
if included, preferably comprises one or more woven fibrous layers
that are not coated with a polymeric composition, wherein multiple
woven layers may be joined by stitching or any other common
method.
[0033] The rigidity, impact and ballistic properties of the
articles formed from the fabric composites of the invention are
affected by the tensile modulus of the polymeric composition
polymer. For example, U.S. Pat. No. 4,623,574 discloses that fiber
reinforced composites constructed with elastomeric matrices having
tensile moduli less than about 6000 psi (41,300 kPa) have superior
ballistic properties compared both to composites constructed with
higher modulus polymers, and also compared to the same fiber
structure without a polymeric matrix composition. However, low
tensile modulus polymeric matrix composition polymers also yield
lower rigidity composites. Further, in certain applications,
particularly those where a composite must function in both
anti-ballistic and structural modes, there is needed a superior
combination of ballistic resistance and rigidity. Accordingly, the
most appropriate type of polymeric composition polymer to be used
will vary depending on the type of article to be formed from the
fabrics of the invention. In order to achieve a compromise in both
properties, a suitable polymeric composition may combine both low
modulus and high modulus materials to form a single polymeric
composition.
[0034] The remaining portion of the composite is preferably
composed of fibers. In accordance with the invention, the fibers
comprising each of the woven and non-woven fibrous layers
preferably comprise high-strength, high tensile modulus fibers. As
used herein, a "high-strength, high tensile modulus fiber" is one
which has a preferred tenacity of at least about 7 g/denier or
more, a preferred tensile modulus of at least about 150 g/denier or
more, and preferably an energy-to-break of at least about 8 J/g or
more, each both as measured by ASTM D2256. As used herein, the term
"denier" refers to the unit of linear density, equal to the mass in
grams per 9000 meters of fiber or yarn. As used herein, the term
"tenacity" refers to the tensile stress expressed as force (grams)
per unit linear density (denier) of an unstressed specimen. The
"initial modulus" of a fiber is the property of a material
representative of its resistance to deformation. The term "tensile
modulus" refers to the ratio of the change in tenacity, expressed
in grams-force per denier (g/d) to the change in strain, expressed
as a fraction of the original fiber length (in/in).
[0035] Particularly suitable high-strength, high tensile modulus
fiber materials include polyolefin fibers, particularly extended
chain polyolefin fibers, such as highly oriented, high molecular
weight polyethylene fibers, particularly ultra-high molecular
weight polyethylene fibers and ultra-high molecular weight
polypropylene fibers. Also suitable are aramid fibers, particularly
para-aramid fibers, polyamide fibers, polyethylene terephthalate
fibers, polyethylene naphthalate fibers, extended chain polyvinyl
alcohol fibers, extended chain polyacrylonitrile fibers,
polybenzazole fibers, such as polybenzoxazole (PBO) and
polybenzothiazole (PBT) fibers, and liquid crystal copolyester
fibers. Each of these fiber types is conventionally known in the
art.
[0036] In the case of polyethylene, preferred fibers are extended
chain polyethylenes having molecular weights of at least 500,000,
preferably at least one million and more preferably between two
million and five million. Such extended chain polyethylene (ECPE)
fibers may be grown in solution spinning processes such as
described in U.S. Pat. No. 4,137,394 or 4,356,138, which are
incorporated herein by reference, or may be spun from a solution to
form a gel structure, such as described in U.S. Pat. Nos. 4,551,296
and 5,006,390, which are also incorporated herein by reference. A
particularly preferred fiber type for use in the invention are
polyethylene fibers sold under the trademark SPECTRA.RTM. from
Honeywell International Inc. SPECTRA.RTM. fibers are well known in
the art and are described, for example, in U.S. Pat. Nos. 4,623,547
and 4,748,064.
[0037] Also particularly preferred are aramid (aromatic polyamide)
or para-aramid fibers. Such are commercially available and are
described, for example, in U.S. Pat. No. 3,671,542. For example,
useful poly(p-phenylene terephthalamide) filaments are produced
commercially by Dupont corporation under the trade name of
KEVLAR.RTM.. Also useful in the practice of this invention are
poly(m-phenylene isophthalamide) fibers produced commercially by
Dupont under the trade name NOMEX.RTM. and fibers produced
commercially by Teijin under the trade name TWARON.RTM..
[0038] Suitable polybenzazole fibers for the practice of this
invention are commercially available and are disclosed for example
in U.S. Pat. Nos. 5,286,833, 5,296,185, 5,356,584, 5,534,205 and
6,040,050, each of which are incorporated herein by reference.
Preferred polybenzazole fibers are ZYLON.RTM. brand fibers from
Toyobo Co. Suitable liquid crystal copolyester fibers for the
practice of this invention are commercially available and are
disclosed, for example, in U.S. Pat. Nos. 3,975,487; 4,118,372 and
4,161,470, each of which is incorporated herein by reference.
[0039] Suitable polypropylene fibers include highly oriented
extended chain polypropylene (ECPP) fibers as described in U.S.
Pat. No. 4,413,110, which is incorporated herein by reference.
Suitable polyvinyl alcohol (PV-OH) fibers are described, for
example, in U.S. Pat. Nos. 4,440,711 and 4,599,267 which are
incorporated herein by reference. Suitable polyacrylonitrile (PAN)
fibers are disclosed, for example, in U.S. Pat. No. 4,535,027,
which is incorporated herein by reference. Each of these fiber
types is conventionally known and are widely commercially
available.
[0040] The other suitable fiber types for use in the present
invention include glass fibers, fibers formed from carbon, fibers
formed from basalt or other minerals, rigid rod fibers such as
M5.RTM. fibers, and combinations of all the above materials, all of
which are commercially available. For example, the fibrous layers
may be formed from a combination of SPECTRA.RTM. fibers and
Kevlar.RTM. fibers. M5.RTM. fibers are manufactured by Magellan
Systems International of Richmond, Va. and are described, for
example, in U.S. Pat. Nos. 5,674,969, 5,939,553, 5,945,537, and
6,040,478, each of which is incorporated herein by reference.
Specifically preferred fibers include M5.RTM. fibers, polyethylene
SPECTRA.RTM. fibers, and aramid Kevlar.RTM. fibers. The fibers may
be of any suitable denier, such as, for example, 50 to about 3000
denier, more preferably from about 200 to 3000 denier, still more
preferably from about 650 to about 2000 denier, and most preferably
from about 800 to about 1500 denier.
[0041] The most preferred fibers for the purposes of the invention
are either high-strength, high tensile modulus extended chain
polyethylene fibers or high-strength, high tensile modulus
para-aramid fibers. As stated above, a high-strength, high tensile
modulus fiber is one which has a preferred tenacity of about 7
g/denier or more, a preferred tensile modulus of about 150 g/denier
or more and a preferred energy-to-break of about 8 J/g or more,
each as measured by ASTM D2256. In the preferred embodiment of the
invention, the tenacity of the fibers should be about 15 g/denier
or more, preferably about 20 g/denier or more, more preferably
about 25 g/denier or more and most preferably about 30 g/denier or
more. The fibers of the invention also have a preferred tensile
modulus of about 300 g/denier or more, more preferably about 400
g/denier or more, more preferably about 500 g/denier or more, more
preferably about 1,000 g/denier or more and most preferably about
1,500 g/denier or more. The fibers of the invention also have a
preferred energy-to-break of about 15 J/g or more, more preferably
about 25 J/g or more, more preferably about 30 J/g or more and most
preferably have an energy-to-break of about 40 J/g or more.
[0042] These combined high strength properties are obtainable by
employing well known processes. U.S. Pat. Nos. 4,413,110,
4,440,711, 4,535,027, 4,457,985, 4,623,547 4,650,710 and 4,748,064
generally discuss the formation of preferred high strength,
extended chain polyethylene fibers employed in the present
invention. Such methods, including solution grown or gel fiber
processes, are well known in the art. Methods of forming each of
the other preferred fiber types, including para-aramid fibers, are
also conventionally known in the art, and the fibers are
commercially available.
[0043] As discussed above, the polymeric composition (matrix) may
be applied to a fiber in a variety of ways, and the term "coated"
is not intended to limit the method by which the polymeric
composition is applied onto the fiber surface or surfaces. For
example, the polymeric composition may be applied in solution form
by spraying or roll coating a solution of the polymeric composition
onto fiber surfaces, wherein a portion of the solution comprises
the desired polymer or polymers and a portion of the solution
comprises a solvent capable of dissolving the polymer or polymers,
followed by drying. Another method is to apply a neat polymer of
the coating material to fibers either as a liquid, a sticky solid
or particles in suspension or as a fluidized bed. Alternatively,
the coating may be applied as a solution or emulsion in a suitable
solvent which does not adversely affect the properties of the fiber
at the temperature of application. For example, the fiber can be
transported through a solution of the polymeric composition to
substantially coat the fiber and then dried to form a coated fiber.
The resulting coated fiber can then be arranged into the desired
network configuration. In another coating technique, a layer of
fibers may first be arranged, followed by dipping the layer into a
bath of a solution containing the polymeric composition dissolved
in a suitable solvent, such that each individual fiber is
substantially coated with the polymeric composition, and then dried
through evaporation of the solvent. The dipping procedure may be
repeated several times as required to place a desired amount of
polymeric composition coating on the fibers, preferably
encapsulating each of the individual fibers or covering 100% of the
fiber surface area with the polymeric composition.
[0044] While any liquid capable of dissolving or dispersing a
polymer may be used, preferred groups of solvents include water,
paraffin oils and aromatic solvents or hydrocarbon solvents, with
illustrative specific solvents including paraffin oil, xylene,
toluene, octane, cyclohexane, methyl ethyl ketone (MEK) and
acetone. The techniques used to dissolve or disperse the coating
polymers in the solvents will be those conventionally used for the
coating of similar materials on a variety of substrates.
[0045] Other techniques for applying the coating to the fibers may
be used, including coating of the high modulus precursor (gel
fiber) before the fibers are subjected to a high temperature
stretching operation, either before or after removal of the solvent
from the fiber (if using the gel-spinning fiber forming technique).
The fiber may then be stretched at elevated temperatures to produce
the coated fibers. The gel fiber may be passed through a solution
of the appropriate coating polymer under conditions to attain the
desired coating. Crystallization of the high molecular weight
polymer in the gel fiber may or may not have taken place before the
fiber passes into the solution. Alternatively, the fiber may be
extruded into a fluidized bed of an appropriate polymeric powder.
Furthermore, if a stretching operation or other manipulative
process, e.g. solvent exchanging, drying or the like is conducted,
the coating may be applied to a precursor material of the final
fiber. In the most preferred embodiment of the invention, the
fibers of the invention are first coated with the polymeric
composition, followed by arranging a plurality of fibers into
either a woven or non-woven fiber layer. Such techniques are well
known in the art.
[0046] Each panel described herein has outer surfaces. In a
preferred embodiment of the invention, at least one polymer film is
attached to at least one outer surface of at least one panel. A
polymer film may be desired to decrease friction between panels,
because some panel types have sticky or rubbery surfaces. Suitable
polymers for said polymer film non-exclusively include
thermoplastic and thermosetting polymers. Suitable thermoplastic
polymers non-exclusively may be selected from the group consisting
of polyolefins, polyamides, polyesters, polyurethanes, vinyl
polymers, fluoropolymers and co-polymers and mixtures thereof. Of
these, polyolefin layers are preferred. The preferred polyolefin is
a polyethylene. Non-limiting examples of polyethylene films are low
density polyethylene (LDPE), linear low density polyethylene
(LLDPE), linear medium density polyethylene (LMDPE), linear
very-low density polyethylene (VLDPE), linear ultra-low density
polyethylene (ULDPE), high density polyethylene (HDPE). Of these,
the most preferred polyethylene is LLDPE. Suitable thermosetting
polymers non-exclusively include thermoset allyls, aminos,
cyanates, epoxies, phenolics, unsaturated polyesters,
bismaleimides, rigid polyurethanes, silicones, vinyl esters and
their copolymers and blends, such as those described in U.S. Pat.
Nos. 6,846,758, 6,841,492 and 6,642,159. As described herein, a
polymer film includes polymer coatings.
[0047] Such optional polymer films may be attached to one or both
of the outer surfaces of a panel using well known lamination
techniques. Typically, laminating is done by positioning the
individual layers on one another under conditions of sufficient
heat and pressure to cause the layers to combine into a unitary
film. The individual layers are positioned on one another, and the
combination is then typically passed through the nip of a pair of
heated laminating rollers by techniques well known in the art.
Lamination heating may be done at temperatures ranging from about
95.degree. C. to about 175.degree. C., preferably from about
105.degree. C. to about 175.degree. C., at pressures ranging from
about 5 psig (0.034 MPa) to about 100 psig (0.69 MPa), for from
about 5 seconds to about 36 hours, preferably from about 30 seconds
to about 24 hours. Alternately, a polymeric film may be attached to
a panel during a molding step described below. In the preferred
embodiment of the invention, optional polymer film layers would
comprise from about 2% to about 25% by weight based on the combined
weight of the fibers, polymeric composition and polymer films, more
preferably from about 2% to about 17% percent by weight and most
preferably from 2% to 12% by weight. The percent by weight of the
polymer film layers will generally vary depending on the number of
fabric layers forming a panel.
[0048] In forming the panels of the invention, multiple fibrous
layers are preferably molded under heat and pressure in a suitable
molding apparatus. Generally, the panels are molded at a pressure
of from about 50 psi (344.7 kPa) to about 5000 psi (34470 kPa),
more preferably about 100 psi (689.5 kPa) to about 1500 psi (10340
kPa), most preferably from about 150 psi (1034 kPa) to about 1000
psi (6895 kPa). The fibrous layers may alternately be molded at
higher pressures of from about 500 psi (3447 kPa) to about 5000
psi, more preferably from about 750 psi (5171 kPa) to about 5000
psi and more preferably from about 1000 psi to about 5000 psi. The
molding step may take from about 4 seconds to about 45 minutes.
Preferred molding temperatures range from about 200.degree. F.
(.about.93.degree. C.) to about 350.degree. F. (.about.177.degree.
C.), more preferably at a temperature from about 200.degree. F. to
about 300.degree. F. (.about.149.degree. C.) and most preferably at
a temperature from about 200.degree. F. to about 280.degree. F.
(.about.121.degree. C.). Suitable molding temperatures, pressures
and times will generally vary depending on the type of polymeric
composition type, polymeric composition content, and type of fiber.
The pressure under which the fabrics of the invention are molded
has a direct effect on the stiffness or flexibility of the
resulting molded product. Particularly, the higher the pressure at
which the fabrics are molded, the higher the stiffness, and
vice-versa. In addition to the molding pressure, the quantity,
thickness and composition of the fabric layers, polymeric
composition type and optional polymer film also directly affects
the stiffness of the articles formed from the inventive
fabrics.
[0049] While each of the molding and consolidation techniques
described herein may appear similar, each process is different.
Particularly, molding is a batch process and consolidation is a
continuous process. Further, molding typically involves the use of
a mold, such as a shaped mold or a match-die mold when forming a
flat panel.
[0050] If a separate consolidation step is conducted to form one or
more single layer, consolidated networks prior to molding, the
consolidation may be conducted in an autoclave, as is
conventionally known in the art. When heating, it is possible that
the polymeric composition can be caused to stick or flow without
completely melting. However, generally, if the polymeric
composition material is caused to melt, relatively little pressure
is required to form the composite, while if the polymeric
composition material is only heated to a sticking point, more
pressure is typically required. The consolidation step may
generally take from about 10 seconds to about 24 hours. Similar to
molding, suitable consolidation temperatures, pressures and times
are generally dependent on the type of polymer, polymer content,
process used and type of fiber.
[0051] The panels or fabrics of the invention may optionally be
calendared under heat and pressure to smooth or polish their
surfaces. Calendaring methods are well known in the art and may be
conducted prior to or after molding.
[0052] The multiple panels of the invention may be adjoined in a
bonded array or may be juxtaposed in a non-bonded array. Methods of
bonding are well known in the art, and include stitching, quilting,
bolting, adhering with adhesive materials, and the like.
Preferably, said plurality of layers are attached by stitching
together at edge areas of the layers.
[0053] The thickness of the individual fabric layers and panels
will correspond to the thickness of the individual fibers.
Accordingly, a preferred woven fibrous layer will have a preferred
thickness of from about 25 .mu.m to about 500 .mu.m, more
preferably from about 75 .mu.m to about 385 .mu.m and most
preferably from about 125 .mu.m to about 255 .mu.m. A preferred
single-layer, consolidated network will have a preferred thickness
of from about 12 .mu.m to about 500 .mu.m, more preferably from
about 75 .mu.m to about 385 .mu.m and most preferably from about
125 .mu.m to about 255 .mu.m. A polymer film is preferably very
thin, having preferred thicknesses of from about 1 .mu.m to about
250 .mu.m, more preferably from about 5 .mu.m to about 25 .mu.m and
most preferably from about 5 .mu.m to about 9 .mu.m. A ballistic
resistant article, including a series of interconnected ballistic
resistant panels and any optional polymer films, has a preferred
total thickness of about 5 .mu.m to about 1000 .mu.m, more
preferably from about 6 .mu.m to about 750 .mu.m and most
preferably from about 7 .mu.m to about 500 .mu.m. While such
thicknesses are preferred, it is to be understood that other film
thicknesses may be produced to satisfy a particular need and yet
fall within the scope of the present invention. The multi-panel
articles of the invention further have a preferred areal density of
from about 0.25 lb/ft.sup.2 (psf) (1.22 kg/m.sup.2 (ksm)) to about
2.0 psf (9.76 ksm), more preferably from about 0.5 psf (2.44 ksm)
to about 1.5 psf (7.32 ksm), more preferably from about 0.7 psf
(3.41 ksm) to about 1.5 psf (7.32 ksm), and most preferably from
about 0.75 psf (3.66 ksm) to about 1.25 psf (6.1 ksm).
[0054] In another embodiment, at least one rigid plate may be
attached to a ballistic resistant article of the invention to
increase protection against armor piercing projectiles. In
ballistic resistant vest applications, articles including a rigid
plate are commonly desirable. Such a rigid plate may comprise a
ceramic, a glass, a metal-filled composite, a ceramic-filled
composite, a glass-filled composite, a cermet, high hardness steel
(HHS), armor aluminum alloy, titanium or a combination thereof,
wherein the rigid plate and the inventive panels are stacked
together in face-to-face relationship. Preferably only one rigid
plate is attached to the top surface of a series of panels, rather
than to each individual panel of a series. The three most preferred
types of ceramics include aluminum oxide, silicon carbide and boron
carbide.
[0055] The ballistic panels of the invention may incorporate a
single monolithic ceramic plate, or may comprise small tiles or
ceramic balls suspended in flexible resin, such as polyurethane.
Suitable resins are well known in the art. Additionally, multiple
layers or rows of tiles may be attached to the plates of the
invention. For example, multiple 3''.times.3''.times.0.1'' (7.62
cm.times.7.62 cm.times.0.254 cm) ceramic tiles may be mounted on a
12''.times.12'' (30.48 cm.times.30.48 cm) panel using a thin
polyurethane adhesive film, preferably with all ceramic tiles being
lined up with such that no gap is present between tiles. A second
row of tiles may then be attached to the first row of ceramic, with
an offset so that joints are scattered. This continues all the way
down to cover the entire armor. For high performance at the lowest
weight, it is preferred that panels are molded before attaching a
rigid plate. However, for large panels, e.g. 4'.times.6' (1.219
m.times.1.829 m) or 4'.times.8' (1.219 m.times.2.438 m), a panel
may be molded in a single, low pressure autoclave process together
with a rigid plate.
[0056] The multi-panel structures of the invention may be used in
various applications to form a variety of different ballistic
resistant articles using well known techniques. For example,
suitable techniques for forming ballistic resistant articles are
described in, for example, U.S. Pat. Nos. 4,623,574, 4,650,710,
4,748,064, 5,552,208, 5,587,230, 6,642,159, 6,841,492 and
6,846,758.
[0057] The multi-panel structures are particularly useful for the
formation of flexible, soft armor articles, including garments such
as vests, pants, hats, or other articles of clothing, and covers or
blankets, used by military personnel to defeat a number of
ballistic threats, such as 9 mm full metal jacket (FMJ) bullets and
a variety of fragments generated due to explosion of hand-grenades,
artillery shells, Improvised Explosive Devices (IED) and other such
devises encountered in military and peace keeping missions. As used
herein, "soft" or "flexible" armor is armor that does not retain
its shape when subjected to a significant amount of stress and is
incapable of being free-standing without collapsing. The
multi-panel structures are also useful for the formation of rigid,
hard armor articles. By "hard" armor is meant an article, such as
helmets, panels for military vehicles, or protective shields, which
have sufficient mechanical strength so that it maintains structural
rigidity when subjected to a significant amount of stress and is
capable of being freestanding without collapsing. The structures
can be cut into a plurality of discrete sheets and stacked for
formation into an article or they can be formed into a precursor
which is subsequently used to form an article. Such techniques are
well known in the art.
[0058] Garments of the invention may be formed through methods
conventionally known in the art. Preferably, a garment may be
formed by adjoining the ballistic resistant articles of the
invention with an article of clothing. For example, a vest may
comprise a generic fabric vest that is adjoined with the ballistic
resistant structures of the invention, whereby the inventive
articles are inserted into strategically placed pockets. For best
soft armor results, the panels having the least amount of polymeric
composition should be positioned closest to a potential ballistic
threat and the panels having the greatest amount of the polymeric
composition should be positioned furthest from the potential
ballistic threat. For best hard armor results, the panels having
the greatest quantity of the polymeric composition should be
positioned closest to a potential ballistic threat, and the panels
having the least amount of polymeric composition should be
positioned furthest from a potential ballistic threat. This allows
for the maximization of ballistic protection, while minimizing the
weight of the vest. As used herein, the terms "adjoining" or
"adjoined" are intended to include attaching, such as by sewing or
adhering and the like, as well as un-attached coupling or
juxtaposition with another fabric, such that the ballistic
resistant articles may optionally be easily removable from the vest
or other article of clothing. Articles used in forming flexible
structures like flexible sheets, vests and other garments are
preferably formed from using a low tensile modulus polymeric matrix
composition. Hard articles like helmets and armor are preferably
formed using a high tensile modulus polymeric matrix
composition.
[0059] The ballistic resistance properties are determined using
standard testing procedures that are well known in the art.
Particularly, the protective power or penetration resistance of a
structure is normally expressed by citing the impacting velocity at
which 50% of the projectiles penetrate the composite while 50% are
stopped by the shield, also known as the V.sub.50 value. As used
herein, the "penetration resistance" of an article is the
resistance to penetration by a designated threat, such as physical
objects including bullets, fragments, shrapnel and the like, and
non-physical objects, such as a blast from explosion. For
composites of equal areal density, which is the weight of the
composite panel divided by the surface area, the higher the
V.sub.50, the better the resistance of the composite. The ballistic
resistant properties of the articles of the invention will vary
depending on many factors, particularly the type of fibers used to
manufacture the fabrics.
[0060] Flexible ballistic armor formed herein preferably have a
V.sub.50 of at least about 1920 feet/second (fps) (585.6 msec) when
impacted with a 16 grain projectile. Flexible ballistic armor
formed herein preferably have a V.sub.50 of at least about 1400
feet/second (fps) (427 m/sec) when impacted with a 17 grain
fragment simulated projectile (fsp).
[0061] The following non-limiting examples serve to illustrate the
invention.
Example 1
[0062] Two continuous rolls of unidirectional fiber prepregs
(unitapes) were prepared from SPECTRA.RTM. fibers. The unitapes
contained 18 wt. % of a polymeric matrix composition consisting of
KRATON.RTM. D1107 styrene-isoprene-styrene block copolymer
elastomer. The rolls were placed on the cross-plying machine
described in U.S. Pat. No. 5,173,138. The prepregs were cross-plied
at 0.degree./90.degree. and consolidated under heat and pressure to
create a continuous two-ply structure. The continuous roll was
further laminated between two 0.35 mil (0.0089 mm) thick LLDPE
films using heat and pressure, forming a laminated continuous roll
(LCR). The material from this roll is designated as Material A in
Table 1 (SR-3111 SPECTRA.RTM. Shield product).
[0063] Twenty five two-ply pieces measuring 45.72 cm.times.45.72 cm
were cut from the Material A LCR laminates and stacked in an array
without molding or otherwise interconnecting the pieces together.
The article so formed was subjected to ballistic testing against a
9 MM Full Metal Jacket (FMJ) bullet (8.04 g weight) according to
NIJ Standard 0101.04 Revision A. Results of the ballistic testing
are shown in Table 1.
Example 2
[0064] In addition to the LCR in Example 1 with 18% polymeric
matrix composition content, another LCR was manufactured with 11 wt
% of a polymeric matrix composition consisting of KRATON.RTM. D1107
styrene-isoprene-styrene block copolymer elastomer. The material
from this roll is designated as Material B in Table 1 (SR-3121
SPECTRA.RTM. Shield product).
[0065] Fourteen two-ply pieces measuring 45.72 cm.times.45.72 cm
were cut from Material B and thirteen two-ply pieces measuring
45.72 cm.times.45.72 cm were cut from Material A. All twenty seven
pieces from Material B and Material A were stacked together in a
single array without molding or otherwise interconnecting the
pieces together. The article so formed was subjected to ballistic
testing against a 9 MM FMJ bullet (124 grain, 8.04 g weight)
according to NIJ Standard 0101.04 Revision A where Material B faced
the bullet. Results of the ballistic testing are shown in Table 1.
As listed in the Tables below, Material 1 is the panel positioned
to be struck first by a ballistic threat; Material 2 is the panel
positioned to be struck second by the ballistic threat.
Example 3
[0066] Similar to Example 2, fourteen two-ply pieces measuring
45.72 cm.times.45.72 cm were cut from Material A and thirteen
two-ply pieces measuring 45.72 cm.times.45.72 cm were cut from
Material B. All twenty seven pieces from Material A and Material B
were stacked together in a single array without molding or
otherwise interconnecting the pieces together. The article so
formed was subjected to ballistic testing against a 9 MM FMJ bullet
(8.04 g weight) according to NIJ Standard 0101.04 Revision A with
Material A positioned to be struck first by the ballistic threat.
Results of the ballistic testing are shown in Table 1.
Example 4
[0067] Example 2 was duplicated with another set of two-ply pieces
cut from Materials B and A (45.72 cm.times.45.72 cm sample size).
Results of the ballistic testing are shown in Table 1.
Example 5
[0068] Example 3 was duplicated with another set of two-ply pieces
cut from Materials A and B (45.72 cm.times.45.72 cm sample size).
Results of the ballistic testing are shown in Table 1.
Example 6
[0069] Twenty-eight two-ply pieces measuring 45.72 cm.times.45.72
cm were cut from Material B and stacked in an array without molding
or otherwise interconnecting the pieces together. The article so
formed was subjected to ballistic testing according to NIJ Standard
0101.04 Revision A. Results of the ballistic testing are shown in
Table 1. Additional layers were included compared to Example 1 to
account for the difference in matrix quantity while maintaining the
same areal density.
TABLE-US-00001 TABLE 1 Total Areal 9 MM Backface Material Material
Density FMJ V.sub.50 Deformation Example 1 2 (kg/m.sup.2) (m/sec)
(mm) 1 A, 25 two- None 3.76 450 36 ply pieces 2 B, 14 two- A, 13
two- 3.76 495 38 ply pieces ply pieces 3 A, 14 two- B, 13 two- 3.76
480 39 ply pieces ply pieces 4 B, 14 two- A, 13 two- 3.76 497 40
ply pieces ply pieces 5 A, 14 two- B, 13 two- 3.76 487 39 ply
pieces ply pieces 6 None B, 28 two- 3.76 495 44 ply pieces
[0070] The ballistic fragment performance of soft armor summarized
in Examples 1 to 6 in Table 1 show that: [0071] 1. Varying the
quantity of polymeric matrix composition within a single shoot pack
(or flexible vest) increases the ballistic resistance against a 9
MM FMJ ballistic threat. [0072] 2. Backface deformation on clay is
lower in a shoot pack with multiple panels having varying polymeric
matrix composition quantities compared to all low resin ballistic
material when tested against a 9 MM FMJ ballistic threat. [0073] 3.
For best soft armor results, the panels having the least amount of
polymeric composition should be positioned closest to a potential
ballistic threat and the panels having the greatest amount of the
polymeric composition should be positioned furthest from the
potential ballistic threat.
Example 7
[0074] Two two-ply continuous pre-consolidated rolls (PCRs) were
made similar to those shown in Examples 1 and 2, but without adding
LLDPE film. The two PCRs have 20% (referred as Material C in Table
2) and 11% (referred as Material D in Table 2) KRATON.RTM. D1107
styrene-isoprene-styrene block copolymer elastomer as the polymeric
matrix composition. As listed in the Tables below, Material 1 is
the panel positioned to be struck first by a ballistic threat;
Material 2 is the panel positioned to be struck second by the
ballistic threat.
[0075] Thirty-seven two-ply pieces measuring 30.48 cm.times.30.48
cm were cut from Material C, stacked in an array and were molded in
a match-die mold, first by pre-heating the stacked pieces for 10
minutes at 120.degree. C., followed by applying 35 bars molding
pressure for 10 minutes, thereby forming a molded panel. Each
two-ply piece had a 0.degree./90.degree. fiber orientation. The
molded panel was subjected to ballistic testing according to US
Military standard MIL-STD-662F, using a .22 caliber fragment
simulating projectile weighing 17 grain and following MIL-P-46593A
(ORD). The V.sub.50 results of the ballistic testing are shown in
Table 2.
Example 8
[0076] Twenty two-ply pieces measuring 30.48 cm.times.30.48 cm were
cut from Material D and nineteen two-ply pieces were cut from
Material C. The two-ply pieces of
[0077] Material D and Material C were stacked together in a single
array and molded in a match-die mold, first by pre-heating the
stacked pieces for 10 minutes at 120.degree. C., followed by
applying 35 bars molding pressure for 10 minutes, thereby forming a
molded panel. Each two-ply piece had a 0.degree./90.degree. fiber
orientation. The molded panel was subjected to ballistic testing
according to US Military standard MIL-STD-662F, using a .22 caliber
fragment simulating projectile weighing 17 grain and following
MILL-P-46593A (ORD). The V.sub.50 results of the ballistic testing
are shown in Table 2. The Material D side was facing the incoming
fragment during testing.
Example 9
[0078] Nineteen two-ply pieces measuring 30.48 cm.times.30.48 cm
were cut from Material C and twenty two-ply pieces were cut from
Material D. The two-ply pieces of Material C and Material D were
stacked together in a single array and molded in a match-die mold,
first by preheating the stacked pieces for 10 minutes at 120 C,
followed by applying 35 bars molding pressure for 10 minutes,
thereby forming a molded panel. Each two-ply piece had a
0.degree./90.degree. fiber orientation. The molded panel was
subjected to ballistic testing according to US Military standard
MIL-STD-662F, using a .22 caliber fragment simulating projectile
weighing 17 grain and following MILL-P-46593A (ORD). The V.sub.50
results of the ballistic testing are shown in Table 2. The Material
C side was facing the incoming fragment during testing.
Example 10
[0079] Example 8 was duplicated with another molded panel with
another set of pieces of Material D and Material C. The Material D
side was facing the incoming fragment during testing. The V.sub.50
results of the ballistic testing are shown in Table 2.
Example 11
[0080] Example 9 was duplicated with another molded panel with
another set of pieces of Material C and Material D. Material C side
was facing the incoming fragment during testing. The V.sub.50
results of the ballistic testing are shown in Table 2, Example
11.
Example 12
[0081] Forty-two two-ply pieces measuring 30.48 cm.times.30.48 cm
were cut from Material D, stacked in an array and were molded in a
match-die mold, first by preheating the stacked pieces for 10
minutes at 120.degree. C., followed by applying 35 bars molding
pressure for 10 minutes, thereby forming a molded panel. Each
two-ply piece had a 0.degree./90.degree. fiber orientation. The
molded panel was subjected to ballistic testing according to US
Military standard MIL-STD-662F, using a .22 caliber fragment
simulating projectile weighing 17 grain and following MIL-P-46593A
(ORD). The V.sub.50 results of the ballistic testing are shown in
Table 2. Additional layers were included compared to Example 7 to
account for the difference in matrix quantity while maintaining the
same areal density.
TABLE-US-00002 TABLE 2 Material Material Total Areal 17 grain FSP
Example 1 2 density (kg/m.sup.2) V.sub.50 (m/sec) 7 C, 37 two- None
4.97 546 ply pieces 8 D, 20 two- C, 19 two- 4.88 562 ply pieces ply
pieces 9 C, 19 two- D, 20 two- 4.97 577 ply pieces ply pieces 10 D,
20 two- C, 19 two- 4.93 569 ply pieces ply pieces 11 C, 19 two- D,
20 two- 4.97 572 ply pieces ply pieces 12 None D, 42 two- 4.97 571
ply pieces
[0082] The ballistic fragment performance of hard armor summarized
in Examples 7 to 12 in Table 2 confirm that by changing polymeric
matrix composition content in a single molded panel (made with
identical fiber type) increases the ballistic resistance against a
.22 caliber, 17 grain fragment simulating projectile. Particularly,
Table 2 shows that by positioning a 20% resin content panel as the
front panel of the article structure, the ballistic resistance is
greater than when it is placed as the rear panel of the structure.
For best hard armor results, the panels having the greatest amount
of polymeric composition should be positioned closest to a
potential ballistic threat and the panels having the least amount
of the polymeric composition should be positioned furthest from the
potential ballistic threat.
Example 13
[0083] Two continuous pre-consolidated rolls (PCR) were made
similar to shown in Example 7. The two PCRs have 20% (referred as
Material C in Table 3) and 11% (referred as Material Din Table 3)
KRATON.RTM. D1107 styrene-isoprene-styrene block copolymer
elastomer, like Examples 7-12.
[0084] One hundred and twenty seven two-ply pieces measuring 30.48
cm.times.30.48 cm were cut from Material C, stacked in an array and
were molded in a match-die mold, first by preheating the stacked
pieces for 25 minutes at 120.degree. C., followed by applying 35
bars molding pressure for 10 minutes, thereby forming a molded
panel. Each two-ply piece had a 0.degree./90.degree. fiber
orientation. The molded panel was subjected to ballistic testing
according to US Military standard MIL-STD-662F, using a high power
rifle US military M80 ball bullet (weight: 9.65 g). Two identical
molded panels were tested to calculate the V.sub.50. The V.sub.50
results of the ballistic testing are shown in Table 3.
Example 14
[0085] Sixty-eight two-ply pieces measuring 30.48 cm.times.30.48 cm
were cut from Material D and sixty-eight two-ply pieces were cut
from Material C. The two-ply pieces of Material D and Material C
were stacked together in a single array and molded in a match-die
mold, first by preheating the stacked pieces for 25 minutes at
120.degree. C., followed by applying 35 bars molding pressure for
10 minutes, thereby forming a molded panel. Each two-ply piece had
a 0.degree./90.degree. fiber orientation. The molded panel was
subjected to ballistic testing according to US Military standard
MIL-STD-662F, using a high power rifle US military M80 ball bullet
(weight: 9.65 g). The Material D side was facing the incoming M80
ball bullet during testing. Two identical molded panels were tested
to calculate the V.sub.50. The V.sub.50 results of the ballistic
testing are shown in Table 3.
Example 15
[0086] Sixty-eight two-ply pieces measuring 30.48 cm.times.30.48 cm
were cut from Material C and sixty-eight two-ply pieces were cut
from Material D. The two-ply pieces of Material C and Material D
were stacked together in a single array and molded in a match-die
mold, first by preheating the stacked pieces for 25 minutes at 120
C, followed by applying 35 bars molding pressure for 10 minutes,
thereby forming a molded panel. Each two-ply piece had a
0.degree./90.degree. fiber orientation. The molded panel was
subjected to ballistic testing according to US Military standard
MIL-STD-662F, using a high power rifle US military M80 ball bullet
(weight: 9.65 g). The Material C side was facing the incoming M80
ball bullet during testing. Two identical molded panels were tested
to calculate the V.sub.50. The V.sub.50 results of the ballistic
testing are shown in Table 3.
Example 16
[0087] One hundred and forty five two-ply pieces measuring 30.48
cm.times.30.48 cm were cut from Material D, stacked in an array and
were molded in a match-die mold, first by preheating the stacked
pieces for 25 minutes at 120.degree. C., followed by applying 35
bars molding pressure for 10 minutes, thereby forming a molded
panel Each two-ply piece had a 0.degree./90.degree. fiber
orientation. The molded panel was subjected to ballistic testing
according to US Military standard MIL-STD-662F, using a high power
rifle US military M80 ball bullet (147 grain; weight: 9.525 g). Two
identical molded panels were tested to calculate the V.sub.50. The
V.sub.50 results of the ballistic testing are shown in Table 3.
Additional layers were included compared to Example 13 to account
for the difference in matrix quantity while maintaining relatively
the same areal density.
TABLE-US-00003 TABLE 3 Total Areal Material Material density M80
ball Example 1 2 (kg/m.sup.2) V.sub.50 (m/sec) 13 C, 127 two- None
17.03 785 ply pieces 14 D, 68 two- C, 68 two- 17.32 797 ply pieces
ply pieces 15 C, 68 two- D, 68 two- 17.14 844 ply pieces ply pieces
16 None D, 145 two- 17.13 820 ply pieces
[0088] The ballistic fragment performance of hard armor summarized
in Examples 13 to 16 in Table 3 confirm that by changing polymeric
matrix composition content the resistance against a rifle bullet
also increases. For best hard armor results the panels having the
greatest amount of polymeric composition should be positioned
closest to a potential ballistic threat and the panels having the
least amount of the polymeric composition should be positioned
furthest from the potential ballistic threat.
[0089] In summary, Examples 1 to 16 show that the ballistic
performance of a composite increases by varying the polymeric
matrix composition content within the same ballistic flexible shoot
pack or molded panels against fragments and high energy rifle
bullets.
[0090] While the present invention has been particularly shown and
described with reference to preferred embodiments, it will be
readily appreciated by those of ordinary skill in the art that
various changes and modifications may be made without departing
from the spirit and scope of the invention. It is intended that the
claims be interpreted to cover the disclosed embodiment, those
alternatives which have been discussed above and all equivalents
thereto.
* * * * *