U.S. patent application number 16/136561 was filed with the patent office on 2019-01-17 for materials gradient within armor for balancing the ballistic performance.
This patent application is currently assigned to HONEYWELL INTERNATIONAL INC.. The applicant listed for this patent is HONEYWELL INTERNATIONAL INC.. Invention is credited to ASHOK BHATNAGAR, TERRY CHERN, DANELLE POWERS, BRIAN WARING.
Application Number | 20190016089 16/136561 |
Document ID | / |
Family ID | 56092277 |
Filed Date | 2019-01-17 |
United States Patent
Application |
20190016089 |
Kind Code |
A1 |
BHATNAGAR; ASHOK ; et
al. |
January 17, 2019 |
MATERIALS GRADIENT WITHIN ARMOR FOR BALANCING THE BALLISTIC
PERFORMANCE
Abstract
Hybrid, multi-panel ballistic resistant articles useful for the
fabrication of body armor. The articles include at least three
different fabric sections that are arranged into a gradient wherein
the outermost, strike-face section of the article is formed from
fibers having the highest tenacity of the article.
Inventors: |
BHATNAGAR; ASHOK; (RICHMOND,
VA) ; POWERS; DANELLE; (CHESTERFIELD, VA) ;
WARING; BRIAN; (CHESTER, VA) ; CHERN; TERRY;
(COLONIAL HEIGHTS, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HONEYWELL INTERNATIONAL INC. |
MORRIS PLAINS |
NJ |
US |
|
|
Assignee: |
HONEYWELL INTERNATIONAL
INC.
MORRIS PLAINS
NJ
|
Family ID: |
56092277 |
Appl. No.: |
16/136561 |
Filed: |
September 20, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14851875 |
Sep 11, 2015 |
10081159 |
|
|
16136561 |
|
|
|
|
62088015 |
Dec 5, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/308 20130101;
B32B 2307/54 20130101; B32B 5/024 20130101; B32B 7/02 20130101;
B32B 2262/0253 20130101; B32B 2266/06 20130101; B32B 2262/0261
20130101; B32B 2262/0246 20130101; B32B 2262/101 20130101; B32B
27/08 20130101; B32B 2250/20 20130101; B32B 27/365 20130101; B32B
27/32 20130101; B32B 2307/708 20130101; B32B 2260/023 20130101;
B32B 2262/0269 20130101; B32B 2266/0235 20130101; B32B 5/08
20130101; B32B 5/22 20130101; B32B 2307/50 20130101; B32B 15/20
20130101; B32B 27/36 20130101; B32B 2262/14 20130101; B32B
2266/0278 20130101; B32B 27/12 20130101; F41H 5/0485 20130101; B32B
15/14 20130101; B32B 5/026 20130101; B32B 27/304 20130101; B32B
5/12 20130101; B32B 2571/02 20130101; B32B 2260/021 20130101; B32B
2262/0223 20130101; B32B 5/022 20130101; B32B 27/283 20130101; B32B
27/34 20130101; B32B 27/38 20130101; B32B 2260/046 20130101; B32B
2262/02 20130101; B32B 2266/025 20130101; B32B 2307/558 20130101;
B32B 5/245 20130101; B32B 5/26 20130101; B32B 2571/00 20130101;
B32B 2307/72 20130101; B32B 15/18 20130101; B32B 2262/0276
20130101 |
International
Class: |
B32B 7/02 20060101
B32B007/02; B32B 5/22 20060101 B32B005/22; F41H 5/04 20060101
F41H005/04; B32B 5/12 20060101 B32B005/12; B32B 5/08 20060101
B32B005/08; B32B 5/02 20060101 B32B005/02; B32B 5/26 20060101
B32B005/26; B32B 27/38 20060101 B32B027/38; B32B 27/36 20060101
B32B027/36; B32B 27/34 20060101 B32B027/34; B32B 27/32 20060101
B32B027/32; B32B 27/30 20060101 B32B027/30; B32B 27/28 20060101
B32B027/28; B32B 27/12 20060101 B32B027/12; B32B 27/08 20060101
B32B027/08; B32B 15/20 20060101 B32B015/20; B32B 15/18 20060101
B32B015/18; B32B 15/14 20060101 B32B015/14; B32B 5/24 20060101
B32B005/24 |
Claims
1. A ballistic resistant composite comprising: a first fibrous
material comprising one or more first fibrous plies, each of the
first fibrous plies comprising fibers that have a tenacity of
greater than 27 g/denier; a second fibrous material attached to the
first fibrous material, said second fibrous material comprising one
or more second fibrous plies, each of the second fibrous plies
comprising fibers that have a tenacity lower than the tenacity of
the fibers of the first fibrous material; and a third fibrous
material attached to the second fibrous material, said third
fibrous material comprising one or more third fibrous plies, each
of the third fibrous plies comprising fibers that have a tenacity
lower than the tenacity of the fibers of the second fibrous
material; wherein the first fibrous material, second fibrous
material and third fibrous material are bonded together and form a
consolidated, unitary composite article.
2. The ballistic resistant composite of claim 1 wherein each of the
fibers of the first fibrous material has a tenacity of 40 g/denier
or more.
3. The ballistic resistant composite of claim 1 wherein each of the
fibers of the first fibrous material has a tenacity of 45 g/denier
or more.
4. The ballistic resistant composite of claim 1 wherein each of the
fibers of the second fibrous material has a tenacity of at least
25% less than the tenacity of each of the fibers of the first
fibrous material.
5. The ballistic resistant composite of claim 1 wherein each of the
fibers of the second fibrous material has a tenacity of 21 g/denier
or less.
6. The ballistic resistant composite of claim 1 wherein each of the
fibers of the third fibrous material has a tenacity of at least 25%
less than the tenacity of each of the fibers of the second fibrous
material.
7. The ballistic resistant composite of claim 1 wherein the third
fibrous material comprises nylon fibers, polyester fibers,
polypropylene fibers, polyolefin fibers or a combination
thereof.
8. The ballistic resistant composite of claim 1 wherein the first
fibrous material comprises ultra-high molecular weight polyethylene
fibers, the second fibrous material comprises either ultra-high
molecular weight polyethylene fibers or aramid fibers or a
combination thereof, and the third fibrous material comprises nylon
fibers.
9. The ballistic resistant composite of claim 1 wherein the first
fibrous material comprises a woven aramid fabric, the second
fibrous material comprises a non-woven aramid fabric, and the third
fibrous material comprises nylon fibers.
10. The ballistic resistant composite of claim 1 wherein the first
fibrous material is a non-woven fabric comprising a plurality of
unidirectionally oriented fibers, the second fibrous material is a
non-woven fabric comprising a plurality of unidirectionally
oriented fibers, and the third fibrous material is either a
non-woven fabric comprising a plurality of unidirectionally
oriented fibers, a woven fabric, a knitted fabric or a felt.
11. The ballistic resistant composite of claim 1 wherein the first
fibrous material is a woven fabric, the second fibrous material is
a woven fabric, and the third fibrous material is either a
non-woven fabric comprising a plurality of unidirectionally
oriented fibers, a woven fabric, a knitted fabric or a felt.
12. The ballistic resistant composite of claim 1 further comprising
a non-fibrous isotropic polymer layer attached to the third fibrous
material, wherein the first fibrous material, second fibrous
material, third fibrous material and the non-fibrous isotropic
polymer layer are bonded together and form a consolidated, unitary
composite article.
13. The ballistic resistant composite of claim 1 wherein the fibers
of the first fibrous material and the fibers of the second fibrous
material are substantially coated with a polymeric binder.
14. A ballistic resistant composite comprising: a first fibrous
material comprising one or more first fibrous plies, each of the
first fibrous plies comprising fibers; a second fibrous material
attached to the first fibrous material, said second fibrous
material comprising one or more second fibrous plies, each of the
second fibrous plies comprising fibers that have a tenacity lower
than the tenacity of the fibers of the first fibrous material; and
a non-fibrous sheet material attached to the second fibrous
material; wherein the first fibrous material, second fibrous
material and third fibrous material are bonded together and form a
consolidated, unitary composite article.
15. The ballistic resistant composite of claim 14 wherein the
non-fibrous sheet material comprises a non-fibrous isotropic
polymer layer.
16. The ballistic resistant composite of claim 14 wherein each of
the fibers of the first fibrous material has a tenacity of 40
g/denier or more and wherein each of the fibers of the second
fibrous material has a tenacity of at least 25% less than the
tenacity of each of the fibers of the first fibrous material.
17. The ballistic resistant composite of claim 14 wherein the first
fibrous material is a non-woven fabric comprising a plurality of
unidirectionally oriented fibers and the second fibrous material is
a non-woven fabric comprising a plurality of unidirectionally
oriented fibers.
18. The ballistic resistant composite of claim 14 wherein the first
fibrous material is a woven aramid fabric and the second fibrous
material is a non-woven aramid fabric.
19. A ballistic resistant composite comprising: a first fibrous
material comprising one or more first fibrous plies, each of the
first fibrous plies comprising fibers, wherein each of said fibers
has a tenacity of greater than 27 g/denier; a second fibrous
material attached to the first fibrous material, said second
fibrous material comprising one or more second fibrous plies, each
of the second fibrous plies comprising fibers, wherein each of said
fibers has a tenacity of at least 50% less than the tenacity of the
fibers of the first fibrous material; and a third fibrous material
attached to the second fibrous material, said third fibrous
material comprising one or more third fibrous plies, each of the
third fibrous plies comprising fibers, wherein each of said fibers
has a tenacity of at least 50% less than the tenacity of the fibers
of the second fibrous material; wherein the first fibrous material,
second fibrous material and third fibrous material are bonded
together and form a consolidated, unitary composite article.
20. The ballistic resistant composite of claim 19 wherein the
consolidated, unitary composite article has a total areal density
of from about 0.75 lb/ft.sup.2 to about 1.5 lb/ft.sup.2.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of co-pending U.S.
application Ser. No. 14/851,875, filed Sep. 11, 2015, which claims
the benefit of U.S. Provisional Application Ser. No. 62/088,015,
filed on Dec. 5, 2014, the disclosures of which are incorporated by
reference herein in their entireties.
BACKGROUND
Technical Field
[0002] This technology relates to ballistic resistant composite
articles having improved backface deformation resistance as well as
superior ballistic penetration resistance. Particularly, this
technology relates to hybrid, multi-panel ballistic resistant
articles that are especially useful for the fabrication of body
armor.
Description of the Related Art
[0003] Ballistic resistant articles such as bullet resistant vests,
helmets, vehicle panels and structural members of military
equipment are typically made from composite armor comprising high
strength fibers. High strength fibers conventionally used to
fabricate composite armor include polyethylene fibers, aramid
fibers such as poly(phenylenediamine terephthalamide), graphite
fibers, nylon fibers, glass fibers and the like. For some
applications, the fibers are formed into woven or knitted fabrics.
For other applications, the fibers are coated with a polymeric
binder material and formed into non-woven fabrics.
[0004] Various ballistic resistant constructions are known that are
useful for the formation of hard or soft body armor articles such
as helmets 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
(UHMW PE). These composites display varying degrees of ballistic
resistance to high speed projectiles such as bullets, shells,
shrapnel and the like.
[0005] The two primary measures of anti-ballistic performance of
composite armor are ballistic penetration resistance and blunt
trauma ("trauma") resistance. A common characterization of
ballistic penetration resistance is the V.sub.50 velocity, which is
the experimentally derived, statistically calculated impact
velocity at which a projectile is expected to completely penetrate
armor 50% of the time and be completely stopped by the armor 50% of
the time. For composites of equal areal density (i.e. the weight of
the composite armor divided by the surface area) the higher the
V.sub.50 the better the penetration resistance of the composite. In
this regard, it is known that the V.sub.50 ballistic performance of
fibrous composite armor is directly related to the strength of the
constituent fibers of the composite.
[0006] Whether or not a high speed projectile penetrates armor,
when the projectile engages the armor the impact also deflects the
body armor at the area of impact, potentially causing significant
non-penetrating, blunt trauma injuries. The measure of the depth of
deflection of body armor due to a bullet impact is known as
backface signature ("BFS"), also known in the art as backface
deformation or trauma signature. Potentially resulting blunt trauma
injuries may be as deadly to an individual as if the bullet had
fully penetrated the armor and entered the body. This is especially
consequential in the context of helmet armor, where the transient
protrusion caused by a stopped bullet can still cross the plane of
the skull underneath the helmet and cause debilitating or fatal
brain damage. Accordingly, there is a need in the art for ballistic
resistant composites having both superior V.sub.50 ballistic
performance as well as low backface signature.
[0007] This disclosure provides a solution to this need.
Particularly, it has been unexpectedly found that body armor having
excellent ballistic penetration resistance performance and backface
signature performance can be achieved at a lower cost by combining
multiple different sections of materials. The sections are arranged
into a gradient wherein the outermost, strike-face section of the
article is formed from fibers having the highest tenacity of the
article, and the outermost section on the opposite side of the
article will be formed from the lowest tenacity fibers of the
article or from no fibers at all. In this regard, each section of
the composite article performs a different function. The first,
outermost strike-face section of fibrous plies functions to break
open the metal casing of a bullet, such as a 9 mm Full Metal Jacket
(FMJ) bullet which comprises a lead core portion covered by a
copper casing (jacket). Breaking open of the casing will thereby
expose the lead core. The second section of fibrous plies will then
deform any remaining portion of the casing material as well as the
bullet core material and also reduce the velocity of the deformed
parts and any projectile fragments. The third section will then
distribute the remaining kinetic energy of the bullet over a large
area and thus reduce the trauma energy transmitted to the user of
the armor. Together, the different sections of material provide
excellent ballistic penetration resistance and trauma
resistance.
SUMMARY
[0008] Provided is a ballistic resistant composite comprising:
[0009] a first fibrous material comprising one or more first
fibrous plies, each of the first fibrous plies comprising fibers
that have a tenacity of greater than 27 g/denier;
[0010] a second fibrous material attached to the first fibrous
material, said second fibrous material comprising one or more
second fibrous plies, each of the second fibrous plies comprising
fibers that have a tenacity lower than the tenacity of the fibers
of the first fibrous material; and
[0011] a third fibrous material attached to the second fibrous
material, said third fibrous material comprising one or more third
fibrous plies, each of the third fibrous plies comprising fibers
that have a tenacity lower than the tenacity of the fibers of the
second fibrous material;
[0012] wherein the first fibrous material, second fibrous material
and third fibrous material are bonded together and form a
consolidated, unitary composite article.
[0013] Further provided is a ballistic resistant composite
comprising:
[0014] a first fibrous material comprising one or more first
fibrous plies, each of the first fibrous plies comprising
fibers;
[0015] a second fibrous material attached to the first fibrous
material, said second fibrous material comprising one or more
second fibrous plies, each of the second fibrous plies comprising
fibers that have a tenacity lower than the tenacity of the fibers
of the first fibrous material; and
[0016] a non-fibrous sheet material attached to the second fibrous
material;
[0017] wherein the first fibrous material, second fibrous material
and third fibrous material are bonded together and form a
consolidated, unitary composite article.
[0018] Also provided is a ballistic resistant composite
comprising:
[0019] a first fibrous material comprising one or more first
fibrous plies, each of the first fibrous plies comprising fibers,
wherein each of said fibers has a tenacity of greater than 27
g/denier;
[0020] a second fibrous material attached to the first fibrous
material, said second fibrous material comprising one or more
second fibrous plies, each of the second fibrous plies comprising
fibers, wherein each of said fibers has a tenacity of at least 50%
less than the tenacity of the fibers of the first fibrous material;
and
[0021] a third fibrous material attached to the second fibrous
material, said third fibrous material comprising one or more third
fibrous plies, each of the third fibrous plies comprising fibers,
wherein each of said fibers has a tenacity of at least 50% less
than the tenacity of the fibers of the second fibrous material;
[0022] wherein the first fibrous material, second fibrous material
and third fibrous material are bonded together and form a
consolidated, unitary composite article.
DETAILED DESCRIPTION
[0023] The composites provided herein include three or more
different sections, at least two of the sections comprising a
plurality of fibrous plies. Each of the fibrous plies comprises a
plurality of fibers and optionally a polymeric binder material on
the fibers. A first fibrous material having first and second
surfaces is positioned as the strike face section of the composite,
i.e. the outermost section that a projectile threat will strike
first. The projectile will first contact the first surface of the
first fibrous material. A second fibrous material having first and
second surfaces is attached to the second surface of the first
fibrous material. A third section having first and second surfaces
is attached to the second surface of the second fibrous material.
The third section may be a fibrous material comprising fibers or
may be a non-fibrous material, such as a non-fibrous sheet.
[0024] Most or all of the fibers forming the first fibrous material
and the second fibrous material are high strength fibers, with the
first fibrous material comprising stronger fibers, i.e. fibers
having a higher tenacity, than the fibers forming the second
fibrous material. As used herein, a "high strength fiber" fiber is
one which has a minimum tenacity of at least 7 g/denier, a
preferred tensile modulus of at least about 150 g/denier, and
preferably an energy-to-break of at least about 8 J/g, each as
measured by ASTM D2256. However, the fibers forming each of the
first fibrous material and the second fibrous material are
substantially greater than 7 g/denier, and most or all of the
fibers forming the first fibrous material are substantially greater
than the fibers forming the second fibrous material. By "most or
all" it is meant that more than 50% of the fibers forming the first
fibrous material have a tenacity that is greater than the tenacity
of at least 50% of the fibers forming the second fibrous material.
In more preferred embodiments, at least 75% of the fibers forming
the first fibrous material have a tenacity that is greater than the
tenacity of at least 75% of the fibers forming the second fibrous
material. In still more preferred embodiments, at least 95% of the
fibers forming the first fibrous material have a tenacity that is
greater than the tenacity of at least 95% of the fibers forming the
second fibrous material. Most preferably, all of the fibers of the
first fibrous material are fibers having a tenacity greater than
all of the fibers of the second fibrous material. In this regard,
the fibers forming each of the first fibrous material and the
second fibrous material are exclusive of fibers or threads employed
to stitch or sew together any of the fibrous plies or sections.
Accordingly, the first fibrous material by itself has significantly
greater ballistic penetration resistance than the second fibrous
material by itself.
[0025] When the third section comprises fibers, it is referred to
herein as a third fibrous material. In accordance with the
preferred embodiments, more than 50% of the fibers forming the
second fibrous material have a tenacity that is greater than the
tenacity of at least 50% of the fibers forming the third fibrous
material. In more preferred embodiments, at least 75% of the fibers
forming the second fibrous material have a tenacity that is greater
than the tenacity of at least 75% of the fibers forming the third
fibrous material. In still more preferred embodiments, at least 95%
of the fibers forming the second fibrous material have a tenacity
that is greater than the tenacity of at least 95% of the fibers
forming the third fibrous material. Most preferably, all of the
fibers of the second fibrous material are fibers having a tenacity
greater than all of the fibers of the third fibrous material.
Accordingly, the both the first fibrous material and the second
fibrous material individually have significantly greater ballistic
penetration resistance than the third fibrous material
individually, and as stated above, the fibers forming each of the
first fibrous material, second fibrous material and third fibrous
material are exclusive of fibers or threads employed to stitch or
sew together a plurality of fibrous plies or sections.
[0026] In accordance with this objective, each of the fibers of the
second fibrous material preferably has a tenacity of at least 25%
less than the tenacity of the fibers of the first fibrous material,
and each of the fibers of the optional third fibrous material
preferably has a tenacity of at least 25% less than the tenacity of
the fibers of the second fibrous material. In further accordance
with this objective, it is preferred that each of the fibers
forming the fibrous plies of the first fibrous material (i.e. the
first fibrous plies) are preferably fibers having a tenacity of
greater than 27 g/denier, more preferably a tenacity of from about
28 g/denier to about 60 g/denier, still more preferably from about
33 g/denier to about 60 g/denier, still more preferably 39 g/denier
or more, still more preferably from at least 39 g/denier to about
60 g/denier, still more preferably 40 g/denier or more, still more
preferably 43 g/denier or more, or at least 43.5 g/denier, still
more preferably from about 45 g/denier to about 60 g/denier, still
more preferably at least 45 g/denier, at least about 48 g/denier,
at least about 50 g/denier, at least about 55 g/denier or at least
about 60 g/denier. Each of the fibers forming the fibrous plies of
the second fibrous material (i.e. the second fibrous plies) are
preferably fibers having a tenacity of from about 20 g/denier to
about 45 g/denier, more preferably from about 20 g/denier to about
40 g/denier, still more preferably from about 20 g/denier to about
35 g/denier, and most preferably from about 20 g/denier to about 30
g/denier. However, the fibers of said second fiber plies may be
higher depending on the tenacity of the fibers forming the first
fibrous plies.
[0027] In embodiments where the third section is a third fibrous
material, each of the fibers forming the fibrous plies of said
third fibrous material (i.e. the third fibrous plies) are
preferably fibers having a tenacity of from about 3 g/denier to
about 34 g/denier (e.g. 33.75 g/d (25% of 45 g/d)), more preferably
from about 5 g/denier to about 30 g/denier, still more preferably
from about 5 g/denier to about 25 g/denier, still more preferably
from about 5 g/denier to about 20 g/denier, still more preferably
from about 5 g/denier to about 15 g/denier, and still more
preferably from about 5 g/denier to about 10 g/denier. However, the
fibers of said third fiber plies may be lower or higher. For
example, in one embodiment, the third fibrous material comprises
fibers having a tenacity of less than 7 g/denier, less than 6
g/denier or less than 5 g/denier.
[0028] In more preferred embodiments, each of the fibers of the
second fibrous material preferably has a tenacity of at least 35%
less than the tenacity of the fibers of the first fibrous material,
and each of the fibers of the optional third fibrous material
preferably has a tenacity of at least 35% less than the tenacity of
the fibers of the second fibrous material. Still more preferably,
each of the fibers of the second fibrous material preferably has a
tenacity of at least 50% less than the tenacity of the fibers of
the first fibrous material, and each of the fibers of the optional
third fibrous material preferably has a tenacity of at least 50%
less than the tenacity of the fibers of the second fibrous
material. In these embodiments, the fiber types forming each
fibrous material section may be the same as or different than the
fiber types forming the other fibrous material sections. It is also
within the scope of the invention that the fibers of the second
fibrous material may be only 10% less or from about 10% to about
25% less, or from about 25% less to about 50% less than the
tenacity of the fibers of the first fibrous material, and the
fibers of the third fibrous material may be only 10% less or from
about 10% to about 25% less, or from about 25% less to about 50%
less than the tenacity of the fibers of the second fibrous
material, but at least a 25% difference is most preferred.
[0029] Additionally, while it is preferred that "each" of the
fibers in a particular fibrous material section has a different
tenacity than "each" of the fibers in "each" adjacent fibrous
material section, one or more of the fibrous material sections may
include a small portion of fibers (e.g. less than 10%) having other
tenacities that may be the same as one or more of the other
sections, as long as most of the fibers (i.e. >50%, .gtoreq.60%,
.gtoreq.70%, .gtoreq.80%, .gtoreq.90%; .gtoreq.95%; .gtoreq.98%; or
.gtoreq.99%) in each consecutive fibrous material section,
beginning at the first, strike face section, have tenacities that
are at least 10% greater, more preferably at least 25% greater,
than the previous fibrous material section. For example, the second
fibrous material section may optionally include a small portion of
fibers/filaments, preferably less than 10% of the total number of
fibers/filaments in the section, that have the same tenacity or a
greater tenacity than the fibers in the first fibrous material
section, or that have the same tenacity or a lower tenacity than
fibers a third fibrous section. This, however, is not preferred.
Any overlap in the above specified tenacity ranges still require
the that the other fiber tenacity requirements of the fibrous
material sections be met, i.e. if the fibers of the first fibrous
material section (i.e. >50%, .gtoreq.60%, .gtoreq.70%,
.gtoreq.80%, .gtoreq.90%; .gtoreq.95%; .gtoreq.98%; or .gtoreq.99%,
or 100% of the fibers) have a tenacity of 28 g/denier, the fibers
of the first fibrous material section (i.e. >50%, .gtoreq.60%,
.gtoreq.70%, .gtoreq.80%, .gtoreq.90%; .gtoreq.95%; .gtoreq.98%; or
.gtoreq.99%, or 100% of the fibers) should have tenacities of at
least 25% less than 28 g/denier, i.e. 21 g/denier or less. Most
preferably all the fibers forming each respective individual
(single) fibrous ply and individual (single) fibrous layer are
identical to each other in polymer type, chemical composition and
tenacity, and most preferably all the fibers forming a single
fibrous material section are identical to each other in polymer
type, chemical composition and tenacity. Accordingly, a fibrous
material section is most clearly distinguished from other fibrous
material sections by the differences in the component fibers
forming each respective section, particularly the tenacity of the
fibers in the different sections.
[0030] The fibers forming the fibrous plies of the each of the
first fibrous material, second fibrous material and optional third
fibrous material may vary depending on the desired tensile
properties for each material. Particularly suitable high tenacity
fibers include polyolefin fibers, such as high molecular weight
polyethylene fibers, particularly ultra-high molecular weight
polyethylene fibers, and 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, polybenzoxazole (PBO) fibers,
polybenzothiazole (PBT) fibers, liquid crystal copolyester fibers,
rigid rod fibers such as M5.RTM. fibers, and glass fibers,
including electric grade fiberglass (E-glass; low alkali
borosilicate glass with good electrical properties), structural
grade fiberglass (S-glass; a high strength
magnesia-alumina-silicate) and resistance grade fiberglass
(R-glass; a high strength alumino silicate glass without magnesium
oxide or calcium oxide). Each of these fiber types is
conventionally known in the art. Also suitable for producing
polymeric fibers are copolymers, block polymers and blends of the
above materials.
[0031] The most preferred fiber types for the first fibrous
material and second fibrous material are high performance fibers
including polyethylene fibers (particularly extended chain
polyethylene fibers), aramid fibers, PBO fibers, liquid crystal
copolyester fibers, polypropylene fibers (particularly highly
oriented extended chain polypropylene fibers), polyvinyl alcohol
fibers, polyacrylonitrile fibers, glass fibers and rigid rod
fibers, particularly M5.RTM. rigid rod fibers. Specifically most
preferred are polyethylene fibers and aramid fibers. The fibers
forming each of the first fibrous material and second fibrous
material may be the same fiber type or may be different fiber
types. When the fibers forming the first fibrous material and
second fibrous material are the same fiber type (e.g. both
comprise, consist of or consist essentially of polyethylene fibers,
or both comprise, consist of or consist essentially of aramid
fibers) the fibers of the second fibrous material must still have a
lower tenacity than the fibers of the first fibrous material,
preferably at least 25% less, more preferably at least 35% less,
most preferably at least 50% less than the tenacity of the fibers
of the first fibrous material.
[0032] In the case of polyethylene, preferred fibers are extended
chain polyethylenes having molecular weights of at least 300,000,
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. Nos. 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.
4,413,110; 4,536,536; 4,551,296; 4,663,101; 5,006,390; 5,032,338;
5,578,374; 5,736,244; 5,741,451; 5,958,582; 5,972,498; 6,448,359;
6,746,975; 6,969,553; 7,078,099; 7,344,668 and U.S. patent
application publication 2007/0231572, all of which are incorporated
herein by reference. Particularly preferred fiber types are any of
the polyethylene fibers sold under the trademark SPECTRA.RTM. from
Honeywell International Inc. SPECTRA.RTM. fibers are well known in
the art. Other useful polyethylene fiber types also include and
DYNEEMA.RTM. UHMW PE yarns commercially available from Royal DSM
N.V. Corporation of Heerlen, The Netherlands.
[0033] Particularly preferred methods for forming UHMW PE fibers
are processes that are capable of producing UHMW PE fibers having
tenacities of at least 39 g/denier, most preferably where the
fibers are multi-filament fibers. The most preferred processes
include those described in commonly-owned U.S. Pat. Nos. 7,846,363;
8,361,366; 8,444,898; 8,747,715; as well as U.S. publication no.
2011-0269359, the disclosures of which are incorporated by
reference herein to the extent consistent herewith. Such processes
are called "gel spinning" processes, also referred to as "solution
spinning," wherein a solution of ultra high molecular weight
polyethylene and a solvent is formed, followed by extruding the
solution through a multi-orifice spinneret to form solution
filaments, cooling the solution filaments into gel filaments, and
extracting the solvent to form dry filaments. These dry filaments
are grouped into bundles which are referred to in the art as either
fibers or yarns. The fibers/yarns are then stretched (drawn) up to
a maximum drawing capacity to increase their tenacity.
[0034] Preferred aramid (aromatic polyamide) fibers are well known
and commercially available, and are described, for example, in U.S.
Pat. No. 3,671,542. For example, useful aramid filaments are
produced commercially by DuPont under the trademark of KEVLAR.RTM..
Also useful herein are poly(m-phenylene isophthalamide) fibers
produced commercially by DuPont of Wilmington, Del. under the
trademark NOMEX.RTM. and fibers produced commercially by Teijin
Aramid Gmbh of Germany under the trademark TWARON.RTM.; aramid
fibers produced commercially by Kolon Industries, Inc. of Korea
under the trademark HERACRON.RTM.; p-aramid fibers SVM.TM. and
RUSAR.TM. which are produced commercially by Kamensk Volokno JSC of
Russia and ARMOS.TM. p-aramid fibers produced commercially by JSC
Chim Volokno of Russia.
[0035] Suitable PBO fibers 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 is incorporated
herein by reference. Suitable liquid crystal copolyester fibers 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, and including VECTRAN.RTM. liquid
crystal copolyester fibers commercially available from Kuraray Co.,
Ltd. of Tokyo, Japan. 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 is widely commercially available.
M5.RTM. fibers are formed from pyridobisimidazole-2,6-diyl
(2,5-dihydroxy-p-phenylene) and were most recently 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. The
term "rigid rod" fibers is not limited to such
pyridobisimidazole-based fiber types, and many PBO and aramid fiber
varieties are often referred to as rigid rod fibers. Commercially
available glass fibers include S2-Glass.RTM. S-glass fibers
commercially available from AGY of Aiken, S.C., HiPerTex.TM.
E-Glass fibers, commercially available from 3B Fibreglass of
Battice, Belgium, and VETROTEX.RTM. R-glass fibers from
Saint-Gobain of Courbevoie, France.
[0036] The fibers forming a third fibrous material may or may not
be formed from high performance fibers, but as noted previously the
fibers of the third fibrous material will have tenacities lower
than each of the first fibrous material and second fibrous
material, preferably comprising fibers having tenacities at least
25% less than the fibers forming the second fibrous material.
Suitable fibers for forming the third fibrous material
non-exclusively include nylon fibers, polyester fibers,
polypropylene fibers, polyolefin fibers or a combination thereof,
preferably having tenacities from about 5 g/denier to about 20
g/denier, more preferably from about 5 g/denier to about 15
g/denier, and still more preferably from about 5 g/denier to about
10 g/denier. Higher or lower tenacity fibers are also useful
provided that their tenacities are lower than the fibers of the
second fibrous plies. In this regard, fibers such as nylon fibers,
polyester fibers, polypropylene fibers or polyolefin fibers, or a
combination thereof, which have tenacities of less than 5 g/denier
are also useful herein. Of these fiber types, nylon fibers are most
preferred, particularly 420 denier or 840 denier nylon fibers and
fabrics formed therefrom, which are widely commercially available.
A particularly preferred third fibrous material section comprises a
woven fabric formed from 840 denier nylon fibers, such as woven
fabrics having a 26.times.26 plain weave construction and an areal
density of 200 g/m.sup.2, which is commercially available. Also
suitable are CORDURA.RTM. brand nylon fabrics commercially
available from Invista North America S.A R.L. of Wilmington, Del.
Particularly preferred nylon fibers are nylon 6 fibers, nylon 6,6
fibers and nylon 4,6 fibers.
[0037] Alternatively, the third section may be a non-fibrous
material, such as a polymer sheet, a metal sheet or an energy
mitigating material such as a foam. Preferred polymer sheets
include one or more isotropic polymer layers, which are isotropic
in regard to their physical properties. Suitable isotropic polymer
layers may be formed from polymers such as acrylics, nylons (such
as nylon 6; nylon 6,6; or nylon 4,6), polyolefins, epoxies,
silicones, polyesters, polycarbonate or polyvinyl chlorides, but
this list is non-exclusive. Methods of making isotropic polymer
layers are conventionally known. Suitable metal sheets
non-exclusively include high hardness steel (HHS), aluminum alloys,
titanium or a combination thereof. Suitable open-cell foams
non-exclusively include polyurethane foams, polyethylene foams,
polyvinyl chloride (PVC) foams, and other thermoplastic resin
foams. Polyurethane foams are the most common. Open-cell foams are
commercially available and are described, for example, in U.S. Pat.
Nos. 6,174,741, 6,093,752, 5,824,710, 5,114,773 and 4,957,798, the
disclosures of which are incorporated herein by reference. Foams
are also described in the publication Handbook of Plastic Foams, by
Arthur H. Landrock, Noves Publication (1995). Foam raw material
manufacturers include The Dow Chemical Company of Midland, Mich.
and Bayer Corporation of Pittsburgh, Pa. Foam converters (from
liquid to flexible foams) include American Excelsior Corp. of
Texas, Foamtech Corporation of Massachusetts, Wis. Foam Products of
Wisconsin, UFP Technologies of Massachusetts, Sealed Air
Corporation of N.J. and McMaster-Carr of Robbinsville, N.J. Rigid,
closed-cell foams may also be used, such as such as a vinyl nitrile
(e.g., polyvinylchloride (PVC) nitrile) foam, a polyethylene foam,
or an ethylene vinyl acetate foam. Examples of suitable
commercially available closed cell foams are neoprene/EPDM/SBr
(neoprene/ethylene propylene diene monomer/styrene-butadiene
rubber) closed cell foams commercially available from McMaster-Carr
of Robbinsville, N.J.; United Foam XRD 15 PCF polyethylene
commercially available from UFP Technologies of Raritan, N.J.
(manufactured by Qycell Corporation of Ontario, CA). The "Adhesive
Backed Open Cell Foam" used in Comparative Examples 7-9 was a 0.25
inch thick water-resistant, super-cushioning open cell polyurethane
foam with an adhesive backing, commercially available from
McMaster-Carr.
[0038] 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,
and they may be circular, flat or oblong in cross-section. They
also may 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 filament. Thus the term "fiber"
includes filaments, ribbons, strips and the like having regular or
irregular cross-section. It is preferred that the fibers have a
substantially circular cross-section. As used herein, the term
"yarn" is defined as a single strand consisting of multiple fibers.
A single fiber may be formed from just one filament or from
multiple filaments. A fiber formed from just one filament is
referred to herein as either a "single-filament" fiber or a
"monofilament" fiber, and a fiber formed from a plurality of
filaments is referred to herein as a "multifilament" fiber. The
term "denier" is a unit of linear density equal to the mass in
grams per 9000 meters of fiber/yarn. In this regard, the fibers may
be of any suitable denier. For example, fibers may have a denier of
from about 50 to about 5000 denier, more preferably from about 200
to 5000 denier, still more preferably from about 650 to about 3000
denier, and most preferably from about 800 to about 1500 denier.
The selection is governed by considerations of ballistic
effectiveness and cost. Finer fibers are more costly to manufacture
and to weave, but can produce greater ballistic effectiveness per
unit weight.
[0039] The "tenacity" of a fiber refers to the tensile stress
expressed as force (grams) per unit linear density (denier) of an
unstressed specimen. The term "fibrous ply" as used herein refers
to a single array of unidirectionally oriented fibers, a single
woven fabric, a single knitted fabric or a single felted fabric.
Each fibrous ply will have both an outer top surface and an outer
bottom surface and a plurality of "fibrous plies" describes more
than one ply of the fibrous structures. A single fibrous ply of
unidirectionally oriented fibers comprises an arrangement of fibers
that are aligned in a unidirectional, substantially parallel array.
This type of fiber arrangement is also known in the art as a
"unitape", "unidirectional tape", "UD" or "UDT." As used herein, an
"array" describes an orderly arrangement of fibers or yarns, which
is exclusive of woven and knitted fabrics, and a "parallel array"
describes an orderly, side-by-side, coplanar parallel arrangement
of fibers or yarns. The term "oriented" as used in the context of
"oriented fibers" refers to the alignment direction of the fibers
rather than to stretching of the fibers. The term "fabric"
describes structures that may include one or more fiber plies, with
or without consolidation/molding of the plies. A non-woven fabric
formed from unidirectional fibers typically comprises a plurality
of non-woven fiber plies that are stacked on each other
surface-to-surface in a substantially coextensive fashion and
consolidated. When used herein, a "single-layer" structure refers
to any monolithic fibrous structure composed of one or more
individual plies, wherein multiple plies have been merged by
consolidation or molding techniques. The term "composite" refers to
combinations of fibers, optionally but preferably with a polymeric
binder material.
[0040] The fibers forming each composite of the invention are
preferably, but not necessarily, at least partially coated with a
polymeric binder material. The polymeric binder material is also
commonly referred to in the art as a polymeric "matrix" material.
These terms are conventionally known in the art and describe a
material that binds fibers together, either by way of its inherent
adhesive characteristics or after being subjected to well known
heat and/or pressure conditions. As used herein, a "polymeric"
binder or matrix material includes resins and rubber. When present,
the polymeric binder/matrix material either partially or
substantially coats the individual fibers, preferably substantially
coating each of the individual filaments/fibers forming a fiber ply
or fiber layer.
[0041] Suitable polymeric binder materials include both low tensile
modulus, elastomeric materials and high tensile modulus, rigid
materials. As used herein throughout, the term tensile modulus
means the modulus of elasticity, which for polymeric binder
materials is measured by ASTM D638. A low or high modulus binder
may comprise a variety of polymeric and non-polymeric materials.
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. A low
modulus polymer is preferably an elastomer having a tensile modulus
of about 4,000 psi (27.6 MPa) or less, more preferably about 2400
psi (16.5 MPa) or less, still 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 low modulus
elastomeric material 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 low modulus
elastomeric material also has a preferred elongation to break of at
least about 50%, more preferably at least about 100% and most
preferably at least about 300%. Whether a low modulus material or a
high modulus material, the polymeric binder 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.
[0042] A wide variety of materials and formulations may be utilized
as a low modulus polymeric binder. 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, polyamides (useful with some
fiber types), acrylonitrile butadiene styrene, polycarbonates, and
combinations thereof, as well as other low modulus polymers and
copolymers curable below the melting point of the fiber. Also
useful are blends of different elastomeric materials, or blends of
elastomeric materials with one or more thermoplastics.
[0043] 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. Also useful are resin
dispersions of styrene-isoprene-styrene (SIS) block copolymer sold
under the trademark PRINLIN.RTM. and commercially available from
Henkel Technologies, based in Dusseldorf, Germany. Conventional low
modulus polymeric binder polymers employed in ballistic resistant
composites include polystyrene-polyisoprene-polystyrene block
copolymers sold under the trademark KRATON.RTM. commercially
produced by Kraton Polymers.
[0044] While low modulus polymeric binder materials are preferred
for the formation of flexible armor materials, high modulus
polymeric binder materials are preferred for the formation of rigid
armor articles. High modulus, rigid materials generally have an
initial tensile modulus greater than 6,000 psi. Useful high
modulus, rigid polymeric binder materials include polyurethanes
(both ether and ester based), epoxies, polyacrylates,
phenolic/polyvinyl butyral (PVB) polymers, vinyl ester polymers,
styrene-butadiene block copolymers, as well as mixtures of polymers
such as vinyl ester and diallyl phthalate or phenol formaldehyde
and polyvinyl butyral. A particularly useful rigid polymeric binder
material is a thermosetting polymer that is 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 useful rigid polymeric binder materials are those
described in U.S. Pat. No. 6,642,159, the disclosure of which is
incorporated herein by reference.
[0045] Most specifically preferred are polar resins or polar
polymers, particularly polyurethanes within the range of both soft
and rigid materials at a tensile modulus ranging from about 2,000
psi (13.79 MPa) to about 8,000 psi (55.16 MPa). Preferred
polyurethanes are applied as aqueous polyurethane dispersions that
are most preferably, but not necessarily, cosolvent free. Such
includes aqueous anionic polyurethane dispersions, aqueous cationic
polyurethane dispersions and aqueous nonionic polyurethane
dispersions. Particularly preferred are aqueous anionic
polyurethane dispersions; aqueous aliphatic polyurethane
dispersions, and most preferred are aqueous anionic, aliphatic
polyurethane dispersions, all of which are preferably cosolvent
free dispersions. Such includes aqueous anionic polyester-based
polyurethane dispersions; aqueous aliphatic polyester-based
polyurethane dispersions; and aqueous anionic, aliphatic
polyester-based polyurethane dispersions, all of which are
preferably cosolvent free dispersions. Such also includes aqueous
anionic polyether polyurethane dispersions; aqueous aliphatic
polyether-based polyurethane dispersions; and aqueous anionic,
aliphatic polyether-based polyurethane dispersions, all of which
are preferably cosolvent free dispersions. Similarly preferred are
all corresponding variations (polyester-based; aliphatic
polyester-based; polyether-based; aliphatic polyether-based, etc.)
of aqueous cationic and aqueous nonionic dispersions. Most
preferred is an aliphatic polyurethane dispersion having a modulus
at 100% elongation of about 700 psi or more, with a particularly
preferred range of 700 psi to about 3000 psi. More preferred are
aliphatic polyurethane dispersions having a modulus at 100%
elongation of about 1000 psi or more, and still more preferably
about 1100 psi or more. Most preferred is an aliphatic,
polyether-based anionic polyurethane dispersion having a modulus of
1000 psi or more, preferably 1100 psi or more.
[0046] When a composite does include a binder, the total weight of
the binder comprising the composite preferably comprises from about
2% to about 50% by weight, more preferably from about 5% to about
30%, more preferably from about 7% to about 20%, and most
preferably from about 11% to about 16% by weight of the fibers plus
the weight of the binder. A lower binder content is appropriate for
woven and knitted fabrics, wherein a polymeric binder content of
greater than zero but less than 10% by weight of the fibers plus
the weight of the binder is typically most preferred, but this is
not intended as strictly limiting. For example, phenolic/PVB
impregnated woven aramid fabrics are sometimes fabricated with a
higher resin content of from about 20% to about 30%, although about
12% content is typically preferred. Typically, weaving or knitting
of fabrics is performed prior to coating the fibers with an
optional polymeric binder, wherein the fabrics are thereafter
impregnated with the binder.
[0047] Methods for applying a polymeric binder material to fibers
to thereby impregnate fiber plies/layers with the binder are well
known and readily determined by one skilled in the art. The term
"impregnated" is considered herein as being synonymous with
"embedded," "coated," or otherwise applied with a polymeric coating
where the binder material diffuses into the fiber ply/layer and is
not simply on a surface of the ply/layer. Any appropriate
application method may be utilized to apply the polymeric binder
material and particular use of a term such as "coated" is not
intended to limit the method by which it is applied onto the
filaments/fibers. Useful methods include, for example, spraying,
extruding or roll coating polymers or polymer solutions onto the
fibers, as well as transporting the fibers through a molten polymer
or polymer solution. Most preferred are methods that substantially
coat or encapsulate each of the individual fibers and cover all or
substantially all of the fiber surface area with the polymeric
binder material.
[0048] As previously stated, each of the fibrous materials,
including the first, second and third fibrous materials, may
comprise woven fabrics, non-woven fabrics formed from
unidirectionally oriented fibers, non-woven felted fabrics formed
from randomly oriented fibers, or knitted fabrics. Woven fabrics
may be 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, three dimensional woven fabrics,
and any of their several variations. Plain weave is most common,
where fibers are woven together in an orthogonal
0.degree./90.degree. orientation, and is preferred. More preferred
are plain weave fabrics having an equal warp and weft count. In one
embodiment, a single layer of woven fabric preferably has from
about 15 to about 55 fiber/yarn ends per inch (about 5.9 to about
21.6 ends per cm) in both the warp and fill directions, and more
preferably from about 17 to about 45 ends per inch (about 6.7 to
about 17.7 ends per cm). The fibers/yarns forming the woven fabric
preferably have a denier of from about 375 to about 1300. The
result is a woven fabric weighing preferably from about 5 to about
19 ounces per square yard (about 169.5 to about 644.1 g/m.sup.2),
and more preferably from about 5 to about 11 ounces per square yard
(about 169.5 to about 373.0 g/m.sup.2). Examples of such woven
fabrics are those designated as SPECTRA.RTM. fabric styles 902,
903, 904, 952, 955 and 960 available from JPS Composite Materials
of Anderson, S.C. or other commercial weavers, fabricated with
SPECTRA.RTM. fibers from Honeywell International Inc. Other
exemplary woven fabrics include fabrics formed from basket weaves,
such as SPECTRA.RTM. fabric style 912. Examples of aramid-based
woven fabrics are those designated as KEVLAR.RTM. fabric styles
704, 705, 706, 708, 710, 713, 720, 745 and 755 available from
DuPont and TWARON.RTM. fabric styles 5704, 5716 and 5931, which are
commercially available from Kolon Industries, Inc.
[0049] Knit fabric structures are constructions composed of
intermeshing loops, with the four major types being tricot,
raschel, net and oriented structures. Due to the nature of the loop
structure, knits of the first three categories are not as suitable
as they do not take full advantage of the strength of a fiber.
Oriented knitted structures, however, use straight inlaid yarns
held in place by fine denier knitted stitches. The fibers are very
straight without the crimp effect found in woven fabrics due to the
interlacing effect on the yarns. These laid in yarns can be
oriented in a monoaxial, biaxial or multi-axial direction depending
on the engineered requirements. It is preferred that the specific
knit equipment used in laying in the load bearing yarns is such
that the yarns are not pierced through.
[0050] Felts may also be formed by one of several techniques known
in the art, such as by carding or fluid laying, melt blowing and
spin laying. A felt is a non-woven network of randomly oriented
fibers, preferably at least one of which is a discontinuous fiber,
preferably a staple fiber having a length ranging from about 0.25
inch (0.64 cm) to about 10 inches (25.4 cm).
[0051] A non-woven unidirectional fibrous ply of the invention may
be formed by conventional methods in the art. For example, in a
preferred method of forming a non-woven unidirectional fibrous ply,
a plurality of fibers are arranged into an array, typically being
arranged as a fiber web comprising a plurality of fibers aligned in
a substantially parallel, unidirectional array. In a typical
process, fiber bundles are supplied from a creel and led through
guides and one or more spreader bars into a collimating comb. This
is typically followed by coating the fibers with a polymeric binder
material. A typical fiber bundle will have from about 30 to about
2000 individual fibers. The spreader bars and collimating comb
disperse and spread out the bundled fibers, reorganizing them
side-by-side in a coplanar fashion. Ideal fiber spreading results
in the individual filaments or individual fibers being positioned
next to one another in a single fiber plane, forming a
substantially unidirectional, parallel array of fibers without
fibers overlapping each other. Similar to woven fabrics, a single
ply of woven fabric preferably has from about 15 to about 55
fiber/yarn ends per inch (about 5.9 to about 21.6 ends per cm), and
more preferably from about 17 to about 45 ends per inch (about 6.7
to about 17.7 ends per cm). Next, if the fibers are to be coated
with a matrix/binder, the coating is applied according to
conventional methods and is then typically dried followed by
forming the coated fibers into a single-ply of a desired length and
width. Uncoated fibers may be bound together with an adhesive film,
by bonding the fibers together with heat, or any other known
method, to thereby form a single-ply.
[0052] Whether unidirectional non-woven, felted non-woven, woven or
knitted, a plurality of fibrous plies may be merged together
according to conventional methods in the art to form each
individual section of the ballistic resistant composite. In this
regard, a plurality of single plies of the selected fabric/fibrous
ply type are stacked on top of each other in coextensive fashion
and merged, i.e. consolidated, together. When a section (e.g. the
first fibrous material, or the second fibrous material, or the
third fibrous material, etc.) comprises felted non-woven, woven or
knitted fibrous plies, each section of fibrous material preferably
includes from about 2 to about 100 fibrous plies, more preferably
from about 2 to about 85 fibrous plies, and most preferably from
about 2 to about 65 fibrous plies. When a section comprises a
plurality of unidirectional non-woven fibrous plies, it is typical
for a plurality of such plies to first be formed into a 2-ply or
4-ply unidirectional non-woven fiber "layer," also referred to in
the art as a "pre-preg," prior to combining a plurality of such
"layers" or "pre-pregs" together to form the section. Each "layer"
or "pre-preg" typically includes from 2 to about 6 fibrous plies,
typically being cross-plied at 0.degree./90.degree., but may
include as many as about 10 to about 20 fibrous plies as may be
desired for various applications, with the layers also being
cross-plied at alternating 0.degree./90.degree. orientations. When
a section (e.g. the first fibrous material, or the second fibrous
material, or the third fibrous material, etc.) comprises such
non-woven unidirectional fiber "layers," the section preferably
comprises from 2 to about 100 fiber layers, more preferably from
about 2 to about 85 fiber layers, and most preferably from about 2
to about 65 fiber layers. The total number of fibrous plies in each
of the first fibrous material, second fibrous material, optional
third fibrous material and any additional fibrous materials may be
different or may be the same, wherein the layers are of any
suitable thickness. The greater the number of total plies in a
section translates to greater ballistic resistance, but also
greater weight.
[0053] With particular regard to fibrous materials comprising
unidirectional non-woven fibrous plies, it is conventionally known
in the art that excellent ballistic resistance is achieved when the
individual fibrous plies are coextensively stacked upon each other
are cross-plied such that the such that the unidirectionally
oriented fibers in each fibrous ply are oriented in a non-parallel
longitudinal fiber direction relative to the longitudinal fiber
direction of each adjacent ply. Most preferably, the fibrous plies
are cross-plied orthogonally at 0.degree. and 90.degree. angles
wherein the angle of the fibers in even numbered layers is
preferably substantially the same and the angle of the fibers in
odd numbered layers is preferably substantially the same, but
adjacent plies can be aligned at virtually any angle between about
0.degree. and about 90.degree. with respect to the longitudinal
fiber direction of another ply. For example, a five ply non-woven
structure may have plies oriented at a
0.degree./45.degree./90.degree./45.degree./0.degree. or at other
angles. 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; 4,623,574; and 4,737,402, all of which are incorporated
herein by reference to the extent not incompatible herewith.
Typically, the fibers in adjacent plies will be oriented at an
angle of from 45.degree. to 90.degree., preferably 60.degree. to
90.degree., more preferably 80.degree. to 90.degree. and most
preferably at about 90.degree. relative to each other.
[0054] Each of the first fibrous material, second fibrous material,
optional third fibrous material and any additional fibrous
materials may be formed from identical fiber types or different
fiber types, and may include the same matrix/binder type or
different matrix/binder types. In one embodiment, the fibers and
polymeric binder forming the first fibrous material are both
chemically the same as the fibers and polymeric binder forming the
second fibrous material. For example, each fibrous material may
comprise ultra-high molecular weight polyethylene fibers coated
with a polyurethane binder. In another embodiment, the fibers and
polymeric binder forming the first fibrous material are both
chemically different than the fibers and polymeric binder forming
the second fibrous material. For example, the first fibrous
material may comprise ultra-high molecular weight polyethylene
fibers coated with a polyurethane binder while the second composite
comprise aramid fibers coated with a
polystyrene-polyisoprene-polystyrene block copolymer binder.
[0055] In a preferred three fibrous section article embodiment
(1.sup.st fibrous material/2.sup.nd fibrous material/3.sup.rd
fibrous material), each of the first fibrous material and the
second fibrous material comprise fibers coated with a polymeric
binder, wherein the fibers and the binder forming the first fibrous
material are both chemically the same as the fibers and binder
forming the second fibrous material, with the fibers of the second
fibrous material having a lower tenacity. However, the third
fibrous material is preferably comprised of fibers that are
chemically different than the fibers of each of the first and
second fibrous materials, which fibers have a lower tenacity than
the fibers of both the first fibrous material and the second
fibrous material. In said embodiment, the third fibrous material
may also include a polymeric binder that is either chemically the
same as or chemically different than the binder of each of the
other fibrous material sections. For example, the first fibrous
material may comprise aramid fiber based fibrous plies coated with
a polyurethane based binder, the second fibrous material may
comprise aramid fiber based fibrous plies coated with a
polyurethane based binder, and the third fibrous material may
comprise nylon fibers coated with a polyurethane based binder. In
another example, the first fibrous material may comprise
polyethylene fiber based fibrous plies coated with a polyurethane
based binder, the second fibrous material may comprise polyethylene
fiber based fibrous plies coated with a polyurethane based binder,
and the third fibrous material may comprise nylon fibers coated
with a polyurethane based binder.
[0056] The sections of fibrous material individually may be the
same or different in fabric structure (e.g., woven, knitted,
unidirectional non-woven or felted non-woven) relative to each
other. Most preferably, the ballistic resistant articles are formed
by a combination of different types of fabrics forming a hybrid
structure. In one preferred embodiment, a three section composite
is formed wherein all of the fibrous plies of the first fibrous
material are woven plies, all the fibrous plies of the second
fibrous material are unidirectional non-woven plies, and all of the
fibrous plies of the third fibrous material are woven plies. In
another preferred embodiment, all of the fibrous plies of the first
fibrous material are woven plies, all the fibrous plies of the
second fibrous material are unidirectional non-woven plies, and all
of the fibrous plies of the third fibrous material are felted
non-woven plies. In yet another preferred embodiment, all of the
fibrous plies of the first fibrous material are unidirectional
non-woven plies, all the fibrous plies of the second fibrous
material are woven plies, and all of the fibrous plies of the third
fibrous material are unidirectional non-woven plies.
[0057] In still other embodiments, some fibrous material sections
may comprise a greater amount of polymeric binder than other
fibrous material sections, or some fibrous material sections may
comprise a polymeric binder while other fibrous material sections
have no polymeric binder (i.e. are matrix-free). In one preferred
three fibrous material section embodiment, the second fibrous
material section has greater polymeric binder content than the
first fibrous material section. This embodiment will increase the
stiffness of the second fibrous material section to therefore
reduce trauma. The third fibrous material in this embodiment may or
may not include a polymeric binder.
[0058] The type and number of fibrous plies affects the areal
density of a ballistic resistant composite article, and the total
number of fibrous plies in a ballistic resistant article provided
herein will vary depending upon the ultimate end use of the
article. For example, in body armor vests for military
applications, in order to form an article that achieves an areal
density of 1.0 lb/ft.sup.2 (psf) (4.88 kg/m.sup.2 (ksm)), a total
of at 22 individual 2-ply (e.g.)0.degree./90.degree. layers may be
required. Minimum levels of body armor ballistic resistance for
military use are categorized by National Institute of Justice (NIJ)
Threat Levels, as is well known in the art.
[0059] Each fibrous material section of the invention has an areal
density of at least 100 g/m.sup.2, preferably having an areal
density of at least 200 g/m.sup.2 and more preferably having an
areal density of at least 976 g/m.sup.2. In preferred embodiments,
the sum of the first fibrous material, second fibrous material, a
third fibrous material or non-fibrous third section, and any
additional fibrous materials produces a ballistic resistant
material having a total combined areal density of from about 0.5
psf (2.44 ksm) to about 8.0 psf (39.04 ksm), more preferably from
about 0.5 psf (2.44 ksm) to about 5.0 psf (24.4 ksm), still more
preferably from about 0.5 psf (2.44 ksm) to about 3.5 psf (17.08
ksm), still more preferably from about 0.75 psf (3.66 ksm) to about
3.0 psf (14.64 ksm), still more preferably from about 0.75 psf
(3.66 ksm) to about 1.5 psf (7.32 ksm), and most preferably from
about 0.9 psf (4.392 ksm) to about 1.5 psf (7.32 ksm).
[0060] As previously stated, in use, the first fibrous material
section is preferably positioned as the front "strike face" section
of the ballistic resistant material, i.e. the section that a
projectile threat will strike first. For maximum backface signature
resistance performance, when the first fibrous material is
positioned as the strike face section, this first section
preferably has an areal density of greater than 50% of the total
combined areal density of the entire composite article. In one
embodiment, the areal density of the first fibrous material section
is greater than about 60% of the total combined areal density of
all combined sections. In another embodiment, the areal density of
the first fibrous material section is greater than about 70% of the
total combined areal density of all combined sections. In most
preferred embodiments, the first fibrous material section comprises
from about 60% to about 75% of the total combined areal density of
all the composite article sections combined, the second fibrous
material comprises from about 20% to about 30% of the total
combined areal density of all the composite article sections, and
the third section (fibrous or not) comprises from about 5% to about
10% of the total combined areal density of all the composite
article sections. In another embodiment, the areal density of the
first composite may be equal to the areal density of the second
composite. In a preferred three composite
(1.sup.st/2.sup.nd/3.sup.rd) article, the first and third
composites combined comprise from about 60% to about 75% of the
total combined areal density and the second composite comprises
from about 25% to about 40% of the total combined areal density. In
a specifically preferred three fibrous composite
(1.sup.st/2.sup.nd/3.sup.rd) configuration, the first and third
composites combined comprise about 75% of the total combined areal
density and the second composite comprises about 25% of the total
combined areal density. In another specifically preferred three
fibrous composite (1.sup.st/2.sup.nd/3.sup.rd) configuration, the
first and third composites combined comprise about 63% of the total
combined areal density and the second composite comprises about 37%
of the total combined areal density. These asymmetrical, unbalanced
configurations are specifically preferred because they exhibit a
combination of superior ballistic penetration resistance and
maximum backface signature resistance performance.
[0061] The thickness of each fibrous material section will
correspond to the thickness of the individual fibers and the number
of fiber plies/layers incorporated into the composite. For example,
a preferred wove fabric, knitted fabric or felted non-woven fabric
will have a preferred thickness of from about 25 .mu.m to about 600
.mu.m per ply/layer, more preferably from about 50 .mu.m to about
385 .mu.m and most preferably from about 75 .mu.m to about 255
.mu.m per ply/layer. A preferred two-ply unidirectional non-woven
fabric composite will have a preferred thickness of from about 12
.mu.m to about 600 .mu.m, more preferably from about 50 .mu.m to
about 385 .mu.m and most preferably from about 75 .mu.m to about
255 .mu.m. A preferred isotropic polymer sheet or metal sheet will
have a preferred thickness of from about 12 .mu.m to about 600
.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.
[0062] When forming the articles provided herein, all the plies
comprising all of the different section may be overlapped on top of
each other to form a stack followed by consolidating the plurality
of layers together at once, or each section may first be
consolidated individually followed by merging the consolidated
sections together. Merging of the fibrous layers and sections into
single-layer composite structures may be accomplished using
conventional techniques in the art, such as consolidation or
molding techniques. In this regard, merging using no pressure or
low pressure is often referred to in the art as "consolidation"
while high pressure merging is often referred to as "molding," but
these terms are also frequently used interchangeably.
[0063] In the preferred embodiments, each stack of overlapping
non-woven fiber plies (unidirectional or felted), woven fabric
plies, knitted fabric plies or a combination thereof is merged
under heat and pressure, or by adhering the coatings of individual
fibrous plies to each other, to thereby form a single-layer,
monolithic element. Methods of consolidating fibrous plies/layers
are well known, such as by the methods described in U.S. Pat. No.
6,642,159. Consolidation can occur via drying, cooling, heating,
pressure or a combination thereof. Heat and/or pressure may not be
necessary, as the fibers or fibrous plies may just be glued
together with an adhesive as is the case in a wet lamination
process. Consolidation may be performed at temperatures ranging
from about 50.degree. C. to about 175.degree. C., preferably from
about 105.degree. C. to about 175.degree. C., and at pressures
ranging from about 5 psig (0.034 MPa) to about 2500 psig (17 MPa),
for from about 0.01 seconds to about 24 hours, preferably from
about 0.02 seconds to about 2 hours. When heating, it is possible
that a present polymeric binder coating can be caused to stick or
flow without completely melting. However, generally, if the
polymeric binder material is caused to melt, relatively little
pressure is required to form the composite, while if the binder
material is only heated to a sticking point more pressure is
typically required. As is conventionally known in the art,
consolidation may be conducted in a calender set, a flat-bed
laminator, a press or in an autoclave. Consolidation may also be
conducted by vacuum molding the material in a mold that is placed
under a vacuum. Vacuum molding technology is well known in the art.
Most commonly, a plurality of orthogonal fiber webs are "glued"
together with the binder polymer and run through a flat-bed
laminator to improve the uniformity and strength of the bond.
[0064] Alternately, merging of the fibrous plies may be achieved by
molding under heat and pressure in a suitable molding apparatus.
Generally, molding is conducted at a pressure of from about 50 psi
(344.7 kPa) to about 5,000 psi (34,470 kPa), more preferably about
100 psi (689.5 kPa) to about 3,000 psi (20,680 kPa), most
preferably from about 150 psi (1,034 kPa) to about 1,500 psi
(10,340 kPa). Molding may alternately be conducted at higher
pressures of from about 5,000 psi (34,470 kPa) to about 15,000 psi
(103,410 kPa), more preferably from about 750 psi (5,171 kPa) to
about 5,000 psi, and more preferably from about 1,000 psi to about
5,000 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. and most preferably at
a temperature from about 200.degree. F. to about 280.degree. F. The
pressure under which the fibrous plies are molded has a direct
effect on the stiffness or flexibility of the resulting molded
product. Particularly, the higher the pressure at which they are
molded, the higher the stiffness, and vice-versa. In addition to
the molding pressure, the quantity, thickness and composition of
the fibrous plies and polymeric binder coating type also directly
affects the stiffness of composite.
[0065] While each of the molding and consolidation techniques
described herein are similar, each process is different.
Particularly, molding is a batch process and consolidation is a
generally 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, and does not necessarily result in a planar
product. Normally consolidation is done in a flat-bed laminator, a
calendar nip set or as a wet lamination to produce soft (flexible)
body armor fabrics. Molding is typically reserved for the
manufacture of hard armor, e.g. rigid plates. In either process,
suitable temperatures, pressures and times are generally dependent
on the type of polymeric binder coating materials, polymeric binder
content, process used and fiber type.
[0066] Alternative consolidation methods are also applicable when
merging a plurality of woven fabrics, knitted fabrics or felted
non-woven fabrics. For example, a plurality of woven fabrics may be
interconnected with each other using 3D weaving methods, such as by
weaving warp and weft threads into a stack of woven fabrics both
horizontally and vertically. A plurality of woven or non-woven
fabrics may also be attached to each other by mechanical attachment
such as stitching/needle punching fabrics together in the
z-direction. Similar techniques may be employed for merging a
plurality of knitted fabrics. Felted fibrous plies may be
consolidated mechanically such as by needle punching,
stitch-bonding, hydro-entanglement, air entanglement, spin bonding,
spin lacing or the like, chemically such as with an adhesive, or
thermally with a fiber to point bond or a blended fiber with a
lower melting point. The preferred consolidation method is needle
punching alone or followed by one of the other methods. The
preferred felt is a needle punched felt.
[0067] When the fibrous plies or sections of fibrous plies are
attached to each other with an intermediate, suitable adhesives
non-exclusively include elastomeric materials such as polyethylene,
cross-linked polyethylene, chlorosulfonated polyethylene, ethylene
copolymers, polypropylene, propylene copolymers, polybutadiene,
polyisoprene, natural rubber, ethylene-propylene copolymers,
ethylene-propylene-diene terpolymers, polysulfide polymers,
polyurethane elastomers, polychloroprene, plasticized
polyvinylchloride using one or more plasticizers that are well
known in the art (such as dioctyl phthalate), butadiene
acrylonitrile elastomers, poly (isobutylene-co-isoprene),
polyacrylates, polyesters, unsaturated polyesters, polyethers,
fluoroelastomers, silicone elastomers, copolymers of ethylene,
thermoplastic elastomers, phenolics, polybutyrals, epoxy polymers,
styrenic block copolymers, such as styrene-isoprene-styrene or
styrene-butadiene-styrene types, and other suitable adhesive
compositions conventionally known in the art. Particularly
preferred adhesives include methacrylate adhesives, cyanoacrylate
adhesives, UV cure adhesives, urethane adhesives, epoxy adhesives
and blends of the above materials. Of these, an adhesive comprising
a polyurethane thermoplastic adhesive, particularly a blend of one
or more polyurethane thermoplastics with one or more other
thermoplastic polymers, is preferred. Most preferably, the adhesive
comprises polyether aliphatic polyurethane. Such adhesives may be
applied, for example, in the form of a hot melt, film, paste or
spray, or as a two-component liquid adhesive.
[0068] The individual plies of individual fibrous material sections
may also be joined together by other suitable means for direct
attachment such as stitching, bolting, screwing or needle punching,
such that their surfaces contact each other, or a combination of
any of the above methods. The individual plies of each individual
section may also remain unconsolidated, followed by
consolidating/molding a unit comprising multiple unconsolidated
composite sections together in a single step, optionally wherein
each of the individual sections are stitched together to maintain
their integrity prior to the single unitary consolidation/molding
step.
[0069] Regardless of the method used to join the plies of each
individual section, all of the sections of the composite article
are to be bonded together by high pressure molding or consolidation
with an intermediate polymer layer or adhesive, or by employing an
existing polymeric binder coating as an adhesive to aid in bonding
the different sections together, to thereby form a consolidated,
unitary composite article. This specifically excludes stitching as
a sole means of attaching the different sections together. It has
been found that bonding the sections together by molding or
adhesive consolidation will increase inter-laminar strength between
the different sections, which translates to higher stiffness and
reduced trauma, i.e. improved backface signature performance.
[0070] The ballistic resistant composites of the invention may also
optionally comprise one or more thermoplastic polymer layers
attached to one or both of their outer surfaces. Suitable polymers
for the thermoplastic polymer layer non-exclusively include
polyolefins, polyamides, polyesters (particularly polyethylene
terephthalate (PET) and PET copolymers), polyurethanes, vinyl
polymers, ethylene vinyl alcohol copolymers, ethylene octane
copolymers, acrylonitrile copolymers, acrylic polymers, vinyl
polymers, polycarbonates, polystyrenes, fluoropolymers and the
like, as well as co-polymers and mixtures thereof, including
ethylene vinyl acetate (EVA) and ethylene acrylic acid. Also useful
are natural and synthetic rubber polymers. Of these, polyolefin and
polyamide layers are preferred. The preferred polyolefin is a
polyethylene. Non-limiting examples of useful polyethylenes are low
density polyethylene (LDPE), linear low density polyethylene
(LLDPE), medium density polyethylene (MDPE), linear medium density
polyethylene (LMDPE), linear very-low density polyethylene (VLDPE),
linear ultra-low density polyethylene (ULDPE), high density
polyethylene (HDPE) and co-polymers and mixtures thereof. Also
useful are SPUNFAB.RTM. polyamide webs commercially available from
Spunfab, Ltd, of Cuyahoga Falls, Ohio (trademark registered to
Keuchel Associates, Inc.), as well as THERMOPLAST.TM. and
HELIOPLAST.TM. webs, nets and films, commercially available from
Protechnic S.A. of Cernay, France.
[0071] Any thermoplastic polymer layers are preferably very thin,
having preferred layer 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. Discontinuous
webs such as SPUNFAB.RTM. non-woven webs are preferably applied
with a basis weight of 6 grams per square meter (gsm). While such
thicknesses are preferred, it is to be understood that other
thicknesses may be produced to satisfy a particular need and yet
fall within the scope of the present invention.
[0072] Such thermoplastic polymer layers may be bonded to the
composite surfaces using well known techniques, such as thermal
lamination. 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
structure. Lamination may be conducted 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. Such thermoplastic polymer layers may
alternatively be bonded to the composite surfaces with hot glue or
hot melt fibers as would be understood by one skilled in the
art.
[0073] In use, the multi-section ballistic resistant composite
articles may be provided with a cover into which the materials are
positioned. Soft body armor covers include woven fabrics, for
example, woven fabrics made from nylon, cotton, and/or other
fibers. One particularly preferred cover material is a rip stop
woven fabric, preferably a rip stop woven nylon fabric which is
formed from 70 denier nylon fibers having a weight of 95 g/m.sup.2
and is typically coated with a polyurethane resin on at least one
its surfaces. Such fabrics are known in the art and are typically
made by weaving nylon threads throughout a base material in
interlocking patterns. These fabrics are very resistant to tearing
and ripping. The cover may be sealed closed via conventional means
in the art, such as stitching. The cover may alternatively be
formed from a material that can be welded or heat sealed, which is
of particular interest where barrier properties are desired, such
as moisture or solvent barriers. The consolidated, unitary,
multi-section composite article may or may not be bonded to the
optional cover. In one exemplary embodiment where a three-section
composite article is positioned in a cover, either loosely or where
the article is bonded to the cover, the third fibrous material
section may be formed from nylon fibers such that a section of
nylon fibers is included within a cover that is also made from
nylon fibers.
[0074] The ballistic resistant composites provided herein may be
used to form articles having superior ballistic penetration
resistance. Articles having superior ballistic penetration
resistance are those which exhibit excellent properties defending
against penetration by deformable projectiles, such as bullets, and
against penetration of fragments, such as shrapnel. The ballistic
resistant composites are also suitable for body armor applications
that require low backface deformation, i.e. optimal blunt trauma
resistance, including flexible, soft armor articles as well as
rigid, hard armor articles, as well as for the defense of vehicles
and structural elements, such as building walls.
[0075] The following examples serve to illustrate the
invention.
EXAMPLES 1-4
[0076] Four different types of shoot packs were prepared from the
materials identified below and tested for ballistic penetration
resistance and backface signature performance:
[0077] Materials
[0078] 1. GOLD FLEX.RTM.
[0079] GOLD FLEX.RTM., commercially available from Honeywell
International Inc. of Morristown, N.J., is a highly flexible
four-ply unidirectional non-woven fabric formed from aramid fibers
having a breaking tenacity of 2350 mN/tex. The fibers in each ply
are parallel to each other and are oriented orthogonally relative
to the fibers in each adjacent ply (conventional
0.degree./90.degree./0.degree./90.degree. construction). The fibers
are coated with a polyisoprene-polystyrene-block copolymer based
binder resin. The four aramid plies were laminated between two
linear low density polyethylene (LLDPE) films, each having a
thickness of 9 .mu.m and an areal density of 8 g/m.sup.2,
positioning said LLDPE layers on both outer surfaces of the
fabric.
[0080] 2. GOLD SHIELD.RTM. GA-2010
[0081] GOLD SHIELD.RTM. GA-2010, commercially available from
Honeywell International Inc., is a highly flexible two-ply
unidirectional non-woven fabric formed from aramid fibers having a
breaking tenacity of 2025 mN/tex. The fibers in each ply are
parallel to each other and are oriented orthogonally relative to
the fibers in each adjacent ply (conventional 0.degree./90.degree.
construction). The fibers are coated with a
polyisoprene-polystyrene-block copolymer based binder resin. The
two aramid plies were laminated between two linear low density
polyethylene (LLDPE) films, each having a thickness of 9 .mu.m and
an areal density of 8 g/m.sup.2, positioning said LLDPE layers on
both outer surfaces of the fabric.
[0082] 3. Nylon Fabric
[0083] A 26.times.26 plain weave woven fabric formed with nylon
fibers having a tenacity below 800 mN/tex and a denier of 840. The
fabric has an areal density of 200 g/m.sup.2.
[0084] Ballistic Testing Methods
[0085] Each shoot pack identified below was tested for ballistic
performance against a 9 mm Full Metal Jacket Remington bullet. Each
shoot pack was mounted on a steel test frame measuring 610
mm.times.610 mm.times.140 mm.+-.2 mm and held in place with
stretchable 2'' wide bands. The steel frame was filled and
compacted with Roma Plastilina #1 clay as recommended by NIJ
0101.04 and NIJ 0101.06. The steel frame was mounted at a
90.degree. orientation to the line of bullets being fired from a
firmly mounted universal receiver. Before testing, the clay inside
steel frame was calibrated to meet the NIJ 0101.04 and NIJ 0101.06
standards.
[0086] To achieve National Institute of Justice NIJ0101.04 and
NIJ0101.06 compliance of a vest and shoot pack construction, each
material construction must successfully complete a two-part
performance test series, one for ballistic penetration resistance
and the other for backface signature performance.
[0087] Backface Signature Test
[0088] The standard method for measuring BFS of soft armor is
outlined by NIJ Standard 0101.04, Type IIIA, where an armor sample
is place in contact with the surface of the deformable Roma
Plastilina #1 clay. This NIJ method is conventionally used to
obtain a reasonable approximation or prediction of actual BFS that
may be expected during a ballistic event in field use for armor
that rests directly on or very close to the body of the user. In
this test, the depth of a non-penetrating projectile impact in the
clay must be 44 mm or less to pass.
[0089] V.sub.50 Projectile Penetration Resistance Test
[0090] V.sub.50 data was acquired taken under conventionally known
standardized techniques, particularly per the conditions of
Department of Defense Test Method Standard MIL-STD-662F. The
V.sub.50 ballistic limit testing is a statistical test that
experimentally identifies the velocity at which a bullet has a 50
percent chance of penetrating the flexible shoot pack. Testing is
conducted to achieve a V.sub.50 value within .+-.15 msec based on
an average of at least eight bullets fired on each shoot pack where
4 bullets completely penetrate the shoot pack and 4 bullets
partially penetrate the shoot pack.
Example 1 (Comparative)
[0091] Three identical 40 cm.times.40 cm square ballistic shoot
packs were assembled by forming a stack of 18 overlapping layers of
the four-ply GOLD FLEX.RTM. fabric specified above. During assembly
all of the layers were aligned so that the orientation of the
fibers in alternating plies remained orthogonal (0.degree.,
90.degree., 0.degree., 90.degree., (0.degree., 90.degree.,
0.degree., 90.degree.), etc., wherein the fibers of all the odd
plies were in parallel with each other and the fibers of all the
even plies of the shoot pack were in parallel with each other.
After stacking all of the 18 total layers, the layers were tack
stitched on each of the four corners of the stack and placed into a
rip stop nylon cover for ballistic testing. The results of all
testing is summarized in Table 1.
TABLE-US-00001 TABLE 1 Areal Backface Material 1 Material 2
Material 3 Density V.sub.50 Signature (# of layers) (# of layers)
(# of layers) (kg/m.sup.2) (m/sec) (mm) 18 0 0 4.20 492 39 18 0 0
4.20 486 38 18 0 0 4.20 484 38 Average 487 38
Example 2
[0092] Three identical 40 cm.times.40 cm square ballistic shoot
packs were assembled by forming a stack of 5 overlapping layers of
the four-ply GOLD FLEX.RTM. fabric specified above followed by 22
layers of the two-ply GOLD SHIELD.RTM. GA-2010 fabric specified
above. During assembly all of the layers were aligned so that the
orientation of the fibers in alternating plies remained orthogonal
(0.degree., 90.degree., 0.degree., 90.degree.), (0.degree.,
90.degree., 0.degree., 90.degree.), etc., wherein the fibers of all
the odd plies were in parallel with each other and the fibers of
all the even plies of the shoot pack were in parallel with each
other. After stacking all of the 27 total layers, the layers were
tack stitched on each of the four corners of the stack and placed
into a rip stop nylon cover for ballistic testing. The results of
all testing is summarized in Table 2.
TABLE-US-00002 TABLE 2 Areal Backface Material 1 Material 2
Material 3 Density V.sub.50 Signature (# of layers) (# of layers)
(# of layers) (kg/m.sup.2) (m/sec) (mm) 5 22 0 4.34 469 33 5 22 0
4.34 466 32 5 22 0 4.34 468 39 Average 468 35
Example 3
[0093] Three identical 40 cm.times.40 cm square ballistic shoot
packs were assembled by forming a stack of 5 overlapping layers of
the four-ply GOLD FLEX.RTM. fabric specified above followed by 9
layers of the two-ply GOLD SHIELD.RTM. GA-2010 fabric specified
above and 12 layers of the nylon woven fabric specified above.
During assembly all of the layers were aligned so that the
orientation of the fibers in alternating plies remained orthogonal
(0.degree., 90.degree., 0.degree., 90.degree.), (0.degree.,
90.degree., 0.degree., 90.degree.), etc., for each of the GOLD
FLEX.RTM. and GOLD SHIELD.RTM. GA-2010, wherein the fibers of all
the odd plies were in parallel with each other and the fibers of
all the even plies of the shoot pack were in parallel with each
other. For the nylon fabric layers, the longitudinal fiber
direction of the weft fibers and the warp fibers, respectively,
were kept parallel to the 0.degree./90.degree. directions of the
fibers of the GOLD FLEX.RTM. and GOLD SHIELD.RTM. GA-2010 plies.
After stacking all of the 26 total layers, the layers were tack
stitched on each of the four corners of the stack and placed into a
rip stop nylon cover for ballistic testing. The results of all
testing is summarized in Table 3.
TABLE-US-00003 TABLE 3 Areal Backface Material 1 Material 2
Material 3 Density V.sub.50 Signature (# of layers) (# of layers)
(# of layers) (kg/m.sup.2) (m/sec) (mm) 5 9 12 4.83 455 33 5 9 12
4.83 453 34 5 9 12 4.83 458 33 Average 455 33
Example 4
[0094] Three identical 40 cm.times.40 cm square ballistic shoot
packs were assembled by forming a stack of 5 overlapping layers of
the four-ply GOLD FLEX.RTM. fabric specified above followed by 9
layers of the two-ply GOLD SHIELD.RTM. GA-2010 fabric specified
above and 14 layers of the nylon woven fabric specified above.
During assembly all of the layers were aligned so that the
orientation of the fibers in alternating plies remained orthogonal
(0.degree., 90.degree., 0.degree., 90.degree.), (0.degree.,
90.degree., 0.degree., 90.degree.), etc., for each of the GOLD
FLEX.RTM. and GOLD SHIELD.RTM. GA-2010, wherein the fibers of all
the odd plies were in parallel with each other and the fibers of
all the even plies of the shoot pack were in parallel with each
other. For the nylon fabric layers, the longitudinal fiber
direction of the weft fibers and the warp fibers, respectively,
were kept parallel to the 0.degree./90.degree. directions of the
fibers of the GOLD FLEX.RTM. and GOLD SHIELD.RTM. GA-2010 plies.
After stacking all of the 28 total layers, the layers were tack
stitched on each of the four corners of the stack and placed into a
rip stop nylon cover for ballistic testing. The results of all
testing is summarized in Table 3.
TABLE-US-00004 TABLE 4 Areal Backface Material 1 Material 2
Material 3 Density V.sub.50 Signature (# of layers) (# of layers)
(# of layers) (kg/m.sup.2) (m/sec) (mm) 5 9 14 7.42 469 33 5 9 14
7.42 466 32 5 9 14 7.42 468 39 Average 468 35
Conclusions
[0095] Examples 2, 3 and 4 illustrate that hybrid materials
assembled such that the highest tenacity fibrous material is
positioned as the strike face which first engages the projectile,
followed by a second lower tenacity fibrous material and still
lower tenacity third material, will achieve excellent ballistic
penetration resistance and backface signature performance at a
lower cost than a composite formed from a single material as in
Example 1. The first material deforms, fragments and slows down the
projectile bullet, and that deformed and fragmented projectile
should stop in either the first section or second section of
fibrous material. The third material section supports the first two
sections of material and distributes the energy which causes
backface deformation to a wide area. Since this third set of
material is not need to deform and slow down the projectile and
projectile fragments, it can be formed from fibers having a lower
breaking tenacity or be a non-fibrous material, such as an energy
mitigating material.
[0096] 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.
* * * * *