Woven bullet resistant fabric

Abstract

A unique new group of “Faux-Sateen, Quasi-Unidirectional(UD)” woven anti-ballistic fabrics is disclosed. Novel and unexpected improvements in ballistic penetration resistance result. After appropriate lamination of at least two layers, ballistic resistance is either maintained or further enhanced, while blunt trauma resistance is improved. Fabric handling during vest fabrication is also greatly improved and significantly less stitching is required. Wearability is also improved.

1 . The production and use of a unique and novel group of Faux-Sateen, Quasi-Unidirectional(UD) woven anti-ballistic fabrics in which the filling yarns on the fabric face float over at least four but not more than ten adjacent warp yarns before being interlaced by one warp yarn.
 The interlacing warp yarn counters (move numbers) are irregularly spaced across the fabric, with no more than two adjacent counters being identical.   At least three different counters are utilized in each repeat.   No two warp yarn interlace points ever touch each other.   No regular sateen and no geometric twill pattern exists.   
   
   
       2 . The invention of  claim 1  in which the interlacing warp yarn counters are varied such that short, mild “broken geometric interlace patterns” of varying slope and length are induced into the fabric. Said patterns slope either gently (<45° angles) or steeply (>/=45° angles) over periods of from three to seven repeats. Each repeat pattern is accompanied by an equal but oppositely sloped pattern offset both vertically and horizontally from the original pattern. 
   
   
       3 . The invention of  claim 1  in which the interlacing warp yarn counters are varied such that no mild or short, “broken geometric interlace patterns” exist. 
   
   
       4 . The invention in  claim 1  in which single layers of the fabric are utilized in anti-ballistic vest designs. 
   
   
       5 . The invention in  claim 1  in which two or more layers of the invention are laminated together for use in anti-ballistic vest designs. 
   
   
       6 . The invention in  claim 1  in which the lamination of two or more layers is accomplished in way in which the back of one layer is always laminated to the face of another layer, and so on, in an alternating fashion. 
   
   
       7 . The invention in  claim 1  in which the lamination of two layers is accomplished in way in which the back of one layer is always laminated to the back of the second layer, or the face of one layer is always laminated to the face of the other layer. 
   
   
       8 . The invention in  claim 1 , wherein the primary protection provided is from ballistic threats, such as small arms (i.e. handguns, rifles, etc.) and/or explosive devices (i.e. grenades, bombs, improvised explosive devices, etc.), but protection from piercing and/or cutting instruments may also be provided. 
   
   
       9 . The invention in  claim 1  wherein the reinforcing fibers utilized are para-aramids such as Twaron, Heracron, Kevlar, etc., ultra high molecular weight polyethylene such as Dyneema, Spectra, etc., copolymer aramids such as Technora, Rusar, AuTx, SVM, Artec, etc., or any other suitable high strength fiber characterized by a minimum tenacity of 20 grams per denier, an minimum break elongation of 2%, and a minimum initial tensile modulus of 350 grams per denier. Examples include but are not limited to PBO, PBI, M5, and single and/or multi-walled carbon nano-tubes. 
   
   
       10 . The invention in  claim 1 , in which the reinforcing fibers range from 200 to 3000 denier, the number of filaments ranges from 100 to 2000, and the areal density of single layers of fabric ranges from 5 to 15 oz/yd 2 . 
   
   
       11 . The invention in  claim 1  in which the number of warp ends and fill ends are balanced, and range from 20 to 40 warp ends and 20 to 40 fill ends/inch. 
   
   
       12 . The invention in  claim 1  in which the number of warp ends and fill ends are un-balanced, and range from 20 to 40 warp ends and the number of fill ends are between one and three less than the warp ends. 
   
   
       13 . The invention in  claim 1  in which the invention is utilized on the strike face of the protective vest in conjunction with one or more other woven and/or UD, and/or Quasi-UD ballistic materials on the body side, or any combination of the above. 
   
   
       14 . The invention in  claim 1  in which the invention is utilized in the middle of the protective vest in conjunction with one or more other woven ballistic materials and/or UD, and/or Quasi-UD ballistic materials on the strike face and body side, or any combination of the above. 
   
   
       15 . The production and use of a unique and novel group of faux-satin and quasi-UD woven anti-ballistic fabrics in which the warp yarns on the fabric face float over at least four but not more than ten adjacent filling yarns before being interlaced by one filling yarn.
 The interlacing filling yarn counters (move numbers) are irregularly spaced across the fabric, with no more than two adjacent counters being identical,   At least three different counters are utilized in each repeat.   No two filling yarn interlace points ever touch each other.   No regular satin and no geometric twill pattern exists.   
   
   
       16 . The invention of  claim 15  in which the interlacing filling yarn counters are varied such that short, mild “broken geometric interlace patterns” of varying slope and length are induced into the fabric. Said patterns slope either gently (<45° angles) or steeply (>/=45° angles) over periods of from three to seven repeats.
 Each repeat pattern is accompanied by an equal but oppositely sloped pattern offset both vertically and horizontally from the original pattern.   
   
   
       17 . The invention of  claim 15  in which the interlacing filling yarn counters are varied such that no mild or short, “broken geometric interlace patterns” exist. 
   
   
       18 . The invention in  claim 15  in which single layers of the fabric are utilized in anti-ballistic vest designs. 
   
   
       19 . The invention in  claim 15  in which two or more layers of the invention are laminated together for use in anti-ballistic vest designs. 
   
   
       20 . The invention in  claim 15  in which the lamination of two or more layers is accomplished in way in which the back of one layer is always laminated to the face of another layer, and so on, in an alternating fashion. 
   
   
       21 . The invention in  claim 15  in which the lamination of two layers is accomplished in way in which the back of one layer is always laminated to the back of the second layer, or the face of one layer is always laminated to the face of the other layer. 
   
   
       22 . The invention in  claim 15 , wherein the primary protection provided is from ballistic threats, such as small arms (i.e. handguns, rifles, etc.) and/or explosive devices (i.e. grenades, bombs, improvised explosive devices, etc.), but protection from piercing and/or cutting instruments may also be provided. 
   
   
       23 . The invention in  claim 15  wherein the reinforcing fibers utilized are para-aramids such as Twaron, Heracron, Keviar, etc., ultra high molecular weight polyethylene such as Dyneema, Spectra, etc., copolymer aramids such as Technora, Rusar, AuTx, SVM, Artec, etc., or any other suitable high strength fiber characterized by a minimum tenacity of 20 grams per denier, an minimum break elongation of 2%, and a minimum initial tensile modulus of 350 grams per denier. Examples include but are not limited to PBO, PBI, M5, and single and/or multi-walled carbon nano-tubes. 
   
   
       24 . The invention in  claim 15 , in which the reinforcing fibers range from 200 to 3000 denier, the number of filaments ranges from 100 to 2000, and the areal density of single layers of fabric ranges from 5 to 15 oz/yd 2 . 
   
   
       25 . The invention in  claim 15  in which the number of warp ends and fill ends are balanced, and range from 20 to 40 warp ends and 20 to 40 fill ends/inch. 
   
   
       26 . The invention in  claim 15  in which the number of warp ends and fill ends are un-balanced, and range from 20 to 40 warp ends and the number of fill ends are between one and three less than the warp ends. 
   
   
       27 . The invention in  claim 15  in which the invention is utilized on the strike face of the protective vest in conjunction with one or more other woven and/or UD, and/or Quasi-UD ballistic materials on the body side, or any combination of the above. 
   
   
       28 . The invention in  claim 1  in which the invention is utilized in the middle of the protective vest in conjunction with one or more other woven ballistic materials and/or UD, and/or Quasi-UD ballistic materials on the strike face and body side, or any combination of the above.