Lightweight laminates and plate-carrier vests and other articles of manufacture therefrom

• US 10,513,088 B2
• Filed: 01/08/2016
• Issued: 12/24/2019
• Est. Priority Date: 01/09/2015
• Status: Active Grant

• Current Assignee: DSM Protective Materials BV (Avient Corp.)
• Original Assignee: DSM IP Assets BV (DSM-Firmenich AG)
• Inventors: Downs, Roland Joseph, Adams, Christopher Michael, McDaniels, Keith Joel
• Primary Examiner(s): Johnson, Stephen
• Application Number:
  US15/542,392
• Publication Number:
  US 20180022060A1
• Time in Patent Office: 1,446 Days
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2323/043 HDPE, i.e. high density polyethylene
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: F41H 1/02 Armoured or projectile- or missile-resistant garments; Composite protection fabrics F41H5/04 takes precedence
• CPC Class Codes: F41H 5/0478 Fibre- or fabric-reinforced layers in combination with plastics layers

Abstract

A lightweight laminate comprises: (a) a first outer layer; (b) at least one internal reinforcing layer; (c) optionally, one or more intervening film layers; and (d) a second outer layer, wherein the at least one internal reinforcing layer is disposed between first and second outer layers, and wherein the second outer layer is saturated, partially saturated and coated, or partially coated with a wet-out resin. Reinforcing layers can comprise unitape further comprising parallel monofilaments embedded in resin. An article of manufacture, such as MOLLE, a plate-carrier, or other military, law enforcement, or recreational apparel or gear comprises the light-weight laminate.

Claims

1. A lightweight laminate comprising:

(a) a first outer layer;

(b) a second outer layer saturated, partially saturated and coated, or partially coated with a wet-out resin at from about 35% by weight to about 70% by weight, based on the total weight of the second outer layer and said wet-out resin; and

(c) at least one internal reinforcing layer disposed between said first and second outer layers, said internal reinforcing layer comprising parallel filaments or monofilaments embedded in a resin matrix.

2. The lightweight laminate of claim 1, wherein said filaments or monofilaments comprise ultra-high molecular weight polyethylene.

3. The lightweight laminate of claim 1, wherein said wet-out resin is present at from about 35% by weight to about 55% by weight, based on the total weight of said second outer layer and said wet-out resin.

4. The lightweight laminate of claim 1, further comprising a backside film bonded by the wet-out resin to said second outer layer, opposite said first outer layer.

5. The lightweight laminate of claim 1, further comprising one or more intervening film layers disposed between at least one of:

said first outer layer and said at least one internal reinforcing layer;

between said at least one internal reinforcing layer and an adjacent internal reinforcing layer when the number of internal reinforcing layers total at least two; and

between said second outer layer and said at least one internal reinforcing layer.

6. The lightweight laminate of claim 1, wherein said second outer layer comprises a woven fabric.

7. A non-ballistic or antiballistic plate-carrier vest comprising:

(a) a lightweight laminate comprising;

(i) a first outer layer;

(ii) at least one internal reinforcing layer; and

(iii) a second outer layer, said at least one internal reinforcing layer disposed between said first and second outer layers, and said second outer layer saturated, partially saturated and coated, or partially coated with a wet-out resin at from about 35% by weight to about 70% by weight, based on the total weight of the second outer layer; and

(b) at least one of a hardware item and a soft item attached to said lightweight laminate.

8. The non-ballistic or antiballistic plate-carrier vest of claim 7, wherein said reinforcing layer comprises parallel filaments or monofilaments embedded in a resin matrix.

9. The non-ballistic or antiballistic plate-carrier vest of claim 8, wherein said filaments or monofilaments comprise ultra-high molecular weight polyethylene.

10. The non-ballistic or antiballistic plate-carrier vest of claim 8, further comprising one or more intervening film layers disposed between at least one of:

said first outer layer and said at least one internal reinforcing layer;

between said at least one internal reinforcing layer and an adjacent internal reinforcing layer when the number of internal reinforcing layers total at least two; and

between said second outer layer and said at least one internal reinforcing layer.

11. The non-ballistic or antiballistic plate-carrier vest of claim 7, wherein said wet-out resin is present at from about 35% by weight to about 55% by weight, based on the total weight of said second outer layer and said wet-out resin.

12. A method of producing a lightweight laminate comprising:

(a) first, laminating a first outer layer, a reinforcing core layer, and a second outer surface layer together such that said reinforcing core layer is disposed between said first and second outer layers, and then, (b) wetting-out said second outer layer with a wet-out resin at from about 35% by weight to about 70% by weight, based on the total weight of the second outer layer and said wet-out resin.

13. The method of claim 12, wherein said reinforcing core layer comprises at least one unitape comprising parallel monofilaments embedded in a resin matrix.

14. The method of claim 13, wherein said monofilaments comprise ultra-high molecular weight polyethylene.

15. The method of claim 13, wherein said step of wetting-out comprises infiltration of resin from said unitape into said second outer layer.

16. The method of claim 12, wherein said second outer layer comprises a woven fabric.

17. The method of claim 12, further including the step of bonding a backside film to the second outer layer opposite said reinforcing core layer.

18. The method of claim 17, wherein said wet-out resin originates from said backside film and bonds said backside film to said second outer layer.

19. The method of claim 17, wherein said backside film comprises a waterproof/breathable membrane.

20. The method of claim 12, wherein said step of wetting-out comprises saturating, partially saturating and coating, or partially coating said second outer layer with said wet-out resin.

21. The method of claim 12, wherein said wet-out resin is present at from about 35% by weight to about 55% by weight, based on the total weight of said second outer layer and said wet-out resin.

22. The method of claim 12, further comprising disposing one or more intervening film layers between at least one of:

said first outer layer and said internal reinforcing layer; and

between said second outer layer and said internal reinforcing layer, prior to lamination in step (a).

23. The method of claim 12, further comprising a step of laminating at least two unitape layers together to form said reinforcing core layer, prior to lamination in step (a).