Bi-directional fabric and fabric composites

• US 20050081571A1
• Filed: 10/19/2004
• Published: 04/21/2005
• Est. Priority Date: 06/07/2002
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Bhatnagar, Ahok, Parrishi, Elizabeth Stroud
• Granted Patent: US 7,073,538 B2
• Time in Patent Office: Days
• US Class Current: 66/202
• CPC Class Codes: D03D 1/0052 Antiballistic fabrics
• CPC Class Codes: D03D 11/00 Double or multi-ply fabrics not otherwise provided for
• CPC Class Codes: D03D 13/006 With additional leno yarn
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/41 with specific twist
• CPC Class Codes: D03D 15/56 elastic
• CPC Class Codes: D03D 15/573 Tensile strength
• CPC Class Codes: D04B 21/165 with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics layered products not united by stitch loops B32B5/22
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2201/28 Cellulose esters or ethers, e.g. cellulose acetate
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2321/02 polyolefins
• CPC Class Codes: D10B 2321/021 polyethylene
• CPC Class Codes: D10B 2321/06 polymers of unsaturated alcohols, e.g. polyvinyl alcohol, or of their acetals or ketals
• CPC Class Codes: D10B 2321/10 polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/021 aromatic polyamides, e.g. aramides
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2331/10 polyurethanes
• CPC Class Codes: D10B 2401/063 high strength
• CPC Class Codes: D10B 2403/02412 : including several arrays of unbent yarn, e.g. multiaxial fabrics
• CPC Class Codes: D10B 2505/02 : Reinforcing materials; Prepregs
• CPC Class Codes: F41H 5/0478 : Fibre- or fabric-reinforced layers in combination with plastics layers
• CPC Class Codes: F41H 5/0485 : all the layers being only fibre- or fabric-reinforced layers
• CPC Class Codes: Y10S 139/01 : Bias fabric digest
• CPC Class Codes: Y10S 428/911 : Penetration resistant layer
• CPC Class Codes: Y10T 442/2615 : Coating or impregnation is resistant to penetration by solid implements
• CPC Class Codes: Y10T 442/2623 : Ballistic resistant
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3203 : Multi-planar warp layers
• CPC Class Codes: Y10T 442/3211 : Multi-planar weft layers
• CPC Class Codes: Y10T 442/3228 : Materials differ
• CPC Class Codes: Y10T 442/3236 : Including inorganic strand material
• CPC Class Codes: Y10T 442/3244 : Including natural strand material [e.g., cotton, wool, etc.]
• CPC Class Codes: Y10T 442/3252 : Including synthetic polymeric strand material
• CPC Class Codes: Y10T 442/326 : Including synthetic polymeric strand material
• CPC Class Codes: Y10T 442/3268 : Including natural strand material
• CPC Class Codes: Y10T 442/3276 : Including polyamide strand material
• CPC Class Codes: Y10T 442/3285 : Including polyester strand material
• CPC Class Codes: Y10T 442/3472 : Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/3528 : Three or more fabric layers
• CPC Class Codes: Y10T 442/3602 : Three or more distinct layers
• CPC Class Codes: Y10T 442/365 : At least one layer is a preformed synthetic polymeric film or sheet
• CPC Class Codes: Y10T 442/3854 : Woven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/3886 : Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/40 : Knit fabric [i.e., knit strand or strip material]
• CPC Class Codes: Y10T 442/413 : Including an elastic strand
• CPC Class Codes: Y10T 442/456 : Including additional strand inserted within knit fabric
• CPC Class Codes: Y10T 442/488 : Including an additional knit fabric layer

Abstract

Bi-directional fabrics, fabric composites, ballistically resistant assemblies thereof, and the methods by which they are made. The bi-directional fabrics are comprised of a first set of strong, substantially parallel, unidirectional yarns lying in a first plane; a second set of strong, substantially parallel, unidirectional yarns lying in a second plane above the first plane and arranged transversely to the first set of yarns; and one or more sets of yarns having lower strength and higher elongation interleaved with the strong yarns. The bi-directional articles of the invention provide superior ballistic effectiveness compared to ordinary woven and knitted fabrics but retain the ease of manufacture on conventional looms and knitting machines.

Claims

1. A woven fabric comprising:

a) a first set of continuous filament unidirectional yarns lying in a first plane;

b) a second set of continuous filament unidirectional yarns lying in a second plane above said first plane and arranged transversely to said first set of yarns;

c) a third set of yarns arranged transversely to said first set of yarns and interlaced with said first set of yarns, each yarn of the third set lying above some and below the remaining yarns of said first set; and

d) a fourth set of yarns arranged transversely to said second and said third sets of yarns and interlaced with said second and said third sets of yarns, each yarn of the fourth set lying above some and below the remaining yarns of said second and said third sets of yarns;

wherein the yarns of each of said first and said second sets have tenacity'"'"'s equal to or greater than about 15 g/d, initial tensile moduli equal to or greater than about 400 g/d and energies-to-break equal to or greater than about 22 J/g, as measured by ASTM D2256; and

wherein the yarns of each of said first and said second sets, in proportion to the yarns comprising each of said third and said fourth sets of yarns, have at least twice the breaking strength and half the elongation to break.

2. The woven fabric of claim 1, wherein the yarns of said first and said second sets are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyolefins, aramids, polybenzazoles and blends thereof.

3. The woven fabric of claim 1, wherein the yarns of said first and said second sets are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyethylene, poly(p-phenylene terephthalamide, poly(m-phenylene isophthalamide), poly(benzobisoxazole, poly(benzobisthiazole), poly(benzobisimidazole) and blends thereof.

4. The woven fabric of claim 1, wherein the yarns of said third and said fourth sets are each selected independently from the group consisting of polyamide, polyester, polyvinyl alcohol, polyolefin, polyacrylonitrile, polyurethane, cellulose acetate, cotton, wool, and copolymers and blends thereof.

5. The woven fabric of claim 1, wherein the yarns of at least one of said third and said fourth sets of yarns is comprised of an elastomeric fiber.

6. The woven fabric of claim 1, wherein the yarns of at least one of said third and said fourth sets of yarns is comprised of staple fibers.

7. The woven fabric of claim 1, wherein the yarns of each of said first and said second sets of yarns, in proportion to the yarns comprising each of said third and said fourth sets of yarns, have at least three times the breaking strength and one-third the elongation to break.

8. The woven fabric of claim 1, wherein the yarns of each of said first and said second sets of yarns, in proportion to the yarns comprising each of said third and said fourth sets of yarns, have at least three times the breaking strength and one-tenth the elongation to break.

9. The woven fabric of claim 1, wherein the spacing of the yarns of each of said first, said second, said third, and said fourth sets of yarns is independently selected from a range of about 5 ends/in (1.97 ends/cm) to about 50 ends/in (19.7 ends/cm).

10. The woven fabric of claim 1, wherein said range is about 8 ends/in (3.15 ends/cm) to about 20 ends/in (7.87 ends/cm).

11. The woven fabric of claim 1, wherein said woven fabric has been calendered.

22. A fabric composite comprising a fabric, selected from the group consisting of a woven fabric having the characteristics as recited in claim 1 and a knitted fabric having the characteristics as recited in claim 12, embedded in a matrix selected from the group consisting of an elastomeric matrix having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638.

23. The fabric composite of claim 22, wherein the fabric is calendered.

24. The fabric composite of claim 23, wherein a plastic film is bonded to at least a portion of one of the surfaces of said fabric composite.

25. The fabric composite of claim 23, wherein an elastomer is coated on at least a portion of at least one surface of said fabric, said elastomer having an initial tensile modulus equal to or less than about 6,000 psi (41.3 MPa), as measured by ASTM D638;

and a plastic film is bonded to at least a portion of said elastomer coated surface.

26. A fabric composite comprising a fabric selected from the group consisting of a calendered woven fabric having the characteristics as recited in claim 11 and a calendered knitted fabric having the characteristics as recited in claim 21 with a plastic film bonded to at least a portion of at least one of said fabric surfaces.

27. A ballistically resistant article comprised of a plurality of fabric sheets plied together in stacked array, wherein at least a majority of said fabric sheets are selected from the group consisting of a woven fabric having the characteristics as recited in claim 1 and a knitted fabric having the characteristics as recited in claim 12.

28. The ballistically resistant article of claim 27, wherein at least a portion of the fabrics are embedded in a matrix selected from the group consisting of an elastomeric matrix having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638.

29. The ballistically resistant article of claim 27, wherein the fabric is calendered.

30. The ballistically resistant article of claim 29, wherein at least a portion of the fabrics are embedded in a matrix selected from the group consisting of an elastomeric matrix having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid matrix having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638.

31. The ballistically resistant article of claim 30, wherein at least a majority of said fabric composite sheets are comprised of the fabric, and wherein disposed between the fabric composite sheets is an elastomeric layer having an initial tensile modulus less than about 6000 psi (41.3 MPa).

32. The ballistically resistant article of claims 27 to 31 additionally comprising a hard face member selected from the group consisting of a metal, a ceramic, a glass, a metal filled composite, a ceramic filled composite or a glass filled composite.

33. A method of producing a ballistically resistant article comprising the steps of:

weaving a fabric with the characteristics as recited in claim 1;

and

plying sheets of said fabric in a stacked array.

34. A method of producing a ballistically resistant article comprising the steps of:

weaving a fabric with the characteristics as recited in claim 11;

and plying sheets of said fabric in a stacked array.

37. The method recited in any of claims 33 to 36 additionally comprising the step of joining said fabric sheets together by joining means.

38. A method of producing a ballistically resistant article comprising the steps of:

a) weaving a fabric with the characteristics as recited in claim 11;

b) embedding the fabric in a matrix selected from the group consisting of an elastomer having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid resin having an initial tensile modulus at least 300,000 psi (2068 MPa), as measured by ASTM D638, to produce a fabric composite;

d) plying sheets of said fabric composite in a stacked array; and

e) bonding and curing said sheets of said fabric composite together to form a unitary article.

39. A method as recited in claim 38 additionally including the step of bonding a plastic sheet to at least a portion of one surface of said fabric composite prior to plying sheets of said fabric composite in a stacked array.

40. A method of producing a ballistically resistant article comprising the steps of:

a) weaving a fabric with the characteristics as recited in claim 11;

b) bonding a plastic film to at least a portion of at least one of said fabric surfaces to produce a fabric composite;

c) plying sheets of said fabric composite in a stacked array; and

d) bonding said sheets of said fabric composite together to form a unitary article.

43. A method of producing a ballistically resistant article comprising the steps of:

a) weaving a fabric with the characteristics as recited in claim 11;

b) embedding the fabric in a matrix consisting essentially of a rigid resin having an initial tensile modulus at least about 300,000 psi (2068 MPa), as measured by ASTM D638, to produce a fabric composite;

c) applying to the surface of said fabric composite an elastomeric material having a tensile modulus less than about 6000 psi (41.3 MPa), as measured by ASTM D638, to produce an elastomeric coated fabric composite;

d) plying sheets of said elastomeric coated fabric composite in a stacked array; and

e) bonding and curing said sheets of said elastomeric coated fabric composite together to form a unitary article.

12. A knitted fabric comprising:

a) a first set of continuous filament unidirectional yarns lying in a first plane;

b) a second set of continuous filament unidirectional yarns lying in a second plane above said first plane and arranged transversely to said first set of yarns; and

c) a third set of yarns forming interlocking loops interlaced with said first and said second set of yarns, each yarn of the third set lying above some and below the remaining yarns of said first and said second sets of yarns;

wherein the yarns of each of said first and said second sets have tenacity'"'"'s equal to or greater than about 15 g/d, initial tensile moduli equal to or greater than about 400 g/d and energies-to-break equal to or greater than about 22 J/g, as measured by ASTM D2256; and

wherein the yarns of each of said first and said second sets, in proportion to the yarns comprising said third set of yarns, have at least twice the breaking strength and one half the elongation to break.

13. The knitted fabric of claim 12, wherein the yarns of said firs and said second sets are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyolefins, aramids, polybenzazoles and blends thereof.

14. The knitted fabric of claim 12, wherein the yarns of said first and said second sets are each selected independently from the group consisting of continuous filament highly oriented high molecular weight polyethylene, poly(p-phenylene terephthalamide, poly(m-phenylene isophthalamide), poly(benzobisoxazole), poly(benzobisthiazole), poly(benzobisimidazole) and blends thereof.

15. The knitted fabric of claim 12, wherein the yarns of said third set of yarns is selected from the group consisting of polyamide, polyester, polyvinyl alcohol, polyolefin, polyacrylonitrile, polyurethane, cellulose acetate, cotton, wool, and copolymers and blends thereof.

16. The knitted fabric of claim 12, wherein the yarns of said third set comprise an elastomeric fiber.

17. The knitted fabric of claim 12, wherein the yarns of said third set comprise staple fibers.

18. The knitted fabric of claim 12, wherein the yarns of each of said first and second sets of yarns, in proportion to the yarns comprising said third set of yarns, have at least three times the breaking strength, and one-tenth the elongation to break.

19. The knitted fabric of claim 12, wherein the spacing of the yarns of each of said first and second sets of yarns is independently selected from a range of about 5 ends/in (1.97 ends/cm) to about 50 ends/in (19.7 ends/cm).

20. The knitted fabric of claim 12, wherein the range is about 8 ends/in (3.15 ends/cm) to about 20 ends/in (7.87 ends/cm).

21. The knitted fabric of claim 12, wherein the fabric has been calendered.

35. A method of producing a ballistically resistant article comprising the steps of:

knitting a fabric with the characteristics as recited in claim 12;

and plying sheets of said fabric in a stacked array.

36. A method of producing a ballistically resistant article comprising the steps of:

knitting a fabric with the characteristics as recited in claim 21;

and plying said sheets of the fabric in a stacked array.

41. A method of producing a ballistically resistant article comprising the steps of:

a) knitting a fabric with the characteristics as recited in claim 21;

b) embedding the fabric in a matrix selected from the group consisting of an elastomer having an initial tensile modulus less than about 6,000 psi (41.3 MPa) and a rigid resin having an initial tensile modulus at least about 300,000 psi (2068 MPa) as measured by ASTM D638 to produce a fabric composite;

c) plying sheets of said fabric composite in a stacked array;

d) bonding and curing said sheets of said fabric composite together to form a unitary article.

42. A method of producing a ballistically resistant article comprising the steps of:

a) knitting a fabric with the characteristics as recited in claim 21;

b) bonding a plastic film to at least a portion of at least one of said fabric surfaces to produce a fabric composite;

c) plying sheets of said fabric composite in a stacked array;

d) bonding said sheets of said fabric composite together to form a unitary article.