Multiaxial Fabric for Ballistic Applications

• US 20090247031A1
• Filed: 12/07/2006
• Published: 10/01/2009
• Est. Priority Date: 12/08/2005
• Status: Active Grant

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Chiou, Minshon J.
• Granted Patent: US 9,012,339 B2
• Time in Patent Office: Days
• US Class Current: 442/135
• CPC Class Codes: A41D 31/245 using layered materials
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• 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: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• 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: Y10T 442/2426 Elemental carbon containing
• CPC Class Codes: Y10T 442/2615 Coating or impregnation is resistant to penetration by solid implements
• CPC Class Codes: Y10T 442/2623 Ballistic resistant

Abstract

The invention concerns multiaxial fabrics comprising a first layer comprising a plurality of first yarns being substantially parallel in a first direction; a second layer comprising a plurality of second yarns being substantially parallel in a second direction and skew of off-set with respect to the first yarns; a third yarn layer comprising a plurality of third yarns being substantially parallel in a third direction and skew of off-set with respect to the first yarns and second yarns; a fourth yarn layer comprising a plurality of fourth yarns being substantially parallel in a fourth direction and skew of off-set with respect to the first, second and third yarns; at least one fiber network layer; and a transverse yarn interlaced transversely within the multiaxial fabric where each layer may be arranged in any sequential order and optionally coated with a high viscosity polymer that has a glass transition temperature Tg in the range of about −40 to about 0° C., and a zero shear melt viscosity of about 2×10⁶ to about 10¹³ poise at 20° C.

Claims

1. A multiaxial fabric comprising:

a first layer comprising a plurality of first yarns being substantially parallel in a first direction,

a second layer comprising a plurality of second yarns being substantially parallel in a second direction and skew or off-set with respect to the first yarns,

at least one fiber network layer,

a third yarn layer comprising a plurality of third yarns being substantially parallel in a third direction and skew or off-set with respect to the first yarns and second yarns,

a fourth yarn layer comprising a plurality of fourth yarns being substantially parallel in a fourth direction and skew or off-set with respect to the first, second and third yarns, and

a transverse yarn interlaced transversely within the multiaxial fabric

wherein each layer may be arranged in any sequential order and optionally coated with a high viscosity polymer that has a Tg in the range of about −

40 to about 0°

C., and a zero shear melt viscosity of about 2×

10⁶ to about 10¹³ poise at 20°

C.

2. The fabric of claim 1 wherein at least one of the first, second, third and fourth yarn layers comprises aramid fiber.

3. The fabric of claim 2 wherein the aramid fiber is poly(p-phenylene terephthalamide).

4. The fabric of claim 1 wherein at least one of the first, second, third and fourth yarn layers comprises polypyridazole fiber.

5. The fabric of claim 4 wherein the polypyridazole is a polypyridobisimidazole.

6. The fabric of claim 4 wherein the polypyridazole is poly[2,6-d]imidazo[4,5-b:

4,5-e]-pyridinylene-1,4-(2,5-dihydroxy)phenylene).

7. The fabric of claim 1 wherein the at least one fiber network layer, comprises an aramid felt.

8. The fabric of claim 7 wherein the aramid is poly(p-phenylene terephthalamide).

9. The fabric of claim 7 wherein the aramid felt comprises poly(p-phenylene terephthalamide) staple fiber.

10. The fabric of claim 1 wherein the transverse yarn comprises fiber of polyester, polyethylene, polyamide, aramid, polyareneazoles, polypyridazoles, or polypyridobisimidazole.

11. The fabric of claim 1 wherein at least one layer is coated with a high viscosity polymer that has a Tg in the range of −

40 to about 0°

C., and a zero shear melt viscosity of about 2×

10⁶ to about 10¹³ poise at 20°

C.

12. The fabric of claim 1 wherein the at least one fiber network layer is a woven, non-woven, or knit structure.

13. The fabric of claim 1 wherein the at least one fiber network layer is a woven, structure.

14. The fabric of claim 1 wherein the at least one fiber network layer is a non-woven structure.

15. The fabric of claim 1 wherein the at least one fiber network layer is a knit structure.

16. A garment comprising the fabric of claim 1.

17. An article comprising the fabric of claim 1.

18. A method of producing a fabric comprising:

providing a first layer comprising a plurality of first yarns being substantially parallel in a first direction,

providing a second layer comprising a plurality of second yarns being substantially parallel in a second direction and skew or off-set with respect to the first yarns,

providing at least one fiber network layer,

providing a third yarn layer comprising a plurality of third yarns being substantially parallel in a third direction and skew or off-set with respect to the first yarns and second yarns,

providing a fourth yarn layer comprising a plurality of fourth yarns being substantially parallel in a fourth direction and skew of off-set with respect to the first, second and third yarns,

consolidating the layers into a consolidated sheet structure and

bonding multiple consolidated sheet structures together.

19. The method of claim 18 wherein at least one of the first, second, third and fourth yarn layers comprises aramid fiber.

20. The method of claim 19 wherein at least one of the first, second, third and fourth yarn layers comprises poly [2,6-d]imidazo[4,5-b:

4,5-e]-pyridinylene-1,4-(2,5-dihydroxy)phenylene) fiber.