Woven multi-layer fabrics and methods of fabricating same

• US 8,573,261 B2
• Filed: 08/03/2012
• Issued: 11/05/2013
• Est. Priority Date: 10/02/2009
• Status: Active Grant

• Current Assignee: Barrday Incorporated
• Original Assignee: Barrday Incorporated
• Inventors: Shahkarami, Shekoufeh
• Primary Examiner(s): Muromoto, Jr., Bobby
• Application Number:
  US13/565,856
• Publication Number:
  US 20130025736A1
• Time in Patent Office: 459 Days
• Field of Search: 2/25, 428/911, 89/360.5
• US Class Current: 139/423
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/0207 Elastomeric fibres
• CPC Class Codes: B32B 2262/0238 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2262/0246 Acrylic resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/06 Vegetal fibres
• CPC Class Codes: B32B 2262/08 Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: B32B 2262/10 Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 5/024 : Woven fabric
• 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 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• 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: D03D 1/0052 : Antiballistic fabrics
• CPC Class Codes: D03D 11/00 : Double or multi-ply fabrics not otherwise provided for
• CPC Class Codes: D03D 11/02 : Fabrics formed with pockets, tubes, loops, folds, tucks or flaps fabrics consisting of a single tube D03D3/02
• CPC Class Codes: D03D 13/004 : with weave pattern being non-standard or providing special effects
• CPC Class Codes: D03D 15/43 : with differing diameters
• CPC Class Codes: D03D 15/46 : Flat yarns, e.g. tapes or films
• CPC Class Codes: D03D 25/005 : Three-dimensional woven fabrics
• CPC Class Codes: F41H 5/0485 : all the layers being only fibre- or fabric-reinforced layers

Abstract

A multi-layer ballistic woven fabric, including an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together to form the upper woven layer. The multi-layer ballistic woven fabric also includes a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together, and a plurality of securing yarns, each securing yarn interwoven with at least some of the upper yarns and some of the lower yarns so as to secure the upper and lower woven layers together. At least one of the securing yarns is woven underneath a first lower weft yarn, then above a second upper weft yarn adjacent the first lower weft yarn, then underneath a third lower weft yarn adjacent the second upper weft yarn and then above a fourth upper weft yarn adjacent the third lower weft yarn.

Claims

1. A multi-layer ballistic woven fabric, comprising:

a. an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together;

b. a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together; and

c. a plurality of securing yarns, each securing yarn interwoven with at least some of the upper yarns and some of the lower yarns so as to secure the upper and lower woven layers together;

d. wherein the multi-layer ballistic woven fabric is formed by interweaving the securing yarns with the warp yarns and weft yarns as the upper woven layer and lower woven layer are made;

e. and wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by between 10% and 95%.

2. The multi-layer ballistic woven fabric of claim 1, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by between 30% and 70%.

3. The multi-layer ballistic woven fabric of claim 1, wherein at least some of the upper yarns and lower yarns are completely offset from each other so as to not overlap.

4. The multi-layer ballistic woven fabric of claim 1, wherein the warp yarns and weft yarns are ballistic yarns.

5. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns include first securing yarns oriented in a first direction and second securing yarns oriented in a second direction.

6. The multi-layer ballistic woven fabric of claim 5, wherein the first securing yarns are separated by a first spacing, and the second securing yarns are separated by a second spacing.

7. The multi-layer ballistic woven fabric of claim 6, wherein the first spacing is between one inch and three inches, and the second spacing is between one inch and three inches.

8. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are aligned with either the warp yarns or the weft yarns, and are separated by a spacing of less than three inches.

9. The multi-layer ballistic woven fabric of claim 1, wherein the warp yarns and weft yarns have a tenacity of at least about 15 grams per denier and a tensile modulus of at least about 400 grams per denier.

10. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are made from a high elongation, low strength, and low modulus yarn.

11. The multi-layer ballistic woven fabric of claim 1, wherein at least one of the securing yarns is woven underneath a first lower weft yarn, then above a second upper weft yarn adjacent the first lower weft yarn, then underneath a third lower weft yarn adjacent the second upper weft yarn and then above a fourth upper weft yarn adjacent the third lower weft yarn.

12. The multi-layer ballistic woven fabric of claim 1, wherein at least one of the securing yarns is woven underneath at least one lower weft yarn, and then above at least one upper weft yarn adjacent the at least one lower weft yarn.

13. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are spaced apart by a distance of more than three inches.

14. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are selected from a group consisting of:

a. natural fibers;

b. cotton;

c. wool;

d. sisal;

e. linen;

f. jute;

g. silk

h. synthetic fibers and filaments;

i. regenerated cellulose;

j. rayon;

k. polynosic rayon;

I. cellulose esters;

m. acrylics;

n. polyacrylonitrile;

o. modacrylics;

p. acrylonitrile-vinyl chloride copolymers;

q. polyamides;

r. polyhexamethylene adipamide (nylon

     66);

s. polycaproamide (nylon

     6);

t. polyundecanoamide (nylon

     11);

u. polyolefin;

v. polyethylene;

w. polypropylene;

x. polyester;

y. polyethylene terephthalate;

z. rubber;

aa. synthetic rubber;

bb. saran;

cc. glass; and

dd. carbon.

15. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns include high performance fibers.

16. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are made of non-ballistic yarns.

17. The multi-layer ballistic woven fabric of claim 16, wherein the securing yarns include Nylon.

18. The multi-layer ballistic woven fabric of claim 15, wherein the securing yarns are made of ballistic yarns.

19. The multi-layer ballistic woven fabric of claim 18, wherein the securing yarns include aramid yarns.

20. The multi-layer ballistic woven fabric of claim 1, wherein the warp and weft yarns are selected from a group consisting of:

a. carbon;

b. basalt;

c. glass;

d. aramid and copolymer aramid fibers;

e. extended chain polyethylene fibers;

f. polyethylene fibers and films;

g. poly(p-phenylene-2,6-benzobisoxa-zole) (PBO); and

h. liquid crystal polymers.

21. The multi-layer ballistic woven fabric of claim 1, wherein three or more woven layers are secured together to form the fabric.

22. The multi-layer ballistic woven fabric of claim 1, further comprising four or more woven layers.

23. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns have a denier of between about 20 denier to about 1000 denier.

24. The multi-layer ballistic woven fabric of claim 1, wherein the securing yarns are made from a high elongation, low strength, and low modulus yarn.

25. A ballistic element comprising at least one multi-layer ballistic woven fabric according to claim 1 laminated for use in at least one of soft armor applications, hard armor applications, rigid applications, and semi-rigid applications.