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.

Description

BACKGROUND OF THE INVENTION

Modern soft body armor was invented in 1972 (U.S. Pat. No. 3,783,449, R. C. Davis, Second Chance Body Armor), initially using high strength woven ballistic nylon. Early concealable vests were fairly heavy, thick and covered only a small portion of the torso. In addition, vest capabilities were limited to stopping low energy handgun bullets. Since 1972, police and military body armor technologies have rapidly evolved as improved fibers, materials and production methods have resulted in higher performing, more protective, lighter, thinner and more wearable vests, offering greater areas of protective coverage. Armor standards have also become more stringent as police and military ballistic threats have increased, and will continue to do so.

Currently, the soft body armor industry utilizes high strength aromatic polyamide (aramid, or para-aramid) fibers, most often composed of poly(p-phenlylene terepthalimide) (PPD-T). DuPont's Kevlar®, Teijin-Twaron's Twaron®, and Kolon's Heracron® are all examples of aramid fibers. Significant quantities of Ultra High Molecular Weight Polyethylene (UHMWPE) fibers such as Honeywell's Spectra® and Dutch State Mine's Dyneema® are also utilized, primarily in fiber reinforced, semi flexoible resin composites, commonly referred to as “unidirectionals.”

Both aramid and UHMWPE ballistic fibers come in a wide variety of masses, or deniers (gm/9000 meters), currently ranging from 200-3000. Tensile properties vary widely, but can be generally characterized as having tenacities above 22 gm/den, break elongations between 2.5-3.5% and tensile moduli greater than 400 gm/den. Recently, Kamensknolokno's co-polymer aramid fiber has also entered the ballisitc fiber market, under various names such as AuTx, Rusar and Artec®.

Woven Ballistic Fabrics: Traditionally, soft body armor manufacturers have utilized a variety of woven ballistic fabrics which are usually plain weaves. Typical examples of these include:

	Ends/Inch	Weight:
	Fiber:	Denier*:	Warp	Fill	Oz/Yd2
	Aramid	500	28	28	3.7
	Aramid	840	24	23	5.1
	Aramid	840	27	27	5.9
	Aramid	1000	22	22	5.6
	Aramid	1500	22	22	8.6
	*Denier = fiber mass in grams/9,000 meters.

Previous efforts to improve ballistic penetration resistance have focused on increasing fiber strength, reducing fiber deniers, increasing the number of finer filaments, optimizing weaves and minimizing fiber damage during conversion to fabric. Additional fabric processing after weaving is sometimes employed. It is also well known that using more layers of lower denier, lighter fabrics improves penetration resistance, but usually at higher expense and increased blunt trauma.

U.S. Pat. No. 4,850,050 (Droste & Kaiser, Akzo, Jul. 15, 1989) discloses 5% performance improvements by utilizing para-aramid yarns having “micro-filaments” (filments below 1.35 denier per filament (dpf), vs. the more traditional 1.5 dpf and higher. Widespread use of this technology (0.75-1.0 dpf) has resulted in lighter, thinner, more flexible, and wearable soft body armor designs being marketed.

U.S. Pat. No. 5,882,791 (Werff, Baltusse and Hofman, Akzo, Mar. 16, 1999) describes further improvements in ballistic performance available by using para-aramid fibers of 0.27-0.72 dpf. At this time, no commercial fibers have appeared in the market.

U.S. Pat. No. 5,187,003 (Chitrangad, DuPont, Feb. 16, 1993) discloses performance improvements available by tailoring para aramid fibers with higher warp yarn elongations than fill yarns. At this time, no commercial fibers have appeared.

U.S. Pat. No. 5,958,804 (Brown, Wachter, Anderson) Sep. 28, 1999 discloses improvements in woven ballistic performance resulting from calendering the woven to flatten the thread line bundles and “set” the weave crimp. UHMPE woven fabric examples are cited. It is not known if this has been commercialized anywhere, as woven UHMPE fabrics are not commonly used in soft body armor.

Recently, a few satin and twill weaves have also been explored for use in soft body armor, with fairly limited success. These are usually treated with film or resin sprays, and frequently laminated, to facilitate handling during vest production.

Some limited use of unusually loosely woven materials has also begun, based on U.S. Pat. No. 6,610,617 (Chiou, DuPont, Aug. 26, 2003). This patent discloses the use of ballistic fabrics woven unusually loose. The principle again, is the known concept of using more thinner, lighter layers to reduce weight and increase fiber mobility.

Examples cited include both plain weaves (P) and Satins (S):

	Ends/Inch	Weigh
	2175Fiber:	Denier:	Warp	Fill	Oz/Yd2
	Aramid	840	18	18	4.0 (P)
	Aramid	840	20	20	4.3 (S)
	Aramid	1000	16	16	4.3 (P)
	Aramid	1000	17	17	4.6 (S

These extremely loose fabrics are very difficult to handle and need stabilization with resins or other means, to keep them from literally falling apart in handling. UHMWPE fibers are not commonly utilized in woven ballistic fabrics.

Non-Woven Ballistic Fabrics: Various non-woven, “unidirectional” (UD) fiber reinforced semi-flexible resin composites have also been widely utilized in the soft body armor industry. These are comprised of 2-4 layers of linear sheets of non-woven high strength fibers. Each layer of fiber sheets is alternately oriented in the 0° and 90° directions, and embedded in resin. After stacking two or four alternately oriented layers of fiber sheets, Thin, saran-like polyethylene film is also applied to both sides of the resultant non-woven UD fabric, when used in soft body armor. These materials are most often incorporated into vest designs with woven aramid fabrics. Indeed, at least one of the several global manufacturers of UD's recommends advantageous combinations of UD's and wovens for optimal performance. Also, it is commonly known that certain bullets can penetrate UD-based designs, unless woven ballistic fabrics are utilized on the strike face. Because they are stiffer, UD's generally provide more blunt trauma resistance than wovens, and many combinations of woven fabric-UD “hybrid” vest designs are presently being utilized. UD's are marketed by Honeywell under the names Spectra Shield (UHMWPE), Spectra Flex (UHMWPE), Spectra Shield Plus (UHMWPE) and Gold Flex (aramid), and by Dutch State Mines (DSM) under the name Dyneema (UHMWPE).

Quasi-Unidirectionals: U.S. Pat. No. 6,610,618 (Bottger, et al, Teijin Twaron. Aug. 26, 2003) and U.S. Pat. No. 6,861,378 (Cunningham, et al, Barrday, Mar. 1, 2005) each disclose woven fabrics designed to utilize weaving looms to produce ballistic fabrics with some of the characteristics of both wovens and unidirectionals.

The Teijin patent discloses two-ply laminates consisting of one fabric woven with high tensile ballistic fibers in the warp and light weight, low tensile polyester fibers (PE) in the fill and the second fabric woven with PET woven in the warp and high tensile ballistic fibers in the fill. The two wovens are then lightly laminated with a thin thermoplastic film between, and on each side of the two, oppositely woven layers.

The Barrday patent describes a woven fabric of relatively low denier nylon or polyester fibers with UD ballistic fibers “laid in” unidirectionally between each woven nylon warp and each woven fill yarn.

Vest Design Diversity: The wide variety of ballistic materials available has resulted in much diversity in how protective vests are designed. Each material has unique characteristics of ballistic penetration and blunt trauma resistance, both of which are required for soft body armor. Two or more materials are sometimes combined to work in concert with each other, sometimes synergistically. These are generally referred to as “hybrid” vests or “multi-component” vests.

Ballistic Standards: Ballistic standards usually specify minimum penetration performance requirements in terms of the different bullets and their velocities, and the maximum behind-armor deformation in the backing material allowed. The latter is thought by to be an indication of the blunt trauma protection afforded. Several different “threat levels,” or “protection levels” are usually described. Vests are usually tested on various clay test backings. To become “certified” aganst a particular standard, a vest design must stop a certain number of bullet impacts at the velocities and angles specified. Additionally, the vests must demonstrate that they resist behind the armor deformation in the clay backing at or below specified maximum “Back Face Signature” (BFS) depths (i.e. the depth of the dent in the clay as measured from the original plain of the clay before impact). Currently fielded US Police armor is certified against the US Department of Justice (DOJ), National Institute of Justice (NU) voluntary body armor standard NIJ STD-0101.04 “Ballistic Resistance of Police Body Armor,” as outlined below:

NIJ STD 0101.04 September, 2000
			Reference	Max. Impact		0 Deg. >	30 Deg. >
Threat Levels	Bullet	Bullet	Velocity	Energy	# Vests	Shots/	Shots/	Max.
Cal.	Wt. (gr)	Type	(Ft/Sec)	(Ft Lbs)	Tested	Panel	Panel	BFS
LEVEL I
.22 LR	40	RNL	1080, +/−30	109	2	4	2	44 mm
.380	95	FMJ	1055, +/−30	248	2	4	2	44 mm
LEVEL IIA
9 MM	124	FMJ	1120, +/−30	364	2	4	2	44 mm
.40 S & W	180	FMJ	1055, +/−30	470	2	4	2	44 mm
LEVEL II
9 MM	124	FMJ	1205, +/−30	420	2	4	2	44 mm
.357MAG.	158	SJSP	1430, +/−30	748	2	4	2	44 mm
LEVEL IIIA
9 MM SMG	124	FMJ	1430, +/−30	587	2	4	2	44 mm
.44 MAG.	240	JHP	1430, +/−30	1136	2	4	2	44 mm
LEVEL III
7.62 M80	148	FMJ	2780, +/−30	2594	2	6	0	44 mm
LEVEL IV
.30-06 M2 AP	166	FMJ	2880, +/−30	3121	2	1	0	44 mm
Special	*	*	*	*	*	*	*	44 mm
* = User Specified

All armors are wet conditioned under a 4″/hr. simulated rain shower for 3 minutes on each side, before being tested. The “04” test clay backing is Roma Plastilina #1 modeling clay. All bullets are hand loaded and fired from un-vented test barrels mounted on universal receivers. Velocities are measured by redundant chronographs placed between the test barrel and the target. Test velocities are intentionally above those found in actual use conditions, to ensure safety margins.

Threat levels I-IIIA are intended for soft concealable body armor designed to stop handgun bullets.

Levels III and IV are for armor designed to stop rifles. Levels III & IV require hard armor plate strike faces, normally comprised of steel or ceramic. Hard armor may be certified as either “stand alone”, or “in conjunction with” a specific soft armor backing.

Following a successful “pass-fail,” or “V-0” (the velocity at which no bullets may penetrate the armor) certification test as described above, the “04” standard also requires two benchmark V-50 “Ballistic Limit” tests using the 9 mm 124 gr. FMJ bullet. V-50 tests empirically determine the velocity at which 50% of the bullets will be stopped by the armor and 50% of the bullets will completely penetrate the armor.

V-50′s characteristically exceed V-0 velocities significantly. V-50 benchmarks are useful in determining safety margins, when comparing different designs, and can be used when evaluating used vs. new armor performances. V-50 tests are also very useful in establishing relative penetration resistance of one ballistic material vs. another or one vest design vs. another. V-50 benchmarks will generally measure 150-300 ft/sec higher than the V-0 “pass-fail” velocity for Level IIA-IIIA armors (Level I armors are not sold as they do not protect against today's street threats.) The most commonly used V-50 test method is the latest iteration of the US military specification MIL-662.

Body Armor Standards Evolution: Body armor standards have historically become more stringent over time, as ballistic threats increased and as perceived needs changed. The commonly used NIJ standard cited above has recently been significantly modified with the issuance of NIJ STD 0101.06 (“06”). Issued in July, 2008 and implemented in January, 2009 its many changes have cumulatively resulted in the greatest increase in test difficulty in history. Higher velocities, clustered shot patterns, closer edge hits, more aggressive bullets, artifically aged armor testing, and increased V-0, V-50 and blunt trauma performance requirements are among the sweeping changes. Unique, novel, different new materials and their applications are needed to meet the much tougher requirements while minimizing the predictable increases in weight, stiffness, cost and the subsequent wearability losses associated with the more difficult “06” standard. This invention has been shown to be one such novel new material that is useful in advancing vest design technologies.

BRIEF SUMMARY OF THE INVENTION

The field of the present invention is soft body armor. The objective of the present invention is to provide novel, unique woven anti-ballistic materials that have superior capability to entangle and ensnare handgun bullets and disperse their energy more laterally, thus providing improved pound-for-pound ballistic penetration resistance. A further objective of the invention is to improve the blunt trauma resistance and manufacturability of these fabrics in a manner that minimizes stiffness and maximizes fiber mobility. This has been accomplished by development of a novel new family of woven fabrics that are both faux-sateen and quasi-unidirectional fabrics, with random-like woven interlace points not previously known or expected to be effective in stopping bullets. With carefully chosen lamination techniques, said fabrics provide unexpectedly high ballistic penetration resistance. Blunt trauma resistance is also improved in an unanticipated manner. Unlike prior art that utilizes either low fiber and/or low fabric densities, with or without low filament densities, this invention uses relatively high fiber and fabric densities that effectively function at surprisingly high ballistic resistance levels. These fabrics contribute to vest wearability, as they facilitate the design of lighter, softer, more flexible and potentially moisture vapor breathable personal body armor.

The penetration resistance and blunt trauma performance of all currently available anti-ballistic fibers appear able to be improved by use of this invention. There is every reason to believe that future high tensile anti-ballistic fibers will also enjoy similar benefits.

Ballistic materials produced using the fabric design, production and lamination techniques described are most effective when used as a strike face over more traditional ballistic materials. Penetration resistance is enhanced as handgun bullets are more effectively cushioned, trapped and ensnared on or very near the strike face of the ballistic pack. Energy is dispersed more widely and more evenly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 are schematic drawings of various woven fabric alternatives based on the three basic weaves: plain, twill and satin. All four drawings depict vertical warp yarns (A) in black and horizontal fill yarns (B) in white. There are countless variations of these three basic weaves. For the purposes of these descriptions the word “counter,” or “move number” specifically refers to the number of fill ends each adjacent warp end interlace point shifts in the fabric. Plain, twill and satin weaves generally have consistent, or regular counter intervals across the fabrics and thus display consistent patterns.

Plain Weaves: FIG. 1 depicts a 1×1 plain weave fabric in which every other warp (machine direction) yarn (A) goes over and then under every other fill yarn (B). Likewise, every other fill yarn (B), or cross-machine direction yarn goes over and then under every other warp yarn. If the same number of warp ends per inch and fill picks per inch are used, the plain weave is said to be balanced. The vast majority of woven ballistic materials utilized today are balanced plain weaves.

FIG. 1A depicts another commonly used plain-woven ballistic fabric, the “basket weave. Basket weaves are plain weaves in which two or more yarns are placed in each warp end (A) and fill pick (B). FIG. 1A depicts a “2×2” basketweave. “2×2” basket weaves are known to be less ballistically efficient than “1×1” plain weaves. Commonly known plain weaves include most taffetas, oxford, baskets, half-baskets, ripstops, ducks etc.

Twill Weaves: FIG. 2 describes one of the second basic weaves, the twill. FIG. 2 is a schematic of a simple, “3×3” twill weave, although many variations are possible. Twills are characterized by diagonal lines from 15° to 75°. These are caused as warp (A) and fill yarns (B) float over two or more of their opposites, with the counter controlled at one or more regular intervals. FIG. 2 shows the simplest of these, a 3×3 balanced twill, with a counter of 1, shifting from left to right. Note the diagonal lines run from right to left at a 45° angle, and the back side of the fabric will be exactly opposite the front. Twills are considered even sided, warp faced, if more warp yarns appear on the face, or filling faced, if more fill yarns appear on the face. Twills can be multiple, broken (pattern interrupted) reversed, etc. Commonly known twill fabrics include serges, herringbones, checks, houndstooths, denim and gabardine. Twill fabrics have not seen much use in the anti-ballistic market, but balanced twills are quite popular for composite structures, where their improved comformability proves useful.

Satins/Sateens: FIG. 3 is a schematic of the third basic weave structure, the sateen. Satins/Sateens differ from twills in that no distinct geometric pattern is seen. If each warp yarn (A) floats over several fill yarns (B) the fabric is known as a satin. If each fill yarn (B) floats over several warp yarns (A) the fabric is known as a sateen, or filling faced satins. Note that a satin face will generate a sateen back, and vice versa as long as both the warp and fill yarns have the same densities. There are no diagonal, geometric patterns, as the interlace points are scattered to prevent patterning. A key requirement for any satin is that no two interlace points may touch—even diagonally—in order to avoid patterning. Satins are usually referred to by their harness number, which is always one more than the number of floats desired. FIG. 3 depicts a seven harness sateen (filling faced satin), in which each fill yarn (B) floats over six warp yarns (A), between single warp yarn (A) interlace points. Each counter, or move number is a “regular” 4, from left to right. “Regular” satins using four or six harnesses are not possible, because there is no single counter that will prevent interlace yarns from touching and forming a pattern, somewhere in the repeat. Satins and Sateens have not historically been seen to offer advantages over plain weaves for soft body armor.

Unidirectionals (UD): FIG. 4 is a breakaway diagram of a typical unidirectional material as frequently utilized in soft body armor. In this case a sheet of resin impregnated, non-woven UD fibers, C, is laid up in the vertical, 0°, or machine direction, and a second set of resin impregnated non-woven, UD fibers is laid up in the horizontal, 90°, or cross-machine direction. Sheets of polyethylene film, E, are placed over and under the two fiber matrixes, and the four layers are compressed together with enough heat to bond all the materials in a fiber reinforced composite non-woven fabric. Sometimes four layers of UD fibersheets are alternatively utilized, 0°, 90°, 0°, 90°, between the two outer film layers. As previously stated, it is widely held that optimum use of UD materials is in hybrid, or multi-component vest designs with wovens.

Quasi-UD Materials: At least two different quasi-UD ballistic materials are currently being utilized in the soft body armor market. FIG. 5 is a diagram borrowed from U.S. Pat. No. 6,861,378, disclosing a woven fabric featuring performance characteristics similar to UD materials. In this example very fine nylon or polyester materials (40-90 denier) are loosely woven in the warp, EW and Fill, EF, directions. Simultaneously, strong ballistic fibers (400-1500 denier) are laid in, in the warp, C, and fill, D directions, in a manner that the light weight woven scrim locks in the much thicker, “nearly” UD fibers. Resins may then be applied to more firmly lock the fibers together, as desired. Each layer of fabric thus becomes a woven fabric, with quasi-unidirectional high strength fibers in both the 0° (machine) and 90° (cross-machine) directions. One obvious disadvantage to this concept is that the light weight woven fibers add weight, without appreciable performance contribution.

FIG. 6 is a breakaway schematic of Twaron LFT SB-1, protected by U.S. Pat. No. 6,610,618. In this case, two similar, but oppositely constructed woven fabrics are produced, G and I, and then laminated with three layers of film, K, under heat and pressure, to form one, fiber-reinforced 0°, 90° quasi-UD composite material. Fabric G is woven with 863 denier Twaron T-2040 ballistic fibers, H, in the warp, and single ends of 126 denier polyester (PE) filament fibers in the fill, H. Each PE fiber, H, is spaced about 1 cm apart and every other fiber alternates sides. Constructed somewhat differently, Fabric I has the 863 denier Twaron, T-2040 fibers oriented in the cross machine fill direction, I, which are then woven pairs of 126 denier polyester (PE) fibers, J, in the warp direction. Each pair of PE fibers, J, is spaced about 1 mm apart and warp pair is woven at 3 mm intervals. Every other warp pair alternates sides. Because in each case the densities of the ballistic fibers are significantly higher that the PE fibers, the ballistic fibers lie in the two ply woven fabric laminate in a 0°, 90° nearly-UD orientation. Here again, a disadvantage to this concept is that the light weight woven fibers add weight, without appreciable performance contribution.

FIG. 7 is a schematic of one preferred embodiment of the present invention disclosed herein, and will be discussed in further detail below.

DETAILED DESCRIPTION OF THE INVENTION

As previously discussed, plain woven ballistic fabrics have been used since the modern soft body armor industry was founded in the early 70's. Plain weaves continue to be considered the best balance of properties for penetration and blunt trauma resistance vs. other weaves, and are overwhelmingly utilized wherever wovens appear in soft body armor. When properly designed and optimized their advantages are high pound-for-pound ballistic penetration resistance, good flexibility and wearability, good consistency, and acceptable blunt trauma. Their primary disadvantage is that “all-woven” vest designs tend to require at least some additional fabrication steps such as stitching and/or laminating through either ballistic pacs or sub-pacs. More importantly, optimizing plain woven fabric ballistic penetration resistance and wearability is generally accomplished with finer yarns and looser weaves, at the expense of blunt trauma resistance.

Since the early 1990's UD ballistic materials have come into progressively increased use. Their high resin contents and stiffness generally make them good choices as anti-blunt trauma elements in hybrid ballistic designs. During this period, several body armor standards have tended to increase their blunt trauma stringency at much faster rates than penetration resistance, helping to stimulate increased use of UD's. UD manufacturers such as Honeywell and Dutch State Mines generally recommend their use with woven ballistic materials, as opposed to by themselves. Another advantage for UD's is that they tend to neither need nor tolerate much additional fabrication such as stitching. Their disadvantages include stiffness negatively impacting wearability, the potential to de-laminate under mechanical action and the tendency to be vulnerable to certain bullets when used on the strike face of a vest design.

The Quasi-UD's have been developed by weavers attempting to re-capture market share from UD's, using novel unique new wovens with some of the advantages of UD's. Use of weaving looms as previously described has also proven to be effective in avoiding infringement of a myriad of UD patents. Historically, Quasi-UD's have tended to have similar advantage—and disadvantages of UD's including vulnerability to certain bullets when used as a strikeface.

Capitalization of the increased fiber mobility and lower weave crimp in “long float” satins or twills has long been the object of visionary ballistic fabric engineers. However, very little success has been realized. Prior attempts have simply not produced practical results. Although some experiments have yielded marginal increases in ballistic resistance, the difficult handling and poorer blunt trauma resistance of such “long float” fabrics have resulted in little commercial success.

For the purposes of this application, any reference to a sateen material should be taken to refer to either a satin or a sateen material. In the context of this discussion, since warp and fill yarns are of the same density, one is merely the flip side of the other.

An unexpected ballistic penetration resistance performance advantage has been discovered with the design, production and testing of a new kind of irregular, variable counter, long float woven ballistic fabrics that can be classified both as “faux-sateen” and “quasi-UD.” Subsequent proprietary lamination of at least two such layers results in good manufacturability, sometimes greater increases in ballistic penetration resistance, and improved blunt trauma resistance. Performance and wearability characteristics superior to present woven, UD and quasi-UD ballistic materials have been demonstrated for this novel, new faux-sateen, and quasi-UD, material design.

FIG. 7 shows a preferred embodiment of the present invention, found to be ideal for use on the strike face of soft ballistic vest designs. The illustration shows a schematic of a Faux-Sateen, Quasi-UD fabric face. In this particular example, each filling yarn floats horizontally over five warp yarns. On the back, or course, the opposite is true, as each warp yarn floats vertically over five filling yarns. Irregular, variable counters (move numbers) are used for interlace shifts (see #'s 1, 2, 3, 4, 5, and 6, below) to accomplish two different characteristics, both of which are thought to be instrumental in achieving the surprisingly improved ballistic penetration resistance:

• • 1. No two (or more) adjacent interlace yarns ever actually touch. The irregularity of the interlacing also disqualifies the fabric for classification as either a plain, twill or “regular” sateen. The fact that this material cannot be classified as a plain weave is self evident. Even though some mild, shifting and “broken” patterning is evident, the lack of regular, consistent geometric patterning means the fabric cannot be classified as a twill. Although the face of the sample fabric most closely resembles a sateen (and the back a satin), the lack of regular counters and the mild patterning disqualifies it as a sateen. Hence the phrase “Faux-Sateen” has been coined as one way to best describe this new fabric It could also be classified a “broken sateen.” Since both the fill yarns on the face and the warp yarns on the back have long floats, with relatively few interlace points (i.e. low weave crimp), the fabric also fits the classification of a novel unique new form of “Quasi-UD.” The improved ballistic resistance is believed to be the result of a new balance of the more advantageous characteristics of all three current types of ballistic materials; wovens, UD and quasi-UD.
  • 2. Short, “broken geometric” yarn interlace pattens, L,M, N, & O (below), are present in a symmetrical and off-set manner. The slopes of these mild patterns are also varied. These characteristics have been found to demonstrate both the high fiber mobility characteristic of high penetration resistance and the no-to-low weave crimp associated with UD's and quasi-UD's. An assymetrical new, “stick-slip” behavior over small areas of adjacent fibers during ballistic impact is observed, along with unusually long fiber distortion lines. The latter is a clear demonstration of superior energy absorption.

After appropriate lamination to stabilize the fabric for handling, while minimizing loss in fiber mobility, unexpected improvements in ballistic resistance result. When a few plies of this material is utilized on the strike face in combination with other woven and/or UD, and/or quasi-UD ballistic materials underneath, improved performance and wearability is accomplished. Bullet impacts are seen to be more gently cushioned and mushroomed, while firmly decelerating projectiles in an improved manner that results in larger mushrooms and increased fiber entanglement with the bullet. Hence impact energy is spread more widely (laterally), penetration resistance is increased, back face signatures are larger in diameter, and more importantly, less deep. Larger, but far less severe bruising during a ballistic impact results. The tendency of high impact energy magnum bullets to turn inside out, shed their skirts, and form a core of high energy concentration leading to penetrations and/or secondary back face cavities is reduced. Bullets are thus trapped and entangled in the strike face plies, leaving the remainder of the ballistic pack the heightened ability to disperse and absorb energy.

Returning to FIG. 7, L, M, N, and O illustrates four different mild, broken geometric patterns, as previously discussed and described below:

Warp yarn interlace points marked L show a set of three gently descending warp yarn interlace points to the right. Each point in the pattern is spaced one warp yarn apart and each pattern of three is spaced vertically, five fill yarns apart. Without magnification, these mild patterns disappear, leaving the visual impression of a totally randomized fabric.

Warp yarn interlace points marked M show a set of three gently descending warp yarn interlace points to the left. Each point in the pattern is spaced one warp yarn apart and each pattern of three is spaced vertically, five fill yarns apart.

Warp yarn interlace points marked N show a set of three steeply descending warp yarn interlace points to the left. Each point in the pattern is in the adjacent warp yarn and each pattern of three is spaced vertically, five fill yarns apart.

Warp yarn interlace points marked O show a set of sets three steeply descending warp yarn interlace points to the right. Each point in the pattern is in the adjacent warp yarn and each pattern of three is spaced vertically, five fill yarns apart.

Returning again to FIG. 7, #'s 1, 2, 3, 4, 5, & 6 illustrate the important novelty of inconsistent counters, or move numbers, and how this could become confusing to one less than fully schooled in the science of weaving. For example, the counter sequence can be seen quite differently, depending on where one starts mapping the fabric. This is best illustrated by demonstrating the six different and irregular counter sequences that exist in this example of one such preferred embodiment:

Counter Cycles Starting at Warp Yarn Interlace Point #1, 2, 3, 4, 5, & 6:

Mapping started from point #1, rising from left to right: 4,3,2,2,3

Mapping started from point #2, rising from left to right: 3,2,2,3,4

Mapping started from point #3, rising from left to right: 2,2,3,4,4

Mapping started from point #4, rising from left to right: 2,3,4,4,3

Mapping started from point #5, rising from left to right: 3,4,4,3,2

Mapping started from point #6, rising from left to right: 4,4,3,2,2

Another important distinction from prior art is that no more than two adjacent (consecutive) counters are identical. A further distinction from prior art is that at least three different counter cycles are utilized.

This combination of long fiber floats and broken, irregular interlace geometry has been found to significantly increase ballistic resistance, as the fibers are able to absorb and transmit energy faster and farther while gently cushioning the bullet and mushrooming it widely without excessive bullet damage. Hence a novel and unique new presentation of high strength fibers (to the bullet) of equal and consistent numbers of long float warp fibers (back or face), and equally long float fill fibers (face or back) is created, in balanced numbers. Although relatively high in fiber density, the very high fiber mobility provided by this novel fabric design, and its irregular, variable counters are seen to be two main contributors to improved ballistic penetration resistance.

This invention also benefits from its partial stabilization by carefully chosen lamination technology, to facilitate handling in vest production, without the negative impact on penetration resistance usually seen in the prior art due to resin impairment of fiber mobility. One known method is by lightly laminating two or more layers together using a discontinuous thermoplastic lace film. The lace film is placed between each two layers to be laminated and then the layers are fed between heated drums under relatively low pressure. The amount of lamination can be varied to balance penetration and blunt trauma needs, by varying the thickness and or substance of the lace and/or the temperature and/or pressure of the drums. Another effective method that has been demonstrated is by use of a third party, proprietary spray resin application followed by heat curing under pressure.

The resultant faux-sateen and quasi-UD laminant maintains its superior ability to trap and ensnare bullets. Used on the strike face over conventional ballistic materials the effect is to gently slow and cushion the bullets, keeping them closer to the front of the ballistic pack. Hence more energy is spread laterally, and the layers beneath may or may not be re-engineered to more effectively resist blunt trauma. Another ideal utilization appears to be when sandwiched between one or more types of conventional woven and/or UD anti-ballistic materials.

Example 1: A 1500 denier para-aramid fabric woven 27×26 results in a high density, 20.8 oz./sq. yd² (osy), 2-ply laminate. Two to three layers of this material placed on the strike face or sandwiched in between conventional lightweight ballistic materials has been found to be highly effective in “cushioning” and “hanging onto” NIJ STD-0101.04 ans NIJ STD-0101.06 test bullets, forcing them to mushroom more widely and and distribute their energy more broadly.

Example 2: An 840 denier para-aramid microfilament fabric woven 29×28 results in a 13.4 osy, 2-ply laminate. Three-four layers of this material placed on the strike face or sandwiched inside conventional plain woven ballistic materials is quite useful in stopping and holding NIJ STD 0101.04 and NIJ STD-0101.06 test rounds, as well as many other handgun test rounds.

These materials are not found to be vulnerable to certain law enforcement bullets which other UD's and quasi-UD's have been found to be vulnerable to, when use on the vest strike face.

The above examples are not meant in any way to limit the application of this invention in terms of fiber deniers or types, weave counts, laminate characteristics or vest designs. It is anticipated that all fiber types and deniers presently utilized by the anti-ballistic garment industry will benefit from the application of these inventions.

Claims

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/yd2.

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/yd2.

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.