Ballistic resistant fabric

Abstract

A ballistic resistant woven fabric utilized in the construction of ballistic resistant protective items is provided. The ballistic resistant woven fabric has a warp which has at least three adjacent fibers in which one fiber in the warp is constructed of a first material and two other adjacent fibers are constructed of a second material. The ballistic resistant woven fabric has a weft which has at least three other adjacent fibers in which one fiber in the weft is constructed of the first material and the two other fibers adjacent to the one fiber in the weft are constructed of the second material.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This is a continuation-in-part of application Ser. No. 09/510,730, filed Feb. 22, 2000.

FIELD OF THE INVENTION

[0002] This invention relates to a ballistic resistant fabric, and more particularly a ballistic resistant fabric that utilizes poly(p-phenylene-2,6-benzobisoxazole).

BACKGROUND OF THE INVENTION

[0003] Numerous ballistic resistant fibers and woven fabrics have been utilized for the construction of ballistic resistant garments. It has been a desire over the years in the ballistic garment industry to strive to improve the reliability and stopping capability of a garment and yet, not compromise wearability. Undesirable wearability may too often lead to early removal of the protective garment or not wearing it at all.

[0004] As improved stronger ballistic resistant fibers are developed, less total weight of the fiber is needed in producing the ballistic resistant fabric that will maintain the needed reliability and stopping capability of a garment. Utilization of these improved fibers result in less weight and bulk to the ballistic resistant fabric.

[0005] One of these fibers that has been developed in recent years is poly(p-phenylene-2,6benzobisoxazole) (PBO) or commercially known as Zylon®, a trademark of the Toyobo Co., Ltd., of Osaka, Japan. This fiber is known for its high strength characteristics however, by the nature and cost of production of this fiber, the fiber is generally significantly more costly than other ballistic resistant fibers. As a result, the fabrics manufactured with this fiber are traditionally more expensive. Thus, in an era of improving ballistic resistant fibers that result in enhancing wearability, increased cost to the user becomes a factor to the wearability of the fabric. Accordingly, a reduction in the cost of producing such desirable fabrics is needed.

[0006] The utilization of PBO fiber in the construction of ballistic resistant fabric has been performed and such fabric has been used in the manufacture of ballistic resistant vests. The ballistic resistant vests employ PBO fibers in a thirty by thirty, warp and weft ends per inch in a plain weave. Emphasis has also been placed on increasing the number of weft and warp PBO fibers beyond thirty per inch, disadvantageously requiring increased amounts of the ballistic resistant material to be used in producing the costly fabric. In addition, PBO fibers have been used in all of the fibers in either the warp or the weft of a woven fabric and a different type of fiber material for all of the fibers in either the crossing weft or warp is used where the PBO fiber is not located. Disadvantageously, however, this does not provide for a homogeneous mix of the fibers and ballistic stopping capabilities, at times, are not readily improved.

SUMMARY OF THE INVENTION

[0007] A ballistic resistant woven fabric is provided for use in ballistic resistant protective products which is cost efficient and economically advantageous. A ballistic resistant woven fabric for use in the construction of ballistic resistant protective items has a warp with at least three adjacent fibers in which one fiber in the warp is constructed of a first material and two other adjacent fibers are constructed of a second material. The ballistic resistant woven fabric has a weft which has at least three other adjacent fibers in which one of the adjacent fibers in the weft is constructed of the first material and the two other fibers adjacent to the one fiber in the weft are constructed of the second material.

DETAILED DESCRIPTION

[0008] Referring to FIG. 1, a sheet of ballistic resistant fabric 110 which may be utilized in the construction of ballistic resistant protective items such as ballistic resistant garments, helmets, vehicles and the like is shown having a plain weave 112. Warp 114 in the plain weave 112 of the sheet of ballistic resistant fabric 110 has consecutively positioned patterns of three adjacent fibers 120, 122A, 122B. In the three adjacent fibers 120, 122A, 122B in the warp 114, one fiber 120 is constructed of a first material and the other two adjacent fibers 122A, 122B are constructed of a second material. Weft 116 in the plain weave 112 of the sheet of ballistic resistant fabric 110 also has consecutively positioned patterns of three other adjacent fibers 124, 126A, 126B. In the three other adjacent fibers 124, 126A, 126B, one fiber 124 in the weft 116 is constructed of the first material and the two other fibers 126A, 126B adjacent to the one fiber 124 in the weft 116 are constructed of the second material. The two different types of fiber materials employed, in some examples, may selectively have different deniers. In one example, the deniers of one of the types of fiber of one material and the denier of the other type for the other material may selectively have a ratio which does not exceed 2.0 with the larger denier positioned in the numerator and the smaller denier positioned in the denominator. In some examples, a ratio of 1.25 or less achieved.

[0009] In the example in FIG. 1, the first material, that certain of the warp fibers 120 and the weft fibers 124 are constructed of, may selectively be poly(p-phenylene-2,6-benzobisoxazole)(PBO) material. PBO is a rigid-rod isotropic liquid crystal polymer high performance fiber made by Toyobo Co., Ltd. of Osaka, Japan and is commonly sold under the trademark name Zylon®. The PBO employed for fibers 120, 124 may selectively have a denier within the range of 200 to 830 denier. Additionally, in the example in FIG. 1, the second material, that certain of the adjacent fibers 122A, 122B in the warp 112 and certain of the adjacent fibers 126A, 126B in the weft 114 are constructed of, may selectively be an aramid material. For instance, microfilament poly(paraphenylene-terephthalamide)(microfilament PPP-T) which is commonly known under the trademark name Twaron® sold by Teijin Twaron BV or poly(paraphenylene-terephthalamide)(PPP-T) which is commonly known under the trademark names Kevlar® or Protera™ which are sold by E. I. duPont de Nemours and Company of Wilmington, Del. may be aramids selectively employed. Microfilament PPP-T (or Twaron®) is a high tensile strength aramid microfilament fiber. The microfilament PPP-T material used in fibers 122A, 122B, 126A, 126B may selectively have a denier in the range of 200 to 830 denier. The PPP-T (Kevlar® or Protera®) which may be suitably employed as the material in fibers 122A, 122B, 126A, 126B also may selectively range in denier from 200 to 830 denier. Other aramid materials may selectively be utilized.

[0010] As seen in FIG. 1, the ballistic resistant woven fabric 110 has a plain weave 112 which is also a balanced weave. Alternatively, an imbalanced plain weave may selectively be employed. The number of fibers 120, 122A, 122B of the warp 114 ranges from 20 to 30 fibers per inch and the number of fibers 124, 126A, 126B of the weft 116 also ranges from 20 to 30 fibers per inch. One or more of any of the warp fibers 120, 122A, 122B may selectively be twisted in which the number of twists in the warp fiber 120, 122A, 122B range from one-half of a revolution per linear inch to six revolutions per linear inch in the fiber. One or more of any of the adjacent weft fibers 124, 126A, 126B may also selectively be twisted with the number of twists in the weft fiber(s) 124, 126A, 126B ranging from one-half of a revolution per linear inch to six revolutions per linear inch of the fiber.

[0011] Still referring to FIG. 1, the three adjacent fibers 120, 122A, 122B in the warp 114 form a pattern of fibers in which the one fiber 120 is formed of a different material than the material for fibers 122A, 122B and the pattern of the three adjacent fibers continues consecutively. As seen in FIG. 1, the ballistic resistant woven fabric 110 has a plurality of patterns of adjacent groups of fibers 120, 122A, 122B positioned consecutively in the warp 114 in which one of the warp fibers 120 is formed of one material and the two other warp fibers 122A, 122B are formed of another material. The groups of three adjacent fibers 124, 126A, 126B in the weft 116 form another pattern comprised of a group of three adjacent fibers with one weft fiber 124 formed of one material and the other two weft fibers 126A, 126B formed of another material. The plain weave 112 of the ballistic resistant woven fabric 110 has a plurality of other patterns of adjacent weft fibers 124, 126A, 126B positioned consecutively in the weft 116 in which one of the weft fibers 124 is formed of one material and the other two adjacent weft fibers 126A, 126B are formed of another material.

[0012] In one approach, one of the warp fibers 120 in each group is constructed of PBO and the other two warp fibers 122A, 122B in the consecutively repeating groups of three fibers in the warp 114 are constructed of microfilament PPP-T; the one weft fiber 124 is also constructed of PBO and the two other adjacent weft fibers 126A, 126B for each group are also constructed of microfilament PPP-T. In an alternative approach, the one material used for the one type of warp fibers 120 and the one type of weft fibers 124 is PBO and the other or second material which is used to construct the other type of warp fibers 122A, 122B and the other type of weft fibers 126A, 126B is PPP-T (Kevlar®/Protera® material). The warp 114 of the plain weave has a pattern with a PBO fiber 120 followed by two fibers 122A, 122B (formed of either PPP-T or microfilament PPP-T); a next pattern of a PBO fiber 120 next to two PPP-T or microfilament PPP-T fibers 122A, 122B, then follows with these patterns continuing in the warp. The weft 116 of the plain weave also has a pattern of a PBO fiber 124 followed by two PPP-T or microfilament PPP-T fibers 126A, 126B, with a next pattern of a PBO fiber 124 next to two (PPP-T or microfilament PPP-T) fibers 126A, 126B following thereafter with the patterns continuing in the weft. Referring now to FIG. 2, a sheet of ballistic resistant fabric 210 which may be utilized in the construction of ballistic resistant protective items is shown having a sateen weave 212. Warp 214 in the sateen weave 212 of the sheet of ballistic resistant fabric 210 has consecutively positioned patterns of three adjacent fibers 220, 222A, 222B. In the three adjacent fibers 220, 222A, 222B in the warp 214, one fiber 220 is constructed of a first material (such as PBO) and the other two adjacent fibers 222A, 222B are constructed of a second material (such as either PPP-T or microfilament PPP-T). Weft 216 in the sateen weave 212 of the sheet of ballistic resistant fabric 210 also has consecutively positioned patterns of three other adjacent fibers 224, 226A, 226B. In the three other adjacent fibers 224, 226A, 226B, one fiber 224 in the weft 216 is constructed of the first material (such as PBO) and the two other fibers 226A, 226B adjacent to the one fiber 224 in the weft 216 are constructed of the second material (such as either PPP-T or microfilament PPP-T). The two different types of fiber materials employed, in some examples, may selectively have different deniers. In one example, the deniers of one of the types of fiber of one material and the denier of the other type for the other material may selectively have a ratio which does not exceed 2.0 with the larger denier positioned in the numerator and the smaller denier positioned in the denominator. In some examples, a ratio of 1.25 or less achieved.

[0013] In the example in FIG. 2, the first material, that certain of the warp fibers 220 and the weft fibers 224 are constructed of, may selectively be poly(p-phenylene-2,6-benzobisoxazole)(PBO) material. The PBO employed for fibers 220, 224 may selectively have a denier within the range of 200 to 830 denier. Additionally, in the example in FIG. 2, the second material, that certain of the adjacent fibers 222A, 222B in the warp 212 and certain of the adjacent fibers 226A, 226B in the weft 214 are constructed of, may selectively be an aramid material. For instance, microfilament poly(paraphenylene-terephthalamide)(microfilament PPP-T) which is commonly known under the trademark name Twaron® or poly(paraphenylene-terephthalamide)(PPP-T) which is commonly known under the trademark names Kevlar® or Protera® may be aramids selectively employed. The microfilament PPP-T (Twaron®) material used in fibers 222A, 222B, 226A, 226B may selectively have a denier in the range of 200 to 830 denier. The PPP-T (Kevlar® or Protera®) which may be alternatively employed as the material in fibers 222A, 222B, 226A, 226B also may selectively range in denier from 200 to 830 denier. Other aramids may also selectively be employed.

[0014] As seen in FIG. 2, the ballistic resistant woven fabric 210 has a sateen weave 212 which is also a balanced weave. Alternatively, an imbalanced sateen weave may selectively be employed. The number of fibers 220, 222A, 222B of the warp 214 ranges from 20 to 30 fibers per inch and the number of fibers 224, 226A, 226B of the weft 216 also ranges from 20 to 30 fibers per inch. The total sum of fibers in an inch of the warp 214 plus an inch of the weft 216 is less than sixty. One or more of any of the warp fibers 220, 222A, 222B in a group may selectively be twisted in which the number of twists in the warp fiber 220, 222A, 222B range from one-half of a revolution per linear inch to six revolutions per linear inch in the fiber. One or more of any of the adjacent weft fibers 224, 226A, 226B in a group may also selectively be twisted with the number of twists in the weft fiber(s) 224, 226A, 226B ranging from one-half of a revolution per linear inch to six revolutions per linear inch of the fiber.

[0015] As further seen in FIG. 2, the sateen weave 212 begins with a warp fiber passing over a first weft fiber and then passes under the next two adjacent weft fibers. The warp fiber continues to repeat thereafter passing over a weft fiber and passing under the next two weft fibers. As will be appreciated by those skilled in the art, the next adjacent warp fiber then is positioned under the first two weft fibers and then over the following weft fiber and continues to repeat this pattern. The third consecutive warp fiber passes under the first weft fiber, over the next weft fiber and under the next following weft fiber. The third consecutive warp fiber then repeats this pattern. The overall weaving pattern then repeats itself as seen in FIG. 2.

[0016] Still referring to FIG. 2, the three adjacent fibers 220, 222A, 222B in the warp 214 form a pattern of fibers in which the one fiber 220 is formed of a different material than the material for fibers 222A, 222B and the pattern of the three adjacent fibers continues consecutively. As seen in FIG. 2, the ballistic resistant woven fabric 210 has a plurality of patterns of adjacent groups of fibers 220, 222A, 222B positioned consecutively in the warp 214 in which one of the warp fibers 220 is formed of one material and the two other warp fibers 222A, 222B are formed of another material. The groups of three adjacent fibers 224, 226A, 226B in the weft 216 form another pattern comprised of a group of three adjacent fibers with one weft fiber 224 formed of one material and the other two weft fibers 226A, 226B formed of another material. The sateen weave 212 of the ballistic resistant woven fabric 210 has a plurality of other patterns of adjacent weft fibers 224, 226A, 226B positioned consecutively in the weft 216 in which one of the weft fibers 224 is formed of one material and the other two adjacent weft fibers 226A, 226B are formed of another material.

[0017] In one approach, one of the warp fibers 220 in each group is constructed of PBO and the other two warp fibers 222A, 222B in the consecutively repeating groups of three fibers in the warp 214 are constructed of microfilament PPP-T; the one weft fiber 224 is also constructed of PBO and the two other adjacent weft fibers 226A, 226B for each group are also constructed of microfilament PPP-T. In an alternative approach, the one material used for the one type of warp fibers 220 and the one type of weft fibers 224 is PBO and the other or second material which is used to construct the other type of warp fibers 222A, 222B and the other type of weft fibers 226A, 226B is PPP-T (Kevlar®/Protera® material). The warp 214 of the sateen weave has a pattern with a PBO fiber 220 followed by two fibers 222A, 222B (formed of either PPP-T or microfilament PPP-T); a next pattern of a PBO fiber 220 next to two PPP-T or microfilament PPP-T fibers 222A, 222B, then follows with these patterns continuing in the warp. The weft 216 of the sateen weave also has a pattern of a PBO fiber 224 followed by two PPP-T or microfilament PPP-T fibers, 226A, 226B, with a next pattern of a PBO fiber 224 next to two (PPP-T or microfilament PPP-T) fibers 226A, 226B following thereafter with the patterns continuing in the weft.

[0018] Referring now to FIG. 3, a sheet of ballistic resistant fabric 310 which may be utilized in the construction of ballistic resistant protective items is shown having a venetian weave 312. Warp 314 in the venetian weave 312 of the sheet of ballistic resistant fabric 310 has consecutively positioned patterns of three adjacent fibers 320, 322A, 322B. In the three adjacent fibers 320, 322A, 322B in the warp 314, one fiber 320 is constructed of a first material (such as PBO) and the other two adjacent fibers 322A, 322B are constructed of a second material (such as an aramid, for example PPP-T or microfilament PPP-T). Weft 316 in the venetian weave 312 of the sheet of ballistic resistant fabric 310 also has consecutively positioned patterns of three other adjacent fibers 324, 326A, 326B. In the three other adjacent fibers 324, 326A, 326B, one fiber 324 in the weft 316 is constructed of the first material (such as PBO) and the two other fibers 326A, 326B adjacent to the one fiber 324 in the weft 316 are constructed of the second material (for instance aramid material such as PPP-T or microfilament PPP-T). The two different types of fiber materials employed, in some examples, may selectively have different deniers. In one example, the deniers of one of the types of fiber of one material and the denier of the other type for the other material may selectively have a ratio which does not exceed 2.0 with the larger denier positioned in the numerator and the smaller denier positioned in the denominator. In some examples, a ratio of 1.25 or less achieved.

[0019] In the example in FIG. 3, the first material, that certain of the warp fibers 320 and the weft fibers 324 are constructed of, may selectively be poly(p-phenylene-2,6-benzobisoxazole)(PBO) material. The PBO employed for fibers 320, 324 may selectively have a denier within the range of 200 to 830 denier. Additionally, in the example in FIG. 3, the second material, that certain of the adjacent fibers 322A, 322B in the warp 312 and certain of the adjacent fibers 326A, 326B in the weft 314 are constructed of, may selectively be an aramid material. For example, microfilament poly(paraphenylene-terephthalamide)(microfilament PPP-T) which is commonly known under the trademark name Twaron® or poly(paraphenylene-terephthalamide)(PPP-T) which is commonly known under the trademark names Kevlar® or Protera® may selectively be employed. The microfilament PPP-T (Twaron®) material used in fibers 322A, 322B, 326A, 326B may selectively have a denier in the range of 200 to 830 denier. The PPP-T (Kevlar® or Protera®) which may be alternatively employed as the material in fibers 322A, 322B, 326A, 326B also may selectively range in denier from 200 to 830 denier.

[0020] As seen in FIG. 3, the ballistic resistant woven fabric 310 has a venetian weave 312 which is also a balanced weave. Alternatively, an imbalanced venetian weave may selectively be employed. The number of fibers 320, 322A, 322B of the warp 314 ranges from 20 to 30 fibers per inch and the number of fibers 324, 326A, 326B of the weft 316 also ranges from 20 to 30 fibers per inch. The total sum of fibers in an inch of the warp 314 plus an inch of the weft 316 is less than sixty. One or more of any of the warp fibers 320, 322A, 322B in a group may selectively be twisted in which the number of twists in the warp fiber 320, 322A, 322B range from one-half of a revolution per linear inch to six revolutions per linear inch in the fiber. One or more of any of the adjacent weft fibers 324, 326A, 326B in a group may also selectively be twisted with the number of twists in the weft fiber(s) 324, 326A, 326B ranging from one-half of a revolution per linear inch to six revolutions per linear inch of the fiber.

[0021] As further seen in FIG. 3, the venetian weave has a first warp fiber passing over three weft fibers and under the next two weft fibers, with the first warp fiber repeating the over three/under two pattern thereafter. As will be appreciated by those skilled in the art, the next or second warp fiber for the venetian weave passes over the first weft fiber, then under the next two weft fibers and over the following two weft fibers and repeats this pattern thereafter. The third warp fiber begins under the first weft fiber and over the next three weft fibers and under the following weft fiber, repeating thereafter. The fourth warp fiber begins by passing over the first two weft fibers, under the next two weft fibers and over the following weft fiber and thereafter repeating the pattern. Finally, a fifth adjacent warp fiber passes under the first two weft fibers and then over the next three weft fibers, repeating the pattern thereafter. The overall venetian weaving pattern then repeats itself throughout the fabric.

[0022] Still referring to FIG. 3, the three adjacent fibers 320, 322A, 322B in the warp 314 form a pattern of fibers in which the one fiber 320 is formed of a different material than the material for fibers 322A, 322B and the pattern of the three adjacent fibers continues consecutively. As seen in FIG. 3, the ballistic resistant woven fabric 310 has a plurality of patterns of adjacent groups of fibers 320, 322A, 322B positioned consecutively in the warp 314 in which one of the warp fibers 320 is formed of one material and the two other warp fibers 322A, 322B are formed of another material. The groups of three adjacent fibers 324, 326A, 326B in the weft 316 form another pattern comprised of a group of three adjacent fibers with one weft fiber 324 formed of one material and the other two weft fibers 326A, 326B formed of another material. The venetian weave 312 of the ballistic resistant woven fabric 310 has a plurality of other patterns of adjacent weft fibers 324, 326A, 326B positioned consecutively in the weft 316 in which one of the weft fibers 324 is formed of one material and the other two adjacent weft fibers 326A, 326B are formed of another material.

[0023] In one approach, one of the warp fibers 320 in a group is constructed of PBO and the other two warp fibers 322A, 322B in the consecutively repeating groups of three fibers in the warp 314 are constructed of microfilament PPP-T; the one weft fiber 324 is also constructed of PBO and the two other adjacent weft fibers 326A, 326B for each group are also constructed of microfilament PPP-T. In an alternative approach, the one material used for the one type of warp fibers 320 and the one type of weft fibers 324 is PBO and the other or second material which is used to construct the other type of warp fibers 322A, 322B and the other type of weft fibers 326A, 326B is PPP-T (Kevlar®/Protera® material). The warp 314 of the venetian weave has a pattern with a PBO fiber 320 followed by two fibers 322A, 322B (formed of either PPP-T or microfilament PPP-T); a next pattern of a PBO fiber 320 next to two PPP-T or microfilament PPP-T fibers 322A, 322B, then follows with these patterns continuing in the warp. The weft 316 of the venetian weave also has a pattern of a PBO fiber 324 followed by two PPP-T or microfilament PPP-T fibers, 326A, 326B, with a next pattern of a PBO fiber 324 next to two (PPP-T or microfilament PPP-T) fibers 326A, 326B following thereafter with the patterns continuing in the weft.

[0024] Referring now to FIG. 4, a sheet of ballistic resistant fabric 410 which may be utilized in the construction of ballistic resistant protective items is shown having a corkscrew weave 412. Warp 414 in the corkscrew weave 412 of the sheet of ballistic resistant fabric 410 has consecutively positioned patterns of three adjacent fibers 420, 422A, 422B. In the three adjacent fibers 420, 422A, 422B in the warp 414, one fiber 420 is constructed of a first material (such as PBO) and the other two adjacent fibers 422A, 422B are constructed of a second material (such as an aramid, for example PPP-T or microfilament PPP-T). Weft 416 in the corkscrew weave 412 of the sheet of ballistic resistant fabric 410 also has consecutively positioned patterns of three other adjacent fibers 424, 426A, 426B. In the three other adjacent fibers 424, 426A, 426B, one fiber 424 in the weft 416 is constructed of the first material (such as PBO) and the two other fibers 426A, 426B adjacent to the one fiber 424 in the weft 416 are constructed of the second material (such as an aramid). The two different types of fiber materials employed, in some examples, may selectively have different deniers. In one example, the deniers of one of the types of fiber of one material and the denier of the other type for the other material may selectively have a ratio which does not exceed 2.0 with the larger denier positioned in the numerator and the smaller denier positioned in the denominator. In some examples, a ratio of 1.25 or less achieved.

[0025] In the example in FIG. 4, the first material, that certain of the warp fibers 420 and the weft fibers 424 are constructed of, may selectively be polyp-phenylene-2,6-benzobisoxazole)(PBO) material. The PBO employed for fibers 420, 424 may selectively have a denier within the range of 200 to 830 denier. Additionally, in the example in FIG. 4, the second material, that certain of the adjacent fibers 422A, 422B in the warp 412 and certain of the adjacent fibers 426A, 426B in the weft 414 are constructed of, may selectively be aramid material. For example, microfilament poly(paraphenylene-terephthalamide)(microfilament PPP-T) which is commonly known under the trademark name Twaron® or poly(paraphenylene-terephthalamide)(PPP-T) which is commonly known under the trademark names Kevlar® or Protera® may selectively be employed. The microfilament PPP-T (Twaron® ) material used in fibers 422A, 422B, 426A, 426B may selectively have a denier in the range of 200 to 830 denier. The PPP-T (Kevlar® or Protera®) which may be alternatively employed as the material in fibers 422A, 422B, 426A, 426B also may selectively range in denier from 200 to 830 denier. Other aramids may also selectively be employed.

[0026] As seen in FIG. 4, the ballistic resistant woven fabric 410 has a corkscrew weave 412 which is also a balanced weave. Alternatively, an imbalanced venetian weave may selectively be employed. The number of fibers 420, 422A, 422B of the warp 414 ranges from 23 to 29 fibers per inch and the number of fibers 424, 426A, 426B of the weft 416 also ranges from 23 to 29 fibers per inch. One or more of any of the warp fibers 420, 422A, 422B in a group may selectively be twisted in which the number of twists in the warp fiber 420, 422A, 422B range from one-half of a revolution per linear inch to six revolutions per linear inch in the fiber. One or more of any of the adjacent weft fibers 424, 426A, 426B in a group may also selectively be twisted with the number of twists in the weft fiber(s) 424, 426A, 426B ranging from one-half of a revolution per linear inch to six revolutions per linear inch of the fiber.

[0027] The five end weft corkscrew weave of FIG. 4 begins with a first warp fiber passing over two first weft fibers, under the next weft fiber, over the following weft fiber and then under the fifth weft fiber, thereafter repeating. The second warp fiber passes under the first weft fiber, over the second, under the third and over the fourth and fifth weft fibers, thereafter repeating. The third warp fiber passes under the first weft fiber, over the second and third, under the fourth and over the fifth weft fiber, thereafter repeating. The fourth warp fiber passes over the first weft fiber, under the second, over the third under the fourth and over the fifth weft fiber, thereafter repeating. Finally, the fifth warp fiber passes over the first weft fiber, under the second, over the third and fourth weft fibers and under the fifth weft fiber, thereafter repeating. As will be appreciated by those in the art, this overall weaving pattern then repeats itself for the five end weft corkscrew weave. As seen in FIG. 4, the fibers are arranged in a five end weft corkscrew weave 412. Other corkscrew weaves which may selectively be employed for the woven ballistic resistant fabric 410 material include: seven end weft corkscrew weave; seven end warp corkscrew weave; nine end weft corkscrew weave; nine end warp corkscrew weave; and thirteen shaft corkscrew weave.

[0028] Still referring to FIG. 4, the three adjacent fibers 420, 422A, 422B in the warp 414 form a pattern of fibers in which the one fiber 420 is formed of a different material than the material for fibers 422A, 422B and the pattern of the three adjacent fibers continues consecutively. As seen in FIG. 4, the ballistic resistant woven fabric 410 has a plurality of patterns of adjacent groups of fibers 420, 422A, 422B positioned consecutively in the warp 414 in which one of the warp fibers 420 is formed of one material and the two other warp fibers 422A, 422B are formed of another material. The groups of three adjacent fibers 424, 426A, 426B in the weft 416 form another pattern comprised of a group of three adjacent fibers with one weft fiber 424 formed of one material and the other two weft fibers 426A, 426B formed of another material. The corkscrew weave 412 of the ballistic resistant woven fabric 410 has a plurality of other patterns of adjacent weft fibers 424, 426A, 426B positioned consecutively in the weft 416 in which one of the weft fibers 424 is formed of one material and the other two adjacent weft fibers 426A, 426B are formed of another material.

[0029] In one approach, one of the warp fibers 420 in a group is constructed of PBO and the other two warp fibers 422A, 422B in the consecutively repeating groups of three fibers in the warp 414 are constructed of microfilament PPP-T; the one weft fiber 424 is also constructed of PBO and the two other adjacent weft fibers 426A, 426B for each group are also constructed of microfilament PPP-T. In an alternative approach, the one material used for the one type of warp fibers 420 and the one type of weft fibers 424 is PBO and the other or second material which is used to construct the other type of warp fibers 422A, 422B and the other type of weft fibers 426A, 426B is PPP-T (Kevlar®/Protera® material). The warp 414 of the corkscrew weave has a pattern with a PBO fiber 420 followed by two fibers 422A, 422B (formed of either PPP-T or microfilament PPP-T); a next pattern of a PBO fiber 420 next to two PPP-T or microfilament PPP-T fibers 422A, 422B, then follows with these patterns continuing in the warp. The weft 416 of the corkscrew weave also has a pattern of a PBO fiber 424 followed by two PPP-T or microfilament PPP-T fibers, 426A, 426B, with a next pattern of a PBO fiber 424 next to two (PPP-T or microfilament PPP-T) fibers 426A, 426B following thereafter with the patterns continuing in the weft.

[0030] While a detailed description of the present invention has been given, it should be appreciated that many variations can be made thereto without departing from the scope of the invention as set forth in the appended claims.

Claims

1. A ballistic resistant woven fabric utilized in the construction of ballistic resistant protective items comprising:

a warp of the ballistic resistant woven fabric which has at least three adjacent fibers in which one fiber is constructed of a first material and two other adjacent fibers are constructed of a second material; and

a weft of the ballistic resistant woven fabric which has at least three other adjacent fibers in which one fiber in the weft is constructed of the first material and two other fibers adjacent to the one fiber in the weft are constructed of the second material.

2. The ballistic resistant woven fabric of claim 1 in which the first material is PBO having a denier within the range of 200 to 830.

3. The ballistic resistant woven fabric of claim 2 in which the second material is an aramid.

4. The ballistic resistant woven fabric of claim 3 in which the second material is microfilament poly(paraphenylene-terephthalamide) having a denier within the range of 200 to 830.

5. The ballistic resistant woven fabric of claim 3 in which the second material is poly(paraphenylene-terephthalamide) having a denier within the range of 200 to 830.

6. The ballistic resistant woven fabric of claim 1 in which the woven fabric has a plain weave.

7. The ballistic resistant woven fabric of claim 6 in which the plain weave is a balanced weave.

8. The ballistic resistant woven fabric of claim 6 in which the plain weave is an imbalanced weave.

9. The ballistic resistant woven fabric of claim 6 in which the three adjacent fibers in the warp form a pattern of fibers, said warp includes a plurality of patterns of the three adjacent fibers positioned consecutively in the warp, and in which the three other adjacent fibers in the weft form another pattern of fibers, and said weft includes a plurality of other patterns of the three other adjacent fibers positioned consecutively in the weft.

10. The ballistic resistant woven fabric of claim 9 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of microfilament poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft constructed of microfilament poly(paraphenylene-terephthalamide).

11. The ballistic resistant woven fabric of claim 9 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft constructed of poly(paraphenylene-terephthalamide).

12. The ballistic resistant woven fabric of claim 6 in which the number of fibers of the warp ranges from 20 to 30 fibers per inch and in which the number of fibers of the weft ranges from 20 to 30 fibers per inch.

13. The ballistic resistant woven fabric of claim 6 in which at least one of the three adjacent fibers of the warp are twisted.

14. The ballistic resistant woven fabric of claim 13 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

15. The ballistic resistant woven fabric of claim 6 in which at least one of the three other adjacent fibers of the weft are twisted.

16. The ballistic resistant woven fabric of claim 15 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

17. The ballistic resistant woven fabric of claim 1 in which the woven fabric has a sateen weave.

18. The ballistic resistant woven fabric of claim 17 in which the sateen weave is a balanced weave.

19. The ballistic resistant woven fabric of claim 17 in which the sateen weave is an imbalanced weave.

20. The ballistic resistant woven fabric of claim 17 in which the three adjacent fibers in the warp form a pattern of fibers, said warp includes a plurality of patterns of the three adjacent fibers positioned consecutively in the warp, and in which the three other adjacent fibers in the weft form another pattern of fibers, and said weft includes a plurality of the other patterns of the three other adjacent fibers positioned consecutively in the weft.

21. The ballistic resistant woven fabric of claim 20 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of microfilament poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft constructed of microfilament poly(paraphenylene-terephthalamide).

22. The ballistic resistant woven fabric of claim 20 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers constructed of poly(paraphenylene-terephthalamide).

23. The ballistic resistant woven fabric of claim 17 in which the total sum of fibers in an inch of the warp plus an inch of the weft is less than sixty.

24. The ballistic resistant woven fabric of claim 23 in which the number of fibers of the warp ranges from 20 to 30 fibers per inch and in which the number of fibers of the weft ranges from 20 to 30 fibers per inch.

25. The ballistic resistant woven fabric of claim 17 in which at least one of the three adjacent fibers of the warp are twisted.

26. The ballistic resistant woven fabric of claim 25 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

27. The ballistic resistant woven fabric of claim 17 in which at least one of the three other adjacent fibers of the weft are twisted.

28. The ballistic resistant woven fabric of claim 17 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

29. The ballistic resistant woven fabric of claim 1 in which the woven fabric has a venetian weave.

30. The ballistic resistant woven fabric of claim 29 in which the venetian weave is a balanced weave.

31. The ballistic resistant woven fabric of claim 29 in which the venetian weave is an imbalanced weave.

32. The ballistic resistant woven fabric of claim 29 in which the three adjacent fibers in the warp form a pattern of fibers, said warp includes a plurality of patterns of the three adjacent fibers positioned consecutively in the warp and in which the three other adjacent fibers in the weft form another pattern of fibers, and the weft includes a plurality of the other patterns of the three other adjacent fibers positioned consecutively in the weft.

33. The ballistic resistant woven fabric of claim 32 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of microfilament poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft are constructed of microfilament poly(paraphenylene-terephthalamide).

34. The ballistic resistant woven fabric of claim 32 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers constructed of PBO and has the two other fibers of the three other adjacent fibers of the weft are constructed of poly(paraphenylene-terephthalamide).

35. The ballistic resistant woven fabric of claim 29 in which the total sum of fibers in an inch of the warp plus an inch of the weft is less than sixty.

36. The ballistic resistant woven fabric of claim 35 in which the number of fibers of the warp ranges from 20 to 30 fibers per inch and in which the number of fibers of the weft ranges from 20 to 30 fibers per inch.

37. The ballistic resistant woven fabric of claim 29 in which at least one of the three adjacent fibers of the warp are twisted.

38. The ballistic resistant woven fabric of claim 37 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

39. The ballistic resistant woven fabric of claim 29 in which at least one of the three other adjacent fibers of the weft are twisted.

40. The ballistic resistant woven fabric of claim 39 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

41. The ballistic resistant woven fabric of claim 1 in which the woven fabric has a corkscrew weave.

42. The ballistic resistant woven fabric of claim 41 in which the corkscrew weave is a balanced weave.

43. The ballistic resistant woven fabric of claim 41 in which the corkscrew weave is an imbalanced weave.

44. The ballistic resistant woven fabric of claim 41 in which the three adjacent fibers in the warp form a pattern of fibers, said warp includes a plurality of patterns of the three adjacent fibers positioned consecutively in the warp, and in which the three other adjacent fibers in the weft form another pattern of fibers, and the weft includes a plurality of the other patterns of the three other adjacent fibers positioned consecutively in the weft.

45. The ballistic resistant woven fabric of claim 44 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of microfilament poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft constructed of microfilament poly(paraphenylene-terephthalamide).

46. The ballistic resistant woven fabric of claim 44 in which the warp has the one fiber of the three adjacent fibers constructed of PBO and the two other fibers of the three adjacent fibers constructed of poly(paraphenylene-terephthalamide), and in which the weft has the one fiber of the three other adjacent fibers of the weft constructed of PBO and the two other fibers of the three other adjacent fibers of the weft constructed of poly(paraphenylene-terephthalamide).

47. The ballistic resistant woven fabric of claim 41 in which the number of fibers of the warp ranges from 23 to 29 fibers per inch and in which the number of fibers of the weft ranges from 23 to 29 fibers per inch.

48. The ballistic resistant woven fabric of claim 41 in which at least one of the three adjacent fibers of the warp are twisted.

49. The ballistic resistant woven fabric of claim 48 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

50. The ballistic resistant woven fabric of claim 41 in which at least one of the three other adjacent fibers of the weft are twisted.

51. The ballistic resistant woven fabric of claim 50 in which the number of twists in the fiber ranges from one-half of a revolution per linear inch of the fiber to six revolutions per linear inch of the fiber.

52. The ballistic resistant fabric of claim 1 in which the one fiber constructed of the first material and the other fiber constructed of the second material each have deniers in a range between 200 to 830.

53. The ballistic resistant fabric of claim 1 in which the denier of the one fiber and the denier of the other fiber have a ratio which does not exceed 2.0 with the larger denier positioned in the numerator and the smaller denier positioned in the denominator.