Abstract: A ballistic-resistant material having a first exterior layer formed of a ballistic-resistant non-woven textile, a second exterior layer formed of a ballistic-resistant non-woven textile, and an interior layer of ballistic-resistant woven textile arranged between the first exterior layer and the second exterior layer. The woven textile is a tight weave. The woven layer a high occupation, high fabric density woven textile at or near the technical jamming point of fabric construction. Also disclosed are articles made from the ballistic-resistant material.

Abstract: Flexible ballistic resistant composite material that has improved resistance to pick-up of water and other liquids, the composite material comprising a plurality of non-woven fibrous layers. The fibrous layers are formed from a network of high tenacity fibers (aramid fibers, extended chain polyethylene fibers and/or rigid rod fibers). The fibers are embedded in a matrix of a thermoplastic polyurethane resin. Preferably, at least two adjacent fiber layers are oriented in a cross-ply arrangement with respect to each other. Flexible armor, such as body vests, are provided which are formed at least in part from the flexible composite material.

Abstract: The invention is directed to a method for depositing particles on a substrate and to a fibrous web comprising deposited particles. A method is provided according to which particles are provided on a surface activated substrate by means of a plasma treatment. The method comprises the subsequent steps of -providing particles, preferably coating said particles; -subjecting said particles to a first plasma treatment before being deposited on said substrate; and -depositing said particles on said surface of said substrate, preferably using a second plasma treatment.

Abstract: A ballistic resistant panel which is formed from a ceramic layer and a plurality of fibrous backing layers. A first fibrous backing layer is adjacent to the ceramic layer, and a second fibrous backing layer is adjacent to the first fibrous backing layer. Each of the fibrous backing layers are formed from a network of high tenacity fibers, but the fibers of each of the backing layers have a different composition. Preferably, the first fibrous layer is stiffer than the second fibrous layer. The panel has a ballistic resistance which is substantially equivalent to or higher than the ballistic resistance of a comparable ceramic panel construction that has only a single fibrous layer of the same type of high tenacity fibers as are in the first and second fibrous backing layers, for substantially the same areal density.

Abstract: Fabric laminates having superior resistance to penetration of fragments, such as shrapnel. The fabrics are formed of high-strength fibers consolidated with from about 7% to about 15% by weight of an elastomeric matrix composition, and in combination with protective layers of a polymer film on each surface of the fabric. The fabrics achieve a significant improvement in fragment resistance compared to fabrics of the prior art, while also maintaining excellent ballistic resistant properties.

Abstract: Multi-panel ballistic resistant articles formed from woven and/or non-woven fibrous panels, each panel including varying quantities of a polymeric composition based on the total weight of the fibers and the polymeric composition. The hybrid structures provide excellent ballistic penetration resistance while maintaining a low weight. The ballistic resistant articles may be strategically positioned to dial in different levels of desired ballistic resistance for various applications.

Abstract: A composite material that is suitable for the protection of personnel and/or property from impact due to ballistic projectiles and method for making same are disclosed herein. In one embodiment, there is provided composite for resisting impact from an oncoming projectile having a front strike face and a back wear face comprising: an elastomer; and an impact resistive substrate wherein at least a portion of the impact resistive substrate is coated by the elastomer to provide the composite having a front strike face coating and a back wear face coating and wherein a ratio of weight of front strike face coating to back wear face coating ranges from 1:1.2 to 1:100.

Abstract: Flexible composites which are ballistic and stab resistant. The composites are formed from at least one, and preferably a plurality of, fibrous layer comprising a network of high tenacity fibers. A stack of a plurality of fibrous layers is consolidated in a desired pattern over a substantial portion of its surface area which results in areas which are consolidated and areas that are unconsolidated. The unconsolidated areas provide flexibility to the overall composite structure and the structure is resistant to ballistic projectiles and/or sharp objects. Body armor formed from the composites is comfortable to wear and reduces the degree of trauma to the wearer as a result of impact by the ballistic projectile or sharp object.

Abstract: Ballistic resistant composites and articles formed therefrom for use in airplanes and other vehicles which meets particular structural, impact and ballistic requirements. An aerospace-specification grade honeycomb is positioned between panels comprising non-woven ballistic resistant fibrous layers, and optionally one or more fire resistant layers. The composites and the articles formed therefrom have superior structural, impact, fire resistance and ballistic performance at a light weight.

Abstract: A panel had a first face and a second face, including a strike face portion having a first plurality of plies each containing fibers in a matrix material. There is a support portion adjacent to the strike face portion, the support portion containing a second plurality of plies each having fibers in a matrix material. Each ply is bound to an adjacent ply and the first fibers are lower-performing relative to the second fibers. Protection from a ballistic threat may be provided by providing such a panel with the strike face disposed toward the threat. In another aspect, a composite ballistic panel may contain fibers in a thermoplastic matrix material, to the substantial exclusion of thermosetting matrix materials.

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

Abstract: An insulation package comprising a layer of material having a cellular structure disposed between a first layer of high-strength polymeric fabric and a second layer of high-strength polymeric fabric. The insulation provides protection for critical fluid systems, such as fuel, hydraulic, electrical, pneumatic, thermal, and mechanical systems from high-energy projectiles such as fragments from the disintegration of high-speed turbines and engines.

Abstract: A method of preparing fibre treatment resin is disclosed herein. In a preferred embodiment, at step 100, the method comprises dispersing ethyl acetic acid copolymers in water to form a mixture at predetermined temperature and at step 102, ammonia is introduced as a flocculent into the mixture to form a suspension; and at step 104, the suspension is cooled to form the fibre treatment resin. Fibres treated with the fibre treatment resin exhibits improved tenacity and enable the fibres to be stretched and absorb the energy of incidental pressure such as those from a projectile.

Abstract: A composite fabric, multi-layer protective panel alternative to an exclusively fine denier, continuous filament yarn protective fabric, multi-layer protective panel. Fabric layers consist of warp and fill sheets of continuous filament yarn of relatively higher denier at a relatively lower cover factor that have their yarns interlocked in a woven pattern by overlapping warp and fill sheets of staple yarns of relatively lower denier, thus raising effective cover factor. Staple yarns have a conspicuous amount of hairiness for greater yarn stability. Ballistic performance is enhanced by depositing a molten mass of fiber material and protruding staple fiber filament ends on a striking projectile upon impact on outer layers, and transporting the additional mass into the panel with a higher coefficient of friction.

Abstract: A flexible penetration-resistant package is described, comprising a) at least one laminate consisting of at least one layer of yarns comprising fibers with a strength of at least 900 MPa as per ASTM D-885, wherein the layer of yarns is bound to at least one polymer continuum having a modulus of elasticity in extension of 5 to 1000 MPa as per ASTM D-882 and wherein the package has an outer surface facing the side under attack and an inner surface facing away from the side under attack, and b) a layer of compressible material, the layer arranged either on the inner surface of the package or at such a position in the package between the laminates that from this position the number of laminates toward the outer surface of the package is at least twice the number of laminates toward the inner surface. The package is used to produce protective clothing, in particular protective vests, suits, and mats.

Abstract: A barrier for protecting contents such as insulation materials or ballistic materials that can be used with body armor or other protective gear. The protective panel comprises a barrier of ultraviolet light- and moisture-resistant fabric ultrasonically welded at its edges and a protective material encased therein. The ultrasonic weld is also ultraviolet light- and moisture-resistant. In the preferred embodiment, the molecular bonds created by the ultrasonic energy are such that a first set of bonds is oriented to a second set of bonds at 90 degrees and both sets of bonds are oriented to the fabric edge at 45 degrees. Optionally, the protective panel can include one or more attachment affixed to the exterior of the barrier using heat.

Abstract: A ballistic composite comprises multiple layers of a fabric having unidirectional ballistic resistant yarns in at least two layers and a resin layer between each pair of such multiple layers adhered to the ballistic resistant yarns but not encapsulation the same and not penetrating the layer of fabric. The ballistic yarn layers are at 90°±5° with respect to each other and the ballistic resistant yarns are stabilized by being woven in a second fabric. The second fabric is formed of yarns having a substantially lower tenacity and tensile modulus than the ballistic resistant yarn. The ballistic resistant yarns have a tenacity of at least about 15 grams per denier and a modulus of at least about 40 grams per denier. The resin in the resin layer has a modulus of at least about 7000 psi.

Abstract: This invention relates to a coated fabric and a method of making the same, and laminates and articles comprising the coated fabric. The fabric comprises a woven substrate having fiber volume fraction of at least 70 percent and non-meltable, rigid rod, high strength filaments having angular cross sections created by densifying the woven substrate. The coated fabrics and laminates are especially useful in rigid armor applications.

Abstract: Ballistic resistant fabric laminates are provided. More particularly, reinforced, delamination resistant, ballistic resistant composites are provided. The delamination resistant, ballistic resistant materials and articles may be reinforced by various techniques, including stitching one or more ballistic resistant panels with a high strength thread, melting the edges of a ballistic resistant panel to reinforce areas that may have been frayed during standard trimming procedures, wrapping one or more panels with one or more woven or non-woven fibrous wraps, and combinations of these techniques. The delamination resistant, ballistic resistant panels may further include at least one rigid plate attached thereto for improving ballistic resistance performance.

Abstract: Flexible composites which are ballistic and stab resistant. The composites are formed from at least one, and preferably a plurality of, fibrous layer comprising a network of high tenacity fibers. A stack of a plurality of fibrous layers is consolidated in a desired pattern over a substantial portion of its surface area which results in areas which are consolidated and areas that are unconsolidated. The unconsolidated areas provide flexibility to the overall composite structure and the structure is resistant to ballistic projectiles and/or sharp objects. Body armor formed from the composites is comfortable to wear and reduces the degree of trauma to the wearer as a result of impact by the ballistic projectile or sharp object.

Abstract: The invention relates to a fabric having both stab resistant and anti-ballistic properties. The fabric is made of yarn of a weight greater than about 500 dtex, and the fabric has a minimum shrinkage factor of at least about 1% achieved through a densification treatment. The invention further relates to a method of producing a such a fabric having the steps of agitating a fabric made of a yarn of a weight greater than about 500 dtex, substantially removing a spin finish from the fabric before, during or after the agitating step, and drying the fabric.

Abstract: An article is disclosed to protect a wearer from spike and ballistic threats that is made from a spike resistant panel and a ballistic resistant panel. Each panel is made from flexible fabric layers. The fabrics in the spike resistant panel are made from first yarns having a linear density of from 50 to 600, with a plurality of filaments. There are 40 to 100 first yarns per inch in both the warp and fill directions. The fabrics in the ballistic resistant panel are made from second yarns having a linear density of from 100 to no more than 840 denier with a plurality of filaments, which provide from 20,000,000 to no more than 90,000,000 filament crossovers per square inch.

Abstract: Composite assemblies are disclosed. Methods of making and using composite assemblies are also disclosed.

Abstract: Protection against blast and ballistic damage is improved by encapsulating or sandwiching rigid inclusions (for example, tiles) or a rigid plate by a high-strain rate hardening elastomer. Typical high-strain rate hardening elastomers include polyurea and polyurethane. If desired, the inclusion or plate may be wrapped in a cloth and/or fabric before encapsulation/sandwiching. The armor may be used independently of a substrate or may be attached by any means to a substrate that it is intended to protect.

Abstract: Flexible body armor formed from flexible composites which have improved knife-stab resistance. The body armor is formed from composites which include layers of a fabric base, formed from high tenacity fibers, and a rubber layer bonded to the fabric base. A thermoplastic bonding layer may be used to bond the fabric and rubber layers together. To provide ballistic resistance, the body armor may also include a ballistic resistant composite of a network of high tenacity fibers.

Abstract: The invention provides a composite textile or material comprising a substrate of high strength fibers, and having a natural or synthetic diamond coating bonded thereto. Preferably, the textile is a high strength fabric including or made from aramide fibers, and the natural or synthetic coating is applied by a process such as plasma or flame spraying, chemical vapor deposition, sintering, or fast pulse laser deposition. The textile or fabric can preferably be used to make or reinforce protective clothing including vests, hats, helmets, jackets, pants, shoes or boots, coats, blankets, rugs, curtains, and the like. The textile or fabric may also include an iodine or iodine containing coating, to absorb radioactive radiation, and to kill airborne pathogens, including bacteria and viruses.

Abstract: A method of making a helmet comprises the steps of cutting a plurality of substantially rectangular, preferably square, blanks from a sheet of resin-impregnated fabric, making curved cuts (1) in each blank to form a crown portion (5) and lobe portions (3) therefrom, arranging a stack of said sheets into a helmet preform such that the lobe portions of any blank partially overlap adjacent lobe portions of the same blank, and molding the helmet from the preform.

Abstract: An armor composite material has been invented which contains a ballistic fabric which has been impregnated with shear thickening fluid. This invention offers a ballistic resistant material that is more flexible and less bulky than comparable, conventional ballistic fabric. The invented material offers superior ballistic performance compared to conventional ballistic fabric-based materials of equal thickness. The invented material can be applied to applications requiring armor that is compact and/or flexible, such as body armor, protective clothing and flexible protective devices and shields, and stab resistant clothing and devices.

Abstract: A penetration-resistant material is described to include at least a double layer of woven fabric, wherein the double layer includes a first layer of fabric composed of a first set of threads having 3.5 to 20 threads/cm, having a linear density of at least 210 dtex, and composing at least 65% of the first layer fabric weight, and a second set of threads comprising 0.5 to 16 threads/cm and having a linear density of at least 50 dtex, with the second set of threads being transverse to the first set of threads, and the ratio of the number of threads/cm of the first set to that of the second set is greater than 1:1, and a second layer of fabric composed of a first set of threads having 0.5 to 16 threads/cm and having a linear density of at least 50 dtex, and a second set of threads having 3.

Abstract: Protective clothing comprises at least one protective material including an array of one or more superposed layers of woven fabric, wherein each fabric layer is flexible and includes at least one fabric, made of yarns having a strength of at least 900 MPa, that is joined to at least one polymer film, and wherein the protective material has an outer surface facing the side of attack and an inner surface facing away from the side of attack, wherein the protective material also has at least one layer of felt, placed in every case on one of the fabric layers.

Abstract: A ballistic laminate structure includes a first high-performance unifabric composite. The unifabric composite incorporates an array of unidirectionally-oriented fiber bundles carried on a fiber-stabilizing scrim and having a tensile strength greater than 7 grams per denier. A second high-performance unifabric composite includes an array of high performance, unidirectionally-oriented fiber bundles. The fiber bundles of the second composite are carried on a fiber-stabilizing scrim and have a tensile strength greater than 7 grams per denier. The first and second unifabric composites are cross-plied at an angle and bonded together to form the ballistic laminate structure.

Abstract: A penetration-resistant material having at least a double layer of woven fabric having a first layer of fabric composed of a first set of threads having 3.5 to 20 threads/cm, a linear density of at least 210 dtex, and at least 65% of the fabric weight, and a second set of threads having 0.5 to 16 threads/cm and a linear density of at least 50 dtex and a second layer of fabric composed of a first set of threads having 0.5 to 16 threads/cm and a linear density of at least 50 dtex, and a second set of threads having 3.5 to 20 threads/cm, a linear density of at least 210 dtex, and at least 65% of the fabric weight. In each layer, the second set are transverse to the first set and the ratio of the number of threads/cm of the second set to that of the first set is >1.

Abstract: A ceramic composite body includes at least two layers: material layer A and material layer B. Material layer A contains phases of a metal and the carbide of this metal. Material layer B contains silicon carbide that has been loosely bound by sintering. A method for fabricating the composite body is included and a protective armor against projectiles.

Abstract: This invention provides multi-layered composites, laminates and composite joints in which at least one resin-impregnated, fiber-containing layer is joined or laminated to a core layer having a lower flexural modulus or higher elongation at break, higher toughness, or a combination of all or some of these properties. The multi-layer composite produced by laminating or joining these materials together has improved shearout, impact and cutting resistance, since stresses caused by outside forces can be more widely distributed throughout the composite.

Abstract: Bi-directional and multi-axial fabrics, fabric composites, ballistically resistant assemblies thereof, and the methods by which they are made. The fabrics are comprised of sets of strong, substantially parallel, unidirectional yarns lying in parallel planes, one above the other , with the direction of the yarns in a given plane rotated at an angle to the direction of the yarns in adjacent planes; and one or more sets of yarns having lower strength and higher elongation interleaved with the strong yarns. The fabrics of the invention provide superior ballistic effectiveness compared to ordinary woven and knitted fabrics but retain the ease of manufacture on conventional looms and knitting machines.

Abstract: A fabric includes a fabric substrate and a plurality guard plate assemblies affixed to the fabric substrate in a spaced relationship to each other. Each guard plate assembly includes a first layer of material affixed to the fabric substrate and a second layer of material joined to the first layer of material on a surface opposite the fabric substrate. The second layer of material has characteristics different than the first layer of material and are chosen commonly to meet the demands of the application to which the fabric is designed.

Abstract: A sheet of unidirectionally-oriented fiber strands includes unidirectional fibers, bonding fibers interwoven with the unidirectional fibers to form a fiber panel, and thermoplastic film laminating the fiber panel there between. In one embodiment, a second sheet of laminated unidirectional fibers is joined to the first sheet of laminated unidirectional fibers with the unidirectional fibers running in a second direction as compared to the first fibers. In yet another embodiment, individual laminated sheets of unidirectional fibers are stitched together to form packets of sheets which may be used singularly or multiple packets may be bundled together.

Abstract: The invention relates to a stab-resisting material, which material consists of a carrier coated with solid particles, which is provided on a packet of fabrics, wherein the coating on said carrier consists of abrasive particles having a diameter of 0.1-3 mm, and wherein the packet of fabrics is thicker than 1.5 mm. The invention also relates to the coated carrier, wherein the abrasive particles have been provided on the carrier by means of an adhesive, which forms an elastic film after curing. In particular a fabric made of Aramid or Nylon fibres may be used as the carrier material. The preferred adhesive is a bituminous adhesive or an adhesive with a base of polyurethane. This material is used in particular in protective clothing.

Abstract: The invention relates to a ballistic-resistant moulded article containing a compressed stack of monolayers, with each monolayer containing unidirectionally oriented reinforcing fibers and at most 30 wt. % of a plastic matrix material and with the fiber direction in each monolayer being rotated with respect to the fiber direction in an adjacent monolayer, characterized in that the density (?p) of the compressed stack is at least 98.0% of the theoretical maximum density. The invention also relates to a process for manufacturing the moulded article. The ballistic-resistant article may be used in, for instance, helmets, as inserts in bullet-proof vests, as armoring on military vehicles and in ballistic-resistant panels.

Abstract: A penetration-resistant material is disclosed comprising at least one layer having a thickness D, the layer comprising a first and second layer of woven fabric, with the first and second layers being bonded together with an adhesive material, the first layer of fabric composed of a first set of threads comprising 3.5 to 20 threads/cm, having a linear density of at least 210 dtex, the filaments forming the threads having a diameter F1, and comprising at least 65% of the fabric weight, and a second set of threads comprising 0.5 to 16 threads/cm and having a linear density of at least 50 dtex, with the second set of threads being at an angle of >0° to 90° with respect to the first set of threads, and the ratio of the number of threads/cm of the first set to that of the second set being >1, and the second layer of fabric being composed of a first set of threads comprising 0.5 to 16 threads/cm and having a linear density of at least 50 dtex, and a second set of threads comprising 3.

Abstract: A ballistic fabric having unidirectional ballistic resistant yarns in at least two layers. The layers are at 90°±5° with respect to each other. The ballistic resistant yarns are stabilized by being woven in a second fabric formed of yarns having a substantially lower tenacity and tensile modulus than the ballistic resistant yarns.

Abstract: Woven fabric laminates having superior resistance to penetration by ballistic projectiles, assemblies thereof, and the method by which they are made. In one embodiment, among others, a laminate of the invention is comprised of a fabric woven from a high strength, high modulus yarn, a surface coating of a low modulus elastomer and a plastic film bonded to its elastomer-coated surface.

Abstract: Bi-directional and multi-axial fabrics, fabric composites, ballistically resistant assemblies thereof, and the methods by which they are made. The fabrics are comprised of sets of strong, substantially parallel, unidirectional yarns lying in parallel planes, one above the other, with the direction of the yarns in a given plane rotated at an angle to the direction of the yarns in adjacent planes; and one or more sets of yarns having lower strength and higher elongation interleaved with the strong yarns. The fabrics of the invention provide superior ballistic effectiveness compared to ordinary woven and knitted fabrics but retain the ease of manufacture on conventional looms and knitting machines.

Abstract: A lightweight ballistic resistant rigid structural panel especially for use in aircraft interiors is disclosed. The rigid structural panel is made up of a core layer including a plurality of sheets of flexible, high-tensile strength fabric interleaved with a plurality of sheets of a thermal-fusible film adhesive, and a sheet of cushioning material adhered to the plurality of sheets of flexible, high-tensile strength fabric. Fiber-reinforced face skins are adhered to exterior surfaces of the panel core for structural strength and rigidity. The rigid structural panel is capable of resisting ballistic attack from handguns and like weapons, while maintaining a high degree of strength and rigidity.

Abstract: The invention pertains to a laminated ballistic structure having an array of layers of substantially alternating n unidirectional (UD) layers of ballistic fiber and m thermoplastic layers, excluding thermoplastic layers at the outer sides of the structure, wherein ½n≦m<n. The UD layers have 1-25 wt. % of an elastomeric material based on a dry fiber weight. Preferably, the UD layers have aramid, PBO, PBI, and/or high density polyethylene fibers and the material of the thermoplastic layers is polyethylene or polypropylene.

Abstract: An anti-projectile barrier fabric which takes the form of a plural-layer assembly of two outer cloth-like layers, each preferably formed of a Nylon material, a pair of foam-like layers, each preferably formed of a cross-linked polyethylene material and disposed inwardly of, and bonded to, the two cloth-like layers, and a central, inner strand layer, preferably formed of elongate, cross-deployed strands of a non-stretchable material, such as Kevlar®, bonded to the confronting inner surfaces of the two foam-like layers.

Abstract: In order to provide a textile protective material made of multiple material layers which meets different requirements simultaneously, it is suggested that at least one material layer be a flame-resistant and/or flame-repellent material and at least one further material layer be a cut protection material, and/or a bulletproof or stabproof material.

Abstract: The invention provides a composite textile or material comprising a substrate of high strength fibers, and having a natural or synthetic diamond coating bonded thereto. Preferably, the textile is a high strength fabric including or made from aramide fibers, and the natural or synthetic coating is applied by a process such as plasma or flame spraying, chemical vapor deposition, sintering, or fast pulse laser deposition. The textile or fabric can preferably be used to make or reinforce protective clothing including vests, hats, helmets, jackets, pants, shoes or boots, coats, blankets, rugs, curtains, and the like. The textile or fabric may also include an iodine or iodine containing coating, to absorb radioactive radiation, and to kill airborne pathogens, including bacteria and viruses.

Abstract: Disclosed herein is a stabproof and bulletproof panel. The stabproof and bulletproof panel includes a bulletproof panel 40 and a plurality of stabproof panels 60. The bulletproof panel 40 is comprised of a front plate 45, a plurality of high density polyethylene films 44 stacked with one on top of another for dispersing impact energy, and a rear plate 46 formed by sewing together a plurality of aromatic polyamide woven fabrics for minimizing frictional heat and deformation. The front plate 45 consists of a plurality of aromatic polyamide woven fabrics 41, a felt 50 formed by forcibly inserting thin aromatic polyamide fibers or high density polyethylene fibers 52 and a shock-absorbing member 51 into a scrim woven in the form of a net using aromatic polyamide fibers or high density polyethylene yarn, and a plurality of aromatic polyamide woven fabrics 43. The stabproof panels 60 are brought into tight contact with the front surface of the bulletproof panel 40.

Abstract: Polyethylene solutions are extruded through a multi-orifice spinneret into a cross-flow gas stream to form a fluid product. The fluid product is stretched at a temperature at which a gel will form at a stretch ratio of at least 5:1 over a length of less than about 25 mm with the cross-flow gas stream velocity at less than about 3 m/min. The fluid product is quenched in a quench bath consisting of an immiscible liquid to form a gel. The gel is stretched. The solvent is removed from the gel to form a xerogel and the xerogel product is stretched in at least two stages to produce a polyethylene yarn characterized by a tenacity of at least 35 g/d, a modulus of at least 1600 g/d and a work to break of at least 65 J/g. The yarn is further characterized by having greater than about 60% of a high strain orthorhombic crystalline component and, optionally, a monoclinic crystalline component greater than about 2% of the crystalline content. Composite panels made with these yarns exhibit excellent ballistic resistance, e.