Stab and ballistic resistant articles and the process of making

Patent metadata

Field	Value
Publication number	US-2016129669-A1
Application number	US-201614996343-A
Country	US
Kind code	A1
Filing date	Jan 15, 2016
Priority date	Mar 15, 2013
Publication date	May 12, 2016
Grant date	—

Abstract

Dimensionally stable open woven fabrics formed from a plurality of high tenacity warp elongate bodies interwoven and bonded with a plurality of transversely disposed, high tenacity weft elongate bodies, composite articles formed therefrom, and to a continuous process for forming the composite articles.

First claim

1 - 6 . (canceled)

7 . A closed, fused sheet comprising a plurality of warp elongate bodies interwoven and bonded with a plurality of transversely disposed weft elongate bodies, said warp elongate bodies and weft elongate bodies each comprising thermoplastic high tenacity elongate bodies having a tenacity of at least about 14 g/denier and a tensile modulus of at least about 300 g/denier, the closed, fused sheet having substantially no gaps between adjacent high tenacity warp elongate bodies and wherein said adjacent high tenacity warp elongate bodies do not overlap; and having substantially no gaps between adjacent high tenacity weft elongate bodies and wherein said adjacent high tenacity weft elongate bodies do not overlap.

8 . The closed, fused sheet of claim 7 further comprising binding warp elongate bodies interwoven in the warp direction, said binding warp elongate bodies being positioned in the space between adjacent high tenacity warp elongate bodies and/or further comprising binding weft elongate bodies interwoven in the weft direction, said binding weft elongate bodies being positioned in the space between adjacent high tenacity weft elongate bodies, wherein said binding warp elongate bodies and said binding weft elongate bodies each at least partially comprise a thermoplastic polymer having a melting temperature that is below a melting temperature of the high tenacity elongate bodies.

9 . A ballistic resistant, closed multilayer article comprising at least two fused sheets of claim 7 attached to each other.

10 . A ballistic resistant, closed multilayer article of claim 9 wherein said fused sheets are thermally fused together in the absence of an additional intermediate adhesive resin.

11 . A ballistic resistant, closed multilayer article comprising at least two fused sheets of claim 8 attached to each other, wherein said fused sheets are thermally fused together in the absence of an additional intermediate adhesive resin.

12 . A process for forming a dimensionally stable open fabric, the process comprising:
a) providing a woven fabric comprising a plurality of warp elongate bodies interwoven and bonded with a plurality of transversely disposed weft elongate bodies, said warp elongate bodies and weft elongate bodies each comprising thermoplastic high tenacity elongate bodies having a tenacity of at least about 14 g/denier and a tensile modulus of at least about 300 g/denier, wherein adjacent warp elongate bodies are spaced apart from each other by a distance equivalent to at least about 10% of the width of the warp elongate bodies and adjacent weft elongate bodies are spaced apart from each other by a distance equivalent to at least about 10% of the width of the weft elongate bodies; b) at least partially melting the thermoplastic polymer of the high tenacity warp elongate bodies and/or the high tenacity weft elongate bodies; and c) allowing the melted thermoplastic polymer of the high tenacity warp elongate bodies and/or the high tenacity weft elongate bodies to solidify, whereby the high tenacity warp elongate bodies and the high tenacity weft elongate bodies are bonded to each other, thereby forming a dimensionally stable open fabric.

13 . The process of claim 12 wherein adjacent warp elongate bodies are spaced apart from each other at their nearest longitudinal edges by more than 1 mm and adjacent high tenacity weft elongate bodies are spaced apart from each other at their nearest longitudinal edges by more than 1 mm.

14 . A process for forming a ballistic resistant closed, thermally fused multilayer article comprising adjoining at least two dimensionally stable open fabrics of claim 12 and thermally pressing the adjoined fabrics under conditions sufficient to attach the fabrics to each other and to flatten the high tenacity warp and weft elongate bodies in each fabric respectively, thereby causing longitudinal edges of adjacent warp high tenacity elongate bodies in each fabric respectively to contact each other, whereby there are substantially no gaps between said adjacent high tenacity warp elongate bodies and wherein said high tenacity warp elongate bodies do not overlap; and thereby causing longitudinal edges of adjacent weft high tenacity elongate bodies in each fabric respectively to contact each other, whereby there are substantially no gaps between said adjacent high tenacity weft elongate bodies and wherein said high tenacity weft elongate bodies do not overlap.

15 . A process for forming a closed, fused sheet comprising pressing the dimensionally stable open fabric of claim 12 under conditions sufficient to flatten the high tenacity warp and weft elongate bodies in each fabric respectively, thereby causing longitudinal edges of adjacent warp high tenacity elongate bodies in each fabric respectively to contact each other, whereby there are substantially no gaps between said adjacent high tenacity warp elongate bodies and wherein said high tenacity warp elongate bodies do not overlap; and thereby causing longitudinal edges of adjacent weft high tenacity elongate bodies in each fabric respectively to contact each other, whereby there are substantially no gaps between said adjacent high tenacity weft elongate bodies and wherein said high tenacity weft elongate bodies do not overlap.

16 . A process for forming a ballistic resistant, closed multilayer article comprising attaching at least two closed, fused sheets of claim 15 to each other.

17 . A process for forming a ballistic resistant closed,
thermally fused multilayer article comprising: a) providing at least one open woven fabric comprising a plurality of warp elongate bodies interwoven and bonded with a plurality of transversely disposed weft elongate bodies, said warp elongate bodies and weft elongate bodies each comprising thermoplastic high tenacity elongate bodies having a tenacity of at least about 14 g/denier and a tensile modulus of at least about 300 g/denier, wherein adjacent warp elongate bodies are spaced apart from each other by a distance equivalent to at least about 10% of the width of the warp elongate bodies and adjacent weft elongate bodies are spaced apart from each other by a distance equivalent to at least about 10% of the width of the weft elongate bodies; b) providing at least one closed, fused sheet of claim 7 ; c) adjoining the at least one open woven fabric and the at least one closed, fused sheet together; and d) thermally pressing the adjoined at least one woven fabric and at least one fused sheet together under conditions sufficient to attach the woven fabric to the fused sheet and to flatten the high tenacity elongate bodies in the woven fabric, thereby causing the longitudinal edges of the adjacent high tenacity warp elongate bodies in the woven fabric to contact each other, whereby there are substantially no gaps between said adjacent high tenacity warp elongate bodies and wherein said high tenacity warp elongate bodies do not overlap.

18 . A process for forming a closed, thermally fused multilayer article comprising:
a) providing an open woven fabric comprising a plurality of warp elongate bodies interwoven and bonded with a plurality of transversely disposed weft elongate bodies, said warp elongate bodies and weft elongate bodies each comprising thermoplastic high tenacity elongate bodies having a tenacity of at least about 14 g/denier and a tensile modulus of at least about 300 g/denier, wherein adjacent warp elongate bodies are spaced apart from each other by a distance equivalent to at least about 10% of the width of the warp elongate bodies and adjacent weft elongate bodies are spaced apart from each other by a distance equivalent to at least ab

Assignees

• Honeywell Int Inc

Inventors

• Tam Thomas
• Boone Mark Benjamin
• Bhatnagar Ashok

Classifications

• F41H1/02

  Armoured or projectile- or missile-resistant garments; Composite protection fabrics {(F41H5/04 takes precedence)} · CPC title

• D03D15/00

  Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used · CPC title

• B32B37/16

  with all layers existing as coherent layers before laminating · CPC title

• D03D1/0041

  Cut or abrasion resistant · CPC title

• B32B27/12 Primary

  next to a fibrous or filamentary layer · CPC title