Ballistic material manufactured from mechanically woven fabric without non-woven fibers and method of manufacturing the same

Abstract

A bonded material and a method for forming the bonded material are disclosed. The bonded material comprises a plurality of woven fabric layers mechanically intertwined together. The plurality of woven fabric layers comprises fibers. The plurality of woven fabric layers are mechanically intertwined with the fibers of the plurality of woven fabric layers without non-woven fibers. At least some of the fibers of the plurality of woven fabric layers extend in a Z direction perpendicular to the xy plane of the plurality of woven fabric layers. A method for forming the bonded material is also provided.

Description

Technology Field

[0001] The disclosed embodiments generally relate to ballistic materials, and more specifically to ballistic materials manufactured from mechanically interwoven woven fabrics without nonwoven fibers and methods for manufacturing such materials. Background Technology

[0002] It is well known in the art to use nonwoven fibers to mechanically intertwine woven fabrics, for example, by needle punching, in order to produce ballistic materials. This involves mechanically pushing nonwoven fibers through woven fabrics by mechanical mechanisms such as barbed needles, water jets, and air jets. The mechanical mechanism repeatedly penetrates the woven fabric to push the nonwoven fibers through the woven fabric so that the nonwoven fibers are wound onto the fibers of the woven fabric and mechanically intertwine, thereby mechanically consolidating the woven fabric. For example, with reference to U.S. Patents No. 7,101,818 and 7,631,405, and U.S. Patent Publications No. 2017 / 0191803 and 2020 / 0025530, a ballistic material and a method are described in which fibers of a nonwoven material are mechanically interwoven in the gaps of a woven fabric material to reinforce the woven fabric material and form a bonded multilayer ballistic material.

[0003] However, nonwoven materials used to form mechanically woven ballistic-resistant materials result in undesirable additional weight. For example, nonwoven materials and the nonwoven fibers within them generally do not provide ballistic performance advantages in themselves and are considered "parasitic weight" within mechanically woven ballistic-resistant materials. Weight is a critical component of ballistic-resistant materials because the weight of ballistic equipment (e.g., vests, helmets, etc.) contributes to and generates fatigue in the wearer after prolonged use. Weight also affects the performance and sustainability of specific ballistic equipment, such as helicopters and other aircraft, where ballistic-resistant materials are used. Therefore, it is desirable to reduce weight while maintaining or improving performance. Furthermore, compared to woven materials, nonwoven materials absorb large amounts of liquid (e.g., water, sweat, etc.), which is undesirable for ballistic equipment.

[0004] Therefore, there is a need and demand for mechanically entangled ballistic materials that are more efficient to manufacture and have the same or improved ballistic performance, with reduced weight and reduced liquid absorption. means of solving the problem

[0005] In one embodiment, the present disclosure provides a bonded material. The bonded material comprises a plurality of woven fabric layers mechanically intertwined together. The plurality of woven fabric layers comprises fibers. The plurality of woven fabric layers are mechanically intertwined with the fibers of the plurality of woven fabric layers without nonwoven fibers. At least some of the fibers of the plurality of woven fabric layers extend in a Z direction perpendicular to the xy plane of the plurality of woven fabric layers.

[0006] In another embodiment, the present disclosure provides a bonded material. The bonded material comprises two or more woven fabric layers mechanically interwoven together without nonwoven fibers. Some fibers of at least one of the two or more woven fabric layers extend in the Z direction to at least one other woven fabric layer of the two or more woven fabric layers.

[0007] In another embodiment, the present disclosure provides a method for forming a bonded material. The method for forming a bonded material comprises the step of forming a bonded material by mechanically interlacing two or more layers of woven fabric together without using nonwoven fibers.

[0008] In one embodiment, the method for forming a bonded material further comprises the step of arranging two or more woven fabric layers in a stack before mechanically interlacing two or more woven fabric layers. In another embodiment, the method for forming a bonded material further comprises the step of heat-treating and calendering the bonded material. In another embodiment, the method for forming a bonded material further comprises the step of applying one or more secondary processing steps to the bonded material.

[0009] In another embodiment, a method for forming a bonded material comprises the step of mechanically interlacing a plurality of woven fabric layers together to form a bonded material. The plurality of woven fabric layers comprises fibers. The plurality of woven fabric layers are mechanically interlaced with the fibers of the plurality of woven fabric layers without non-woven fibers. At least some of the fibers of the plurality of woven fabric layers extend in the Z direction perpendicular to the xy plane of the plurality of woven fabric layers.

[0010] In one embodiment, the method for forming a bonded material further comprises the step of arranging a plurality of woven fabric layers together in a stack before mechanically interlacing a plurality of woven fabric layers together. In another embodiment, the method for forming a bonded material further comprises the step of heat-treating and calendering the bonded material. In another embodiment, the method for forming a bonded material further comprises the step of applying one or more secondary processing steps to the bonded material. Brief explanation of the drawing

[0011] FIG. 1 is a front view of a ballistic material according to an exemplary embodiment. FIG. 2 is a flowchart of a method for forming a ballistic material according to an exemplary embodiment. FIG. 3 is a perspective view of a ballistic article according to an exemplary embodiment. Specific details for implementing the invention

[0012] In the following detailed description, reference is made to the accompanying drawings, which describe exemplary embodiments of the present invention and constitute part of the present invention. These embodiments are described in sufficient detail to enable those skilled in the art to manufacture and use them. Furthermore, it is understood that structural, logical, or procedural changes may be made to the exemplary embodiments disclosed herein without departing from the spirit or scope of the present invention.

[0013] As used herein, "needle-bonding" refers to a method of bonding woven fabrics together using needles without using non-woven fibers, in which hook needles are pressed through the woven fabric and then pulled out to mechanically intertwine the fibers of the woven fabric to form a bonded material.

[0014] As used herein, “fiber” is an elongated body having a length dimension much greater than the transverse dimensions of width and thickness. The term “fiber” includes monofilaments, multifilaments, ribbons, strips, staples, and other forms of chopped, cut, or discontinuous fibers having regular or irregular cross-sections. The term “fiber” also includes a plural of any of the above or a combination thereof. Fibers may also be in the form of split films or tapes.

[0015] As used herein, "yarn" is a continuous strand of many fibers, including natural or artificial fibers, that is, the same or two or more different fibers. Yarn is often referred to as a "tow" or "end."

[0016] As used herein, the "layer" is a body that can be rigidly or flexibly curved in three directions, but has length and width dimensions that are much larger than the thickness dimensions when laid flat in a plane.

[0017] As used herein, "tape" is a flat, narrow, monolithic strip of material having a length greater than the ratio of the maximum to the minimum dimension of the average cross section over the length of the tape article, with a width and average cross-sectional aspect ratio, i.e., at least about 3:1. The cross section of the tape in this disclosure may be rectangular, elliptical, polygonal, irregular, or any shape satisfying the width, thickness, and aspect ratio requirements outlined herein. Examples of commercially available tapes include Tensylon® from DuPont, Wilmington, Delaware, USA.

[0018] As used herein, "woven fabric" is any structure having multiple identical or two or more different types of fibers or yarns woven together. Generally, such woven fabrics are manufactured by twisting a set of yarns called weft or filler yarns. Woven fabrics may essentially have any weaving method, such as plain weave, crowfoot weave, leno weave, mock leno weave, basket weave, satin weave, twill weave, unbalanced weave, etc., and combinations thereof. Plain weave and twill weave are the most common and preferred.

[0019] As used herein, "cover factor" means the area size (e.g., percentage) of a woven fabric covered by yarn or fiber.

[0020] As used herein, "V50" is a standard test of ballistic performance and refers to the velocity at which 50% of a projectile fired at a ballistic target passes through the target. Therefore, a higher V50 indicates superior ballistic performance. The V50 data provided herein was obtained in accordance with NIJ Standard-0101.06 (Projectile Testing by Law Enforcement Agencies) and MIL STD-662F (Military Fragmentation Testing).

[0021] As used herein, "Decitex" or "dtex" is a measure of the linear density of a fiber or yarn, specifically the mass in grams of 10,000 meters of fiber or yarn. "Denier" and the abbreviation "d" is 9 / 10 times the decitex, specifically the weight in grams of 9,000 meters of yarn.

[0022] As used herein, the terms “initial tensile modulus,” “tensile modulus,” and “modulus” refer to the elastic modulus measured by ASTM D2256 - Standard Test Method for Tensile Properties of Yarns by the Single-Strand Method.

[0023] As used herein, the singular form includes the plural form, and references to specific numerical values ​​include at least that specific value unless otherwise evident from the context. Where a range of values ​​is indicated, other embodiments include from one specific value and / or up to another specific value. Likewise, where a value is expressed as an approximation using the antecedent "about," the specific value will be understood to constitute another embodiment. All ranges are inclusive and combinable.

[0024] FIG. 1 illustrates an exemplary ballistic-resistant material. The ballistic-resistant material (100) comprises two or more woven fabric layers (120) mechanically interwoven without nonwoven fibers or materials so that fibers (130) of the woven fabric layers (120) are mechanically interwoven in the gaps of the woven fabric layers (120) to form a solidified material without nonwoven fibers or materials (e.g., 1201, 1202, 1203… 120 nIt includes a stack (110) of ). During mechanical entanglement, some of the fibers (130) of the woven fabric layer (120) extend in the Z direction perpendicular to the xy plane of the woven fabric layer (120). In some embodiments, some fibers (130) of at least one woven fabric layer (120) extend in the Z direction to at least one other woven fabric layer (120). In some embodiments, some fibers (130) of at least one woven fabric layer (120) extend in the Z direction to at least two other woven fabric layers (120). In some embodiments, some fibers (130) of at least one woven fabric layer (120) are mechanically entangled with some fibers (130) of at least one other woven fabric layer (120). In some embodiments, some fibers (130) of at least one woven fabric layer (120) are mechanically intertwined with some fibers (130) of at least two other woven fabric layers (120).

[0025] A stack (110) of woven fabric layers (120) without nonwoven fibers can be mechanically entangled and bonded using any mechanical entanglement method known in the art that can be used to mechanically entangle a woven fabric without nonwoven fibers, including but not limited to needle bonding, hydroentanglement, or the use of an air jet (e.g., air entanglement). Such mechanical entanglement helps to hold the fibers (130) in place and prevents the stack (110) of woven fabric layers (120) from tearing and / or peeling off from each other. Additionally, such mechanical entanglement improves the dimensional stability and overall strength of the stack (110) of woven fabric layers (120) (e.g., mechanical entanglement increases the density of the material, thereby allowing more fibers to be interlocked per unit volume), while also imparting some degree of flexibility to the stack (110) of woven fabric layers (120).

[0026] A preferred method of mechanical entanglement is needle entanglement. A needle loom is used during needle entanglement to entangle a stack (110) of woven fabric layers (120). Needle looms are manufactured, for example, by Oskar Dilo Maschinenfabrik KG in Eberhach / N, Germany, Ferher AG in Linz, Austria, and Asselin in Elboeuf, France. During needle entanglement, hook needles are pressed into and pulled out of the stack (110) of woven fabric layers (120), causing the fibers (130) of the woven fabric layers (120) to become entangled.

[0027] woven fabric layer

[0028] The woven fabric layer (120) may include any number of layers. In some embodiments, the woven fabric layer (120) has about 2 to about 1000 layers, in other embodiments about 2 to 500 layers, in other embodiments about 2 to 100 layers, in other embodiments about 2 to 50 layers, in other embodiments about 2 to 25 layers, and in other embodiments about 2 to 10 layers.

[0029] In some embodiments, each woven fabric layer (120) is about 20 g / m² 2 Up to about 1500 g / m² 2 , in other embodiments, about 50 g / m 2 Up to about 1000 g / m² 2 , in other embodiments, about 100 g / m 2 Up to about 800 g / m² 2 , and in other embodiments, about 130 g / m² 2 Up to 500 g / m² 2 It has a basis weight of

[0030] Each woven fabric layer (120) is made of yarn (140) (e.g., warp (140) a ) and weft (140 bIt may include )). In some embodiments, each woven fabric layer (120) has a plurality of yarns (140), and in other embodiments, each woven fabric layer (120) does not have yarns (140). In some embodiments, the yarns (140) of each woven fabric layer (120) have a linear density of about 50 dtex to about 5600 dtex, in other embodiments about 500 dtex to about 5000 dtex, in other embodiments about 50 dtex to about 1500 dtex, in other embodiments about 100 dtex to about 850 dtex, and in other embodiments about 1000 dtex to about 3500 dtex. In some embodiments, the yarn (140) of at least one woven fabric layer (120) has a linear density of about 50 dtex to about 5600 dtex, in other embodiments about 500 dtex to about 5000 dtex, in other embodiments about 50 dtex to about 1500 dtex, in other embodiments about 100 dtex to about 850 dtex, and in other embodiments about 1000 dtex to about 3500 dtex.

[0031] In some embodiments, the yarn (140) of each woven fabric layer (120) has the same linear density, in other embodiments, the yarn (140) of at least one woven fabric layer (120) has the same linear density as the yarn of another woven fabric layer (120), in other embodiments, the yarn (140) of at least one woven fabric layer (120) has a different linear density than the yarn (140) of another woven fabric layer (120), and in other embodiments, the yarn (140) of each woven fabric layer (120) has a different linear density. In some embodiments, the yarn (140) of at least one woven fabric layer (120) has a linear density at least 15% greater than the yarn (140) of another woven fabric layer (120), in some embodiments, has a linear density at least 35% greater than the yarn of another woven fabric layer (120), and in some embodiments, has a linear density 50% greater than the yarn (140) of another woven fabric layer (120). In some embodiments, the yarn (140) of one or more woven fabric layers (120) has a linear density that is at least 15% greater than the yarn (140) of one or more other woven fabric layers (120), in some embodiments, has a linear density that is at least 35% greater than the yarn (140) of one or more other woven fabric layers (120), and in some embodiments, has a linear density that is 50% greater than the yarn (140) of one or more other woven fabric layers (120).

[0032] In some embodiments, each woven fabric layer (120) has a yarn count of about 2 to about 39 ends / inch (5.08 to 99.06 ends / centimeters) in the warp, about 3 to about 24 ends / inch (7.62 to 60.96 ends / centimeters) in other embodiments, about 4 to about 18 ends / inch (10.16 to 45.72 ends / centimeters) in other embodiments, and about 18 to about 39 ends / inch (45.72 to 99.06 ends / centimeters) in other embodiments. In some embodiments, each woven fabric layer (120) has a yarn count of about 2 to about 39 ends / inch (5.08 to 99.06 ends / centimeters) in the weft or filler yarn, about 3 to about 24 ends / inch (7.62 to 60.96 ends / centimeters) in other embodiments, about 4 to about 18 ends / inch (10.16 to 45.72 ends / centimeters) in other embodiments, and about 18 to about 39 ends / inch (45.72 to 99.06 ends / centimeters) in other embodiments.

[0033] In some embodiments, the woven fabric layer (120) is a unidirectional configuration with yarns (140) flowing in the same direction. In some embodiments, the woven fabric layer (120) is a semi-unidirectional configuration with yarns (140) that can be laid in more than one direction. As used herein, “unidirectional” encompasses both unidirectional and semi-unidirectional fabrics unless otherwise required by the context.

[0034] fiber

[0035] Each woven fabric layer (120) has a plurality of fibers (130). The fibers (130) may be made of yarn (140). The fibers (130) may be of any length or texture.

[0036] In some embodiments, the fiber (130) has a toughness of at least 10 g / dtex (11.1 g / denier (gpd)), in other embodiments at least 15 g / dtex (16.7 g / denier (gpd)), in other embodiments at least 30 g / dtex (33.3 g / denier (gpd)), in other embodiments at least 35 g / dtex (38.9 g / denier (gpd)), in other embodiments at least 40 g / dtex (44.4 g / denier (gpd)), and in other embodiments at least 50 g / dtex (55.5 g / denier (gpd)). In some embodiments, the fiber has a toughness of about 10 g / dtex to about 80 g / dtex (11.1 gpd to about 33.3 gpd), in other embodiments about 15 g / dtex to about 30 g / dtex (16.7 gpd to about 33.3 gpd), in other embodiments about 35 g / dtex to about 50 g / dtex (38.9 gpd to about 55.5 gpd), and in other embodiments about 40 g / dtex to about 80 g / dtex (44.4 gpd to about 88.8 gpd). In some embodiments, the fiber (130) has a tensile modulus of at least about 100 g / dtex. In another embodiment, the fiber (130) has a tensile modulus of about 150 g / dtex to about 2700 g / dtex, and in another embodiment, about 200 g / dtex to 2200 g / dtex. In some embodiments, the fiber (130) has a linear density of about 0.1 dtex to about 5600 dtex, in another embodiment about 0.1 dtex to about 2500 dtex, in another embodiment about 0.1 dtex to about 1000 dtex, in another embodiment about 0.1 dtex to about 100 dtex, and in another embodiment about 0.5 dtex to about 25 dtex.In some embodiments, the fiber (130) has a breaking elongation of about 1 to about 550%, in other embodiments about 1 to about 125%, in other embodiments about 1 to about 10%, and in other embodiments about 2 to about 6%.

[0037] The fiber may be manufactured from any polymer known in the art that produces high-strength fibers, including but not limited to polyamides, polyolefins, polyazoles, or blends / mixtures thereof. In some embodiments, the fiber (130) may be aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multi-component fibers, and combinations thereof.

[0038] When the polymer is a polyamide, an aramid is preferred. As used herein, "aramid" refers to a polyamide polymer in which at least 85% of the amide (-CONH-) linkages are directly attached to two aromatic rings. A para-aramid polymer is an aramid polymer in which the amide linkages are at the para position relative to each other. One preferred para-aramid polymer is poly(paraphenylene terephthalamide) or PPD-T. Additives may be used with the aramid, and indeed, it has been found that other polymer materials may be blended with the aramid in an amount of up to 10% by weight, or copolymers in which another diamine is substituted for 10% of the diamine of the aramid or another chlorotic acid is substituted for 10% of the chlorotic acid of the aramid may be used. Suitable aramid fibers are described in the literature [Man-Made Fibres - Science and Technology, Volume 2, Section titled Fibre-Forming Aromatic Polyamides, page 297, W. Black et al., Interscience Publishers, 1968]. Aramid fibers and their production are also disclosed in U.S. Patents No. 3,767,756; No. 4,172,938; No. 3,869,429; No. 3,869,430; No. 3,819,587; No. 3,673,143; No. 3,354,127; and No. 3,094,511.

[0039] Other useful para-aramids include aramid copolymers produced from the incorporation and / or substitution of other aromatic diamines and other aromatic diacid chlorides, such as, for example, 2,6-naphthaloyl chloride or chloro- or dichloroterephthaloyl chloride or 3,4'-diaminodiphenyl ether. Another preferred para-aramid is an aramid copolymer derived from 5(6)-amino-2-(p-aminophenyl)benzimidazole (DAPBI), para-phenylenediamine (PPD), and terephthaloyl dichloride (TCl or T, also commonly referred to as terephthaloyl chloride); Examples include those described in, for instance, U.S. Patent Publication No. 2014 / 0357834, Russian Patent Application No. 2,045,586, and, for instance, the literature [Sugak et al., Fibre Chemistry Vol 31, No 1, 1999]; U.S. Patent No. 4,018,735; and other such fibers provided in WO 2008 / 061668 and US 2014 / 357834-A1.

[0040] Examples of commercially available para-aramid fibers include Kevlar® from DuPont in Wilmington, Delaware, USA, and Twaron® from Teijin Aramid in Arnhem, Netherlands. Examples of aramid copolymer fibers include Armos® and Rusar® from Kamenskvolokno in Kamensk-Shakhtinsky, Russia.

[0041] When the fiber is a polyolefin, polyethylene or polypropylene is preferred. The term "polyethylene" means a predominantly linear polyethylene material with a molecular weight of preferably more than one million, which may contain a small amount of chain branching or comonomers not exceeding five modification units per 100 major chain carbon atoms, and may contain one or more polymeric additives, such as alkene-1 polymers, particularly low-density polyethylene, propylene, etc., in an amount of about 50 weight percent or less, or low molecular weight additives, such as commonly incorporated antioxidants, lubricants, UV blockers, colorants, etc. Such is generally known as extended chain polyethylene (ECPE) or ultra-high molecular weight polyethylene (UHMWPE). The manufacture of polyethylene fibers is discussed in U.S. Patents No. 4,478,083, 4,228,118, 4,276,348 and Japanese Patents No. 60-047,922, 64-008,732. High molecular weight linear polyolefin fibers are commercially available. The manufacture of polyolefin fibers is discussed in U.S. Patent No. 4,457,985. Examples of commercially available polyethylene fibers include Spectra® fibers by Honeywell International Inc., Morristown, New Jersey, USA, and Dyneema® by Koninklijke DSM NV, Heerlen, Netherlands.

[0042] When the fiber is a polyazole, polybenzazole and polypyridazole are preferred. Suitable polyazoles include homopolymers and copolymers. Additives may be used with the polyazole, and up to 10 weight percent of other polymeric materials may be blended with the polyazole. Additionally, copolymers in which another monomer is substituted for at least 10% of the polyazole monomer may be used. Suitable polyazole homopolymers and copolymers can be prepared by known procedures such as those described in or derived therefrom U.S. Patents No. 4,533,693 (Wolfe et al., August 6, 1985), No. 4,703,103 (Wolfe et al., October 27, 1987), No. 5,089,591 (Gregory et al., February 18, 1992), No. 4,772,678 (Sybert et al., September 20, 1988), No. 4,847,350 (Harris et al., August 11, 1992), and No. 5,276,128 (Rosenberg et al., January 4, 1994).

[0043] Preferred polybenzazoles are polybenzimidazole, polybenzothiazole, and polybenzoxazole. If the polybenzazole is polybenzothiazole, it is preferably poly(p-phenylenebenzobistiazole). If the polybenzazole is polybenzoxazole, it is preferably poly(p-phenylenebenzobisoxazole), and more preferably poly(p-phenylene-2,6-benzobisoxazole), referred to as PBO.

[0044] Preferred polypyridazoles are polypyridimidazole, polypyridothiazole, and polypyridoxazole. In some embodiments, the preferred polypyridazole is polypyridobisazole. The preferred poly(pyridobisazole) is poly(1,4-(2,5-dihydroxy)phenylene-2,6-pyrido[2,3-d:5,6-d']bisimidazole, referred to as PIPD. Suitable polypyridazoles, including polypyridobisazole, can be produced by known procedures such as those described in U.S. Patent No. 5,674,969. Examples of para-phenylene benzobisoxazole (PBO) fibers include Zylon® (Toyobo, Osaka, Japan).

[0045] Other useful aromatic polymers include aromatic unsaturated polyesters, such as polyethylene terephthalate, aromatic polyimide, aromatic polyamideimide, aromatic polyesteramideimide, aromatic polyetheramideimide, and aromatic polyesterimide. Copolymers of any of the aforementioned types of materials may also be used.

[0046] If the fiber is polyester, vinyl-ester and ortho-polyester resins are preferred. The vinyl-ester resin is a reaction product of an epoxy resin and an unsaturated fatty acid, such as methacrylic acid or acrylic acid. Most preferably, the epoxy resin used is of the diglycidyl ether / bisphenol-A type. Other epoxy resins, such as epoxy novolak or halogenated epoxy, are also preferred. The ortho-polyester is a reaction product of a glycol, an unsaturated aliphatic dibasic acid or its anhydride, and a saturated ortho-aromatic acid or its anhydride. The glycol is usually propylene glycol, but other glycols, such as ethylene glycol, diethylene glycol, dipropylene glycol, etc., may be used. The unsaturated dibasic acid or anhydride is usually maleic acid, fumaric acid, or maleic anhydride, but other similar acids or anhydrides may be used. The ortho-aromatic acid or anhydride is preferably an ortho-phthalic acid or anhydride, but may be other saturated ortho-aromatic acids and acids modified by halogenation with chlorine. Vinyl-ester resins and ortho-phthalic acid and isophthalic acid polyester resins are generally cured by reaction with monomers such as styrene or substituted styrene, such as vinyl toluene or α-methyl styrene, but other monomers such as methyl methacrylate, methyl acrylate, diallyl phthalate, trialyl cyanurate, etc. are also possible.

[0047] When the fiber is graphene, a multilayer consisting of single sheets of carbon atoms bonded together in a honeycomb pattern is preferred.

[0048] If the fibers are carbon nanotubes, they consist of single-walled carbon nanotubes with diameters in the nanometer range. Single-walled carbon nanotubes are an intermediate between one of the allotropes of carbon, namely fullerene cages and flat graphene.

[0049] If the fiber is spider silk, natural silk or synthetic silk may be used. Natural silk is generally a protein fiber spun into silk by spiders to create a web. Synthetic silk is Bombix mori ( Bombyx mori ) Silkworm, E. coli( E. coli It consists of fibers derived from other organisms, including but not limited to ), goats, tobacco plants, and potato plants.

[0050] ballistic materials

[0051] The thickness and weight of the ballistic material (100) may vary depending on various factors including, but not limited to, the layer type and number of woven fabric layers (120), the degree of mechanical entanglement, the fabric structure, the cotton density, and the weave coverage of the woven fabric layers (120).

[0052] The ballistic material (100) may have any thickness or weight. In some embodiments, the thickness of the ballistic material (100) is about 0.025 in. (0.0635 cm) to about 4.0 in. (10.06 cm), and in other embodiments, about 0.10 in. (0.254 cm) to about 2.0 in. (5.03 cm). In some embodiments, the ballistic material (100) is about 0.034 kg / m² 2 (0.0070 lb / ft 2 ) to about 9.8 kg / m² 2 (2.0 lb / ft 2 ), in other embodiments, about 0.034 kg / m 2 (0.0070 lb / ft 2 ) to about 3.1 kg / m² 2 (0.63 lb / ft 2 ), in other embodiments, about 0.17 kg / m 2 (0.035 lb / ft 2 ) to about 9.8 kg / m² 2 (2.0 lb / ft 2 ), in other embodiments, about 0.17 kg / m 2(0.035 lb / ft 2 ) to about 2.2 kg / m² 2 (0.45 lb / ft 2 ), and in other embodiments, about 0.17 kg / m² 2 (0.035 lb / ft 2 ) to about 0.85 kg / m² 2 (0.17 lb / ft 2 It has a surface density of ).

[0053] In some embodiments, the ballistic material (100) has a V50 range of about 750 ft / s to about 3000 ft / s when tested using a 9 mm projectile according to NIJ Standard - 0101.06 (projectile testing by law enforcement) or a 17-grain fragmentation mock projectile according to MIL STD-662F (fragmentation testing), about 600 ft / s to about 4000 ft / s in other embodiments, and about 500 ft / s to about 20,000 ft / s in other embodiments.

[0054] In addition to performance benefits, the ballistic material (100) does not require additional assembly of woven fabric layers (120). For example, if a bulletproof vest manufacturer uses the ballistic material (100) to make a bulletproof vest, the manufacturer can cut units of the ballistic material (100) from a single roll that has been tested to meet specific ballistic requirements. This method avoids the additional labor of cutting, laminating, counting, and quilting or stitching many layers of ballistic fabric together. Thus, the ballistic material (100) is a "ready-made" ballistic material that offers economic and performance benefits and can be used as a building block to create various configurations of numerous potential products for ballistic supplies.

[0055] Manufacturing method

[0056] FIG. 2 is a flowchart of an exemplary method for forming a ballistic material. In step (21), two or more woven fabric layers (120) are arranged in a stack (110).

[0057] The yarns (140) of the woven fabric layer (120) are preferably arranged crosswise at a 90-degree angle to each other, and the lightweight yarns are lightly stitched, sewn, or woven together to hold them in place so that the woven fabric layer (120) remains manageable during the manufacturing process without separating or bending the individual tows or yarns (140).

[0058] In step (22), a stack (110) of woven fabric layers (120) without nonwoven fibers is mechanically entangled together to form a fused material by any mechanical entanglement method known in the art that can be used to mechanically entangle woven fabrics without nonwoven fibers, including but not limited to needle entanglement, hydraulic entanglement, or the use of an air jet (e.g., air entanglement). Thus, the fibers (130) of the woven fabric layers (120) are mechanically entangled within the gaps of the woven fabric layers (120) to form a fused material without nonwoven fibers and materials.

[0059] In step (23), the solidified material may be heat-treated and calendered. Heat treatment and calendering are performed to increase the density of the solidified material. In some embodiments, the density of the solidified material is increased by about 5% to about 55%, in other embodiments by about 8% to about 40%, and in other embodiments by about 10% to 40%.

[0060] In step (24), one or more secondary processing steps may be applied to the bonded material. The secondary processing steps may include any known in the art, including but not limited to the application of one or more treatment agents or coatings (e.g., water-repellent coatings) and stitching and / or lamination of the bonded material.

[0061] Steps (21, 22, 23, 24) are preferably performed in that order. However, the steps may be performed in any order and / or in combination with other steps.

[0062] Ballistics and Industrial Applications

[0063] FIG. 3 illustrates an exemplary ballistic article. The ballistic article (300) comprises one or more ballistic materials (305) (e.g., 3051…305 n Each ballistic material (305) includes the yarn (340) of the woven fabric layer (320) (e.g., warp (340) a ) and weft (340 b The fibers (330) of the )) are mechanically intertwined in the gaps of the woven fabric layers (320) to form a solidified material without nonwoven fibers or material, and the stack (310) of two or more woven fabric layers (320) is mechanically intertwined together without nonwoven fibers or material.

[0064] One or more ballistic materials (305) may comprise any number of individual ballistic materials. In some embodiments, one or more ballistic materials (305) comprise 1 to 5 ballistic materials, in other embodiments 1 to 50 ballistic materials, in other embodiments 1 to 100 ballistic materials, and in other embodiments 1 to 500 ballistic materials.

[0065] If one or more ballistic materials (305) comprise more than one ballistic material (i.e., two or more), the one or more ballistic materials (305) may be mechanically joined together by stitching or other forms of mechanical joining known in the art. If such one or more ballistic materials (305) are mechanically joined together by stitching, any type of stitching known in the art may be used, including but not limited to plain stitch, quilt stitch, and cross stitch.

[0066] Articles and ballistic materials as disclosed herein are useful in a wide range of articles and may be used in any ballistic articles known in the art, including but not limited to protective clothing or bulletproof clothing that protects body parts from projectiles, such as vests, jackets, etc.; rigid protective clothing or rigid composite protective clothing; rigid and soft containment structures; bomb containment structures; cushioning panels; and aircraft. The term “projectile” is used herein to mean a bullet or other object or fragment thereof, such as that fired from a gun.

[0067] Test method

[0068] In the following examples, the following test method was used.

[0069] Linear density: The linear density of a yarn or fiber is determined by weighing a known length of the yarn or fiber according to the procedure described in ASTM D1907-97.

[0070] Cotton density: The cotton density of a fabric layer is determined by measuring the weight of each single layer of a selected size, for example, 10 cm x 10 cm. The cotton density of a composite structure is determined by the sum of the cotton densities of the individual layers.

[0071] Ballistic Penetration Performance: Ballistic tests of multilayer solidified materials were performed according to NIJ Standard-0101.06 (Projectile Test) and MIL STD-662F (Military Fragment Test). For each embodiment, four targets were tested, and 6 to 9 rounds were fired at each dry target at a 0-degree incline. The recorded V50 value is the average value for the number of shots fired for each embodiment.

[0072] Examples

[0073] The following examples are provided to illustrate exemplary embodiments of the present invention and should not be interpreted as limiting the invention in any way.

[0074] Example 1

[0075] Seven woven layers of aramid copolymer fabric (each with a thickness of 0.070") were laminated and needle-bonded. The resulting bonded material was approximately 0.19 lb / ft². 2 It was weighed as . Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0076] Comparative Example 2

[0077] A stack was formed by overlapping one nonwoven layer of para-aramid fibers (thickness 0.02") onto seven woven layers of aramid copolymer fabric (thickness 0.070") each. Subsequently, the stack was needle-punched. The resulting bonded material had a yield of approximately 0.21 lb / ft². 2 It was weighed as (10% heavier than Example 1). Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0078] Example 3

[0079] Seven woven layers of UHMWPE polymer fabric (each with a thickness of 0.050") were laminated and needle-bonded. The resulting bonded material was approximately 0.15 lb / ft². 2 It was weighed as . Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0080] Comparative Example 4

[0081] A single nonwoven layer of para-aramid fibers (thickness 0.020") was layered over seven woven layers of UHMWPE polymer fabric (thickness 0.050") each to form a stack. Subsequently, the stack was needle-punched. The resulting bonded material had a yield of approximately 0.16 lb / ft². 2It was weighed as (10% heavier than Example 3). Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The results for V50 are shown in Table 1.

[0082] Example 5

[0083] Seven woven layers of para-aramid fabric (each with a thickness of 0.070") were laminated. The stack was needle-bonded. The resulting bonded material yielded approximately 0.20 lb / ft³. 2 It was weighed as . Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0084] Comparative Example 6

[0085] A stack was formed by overlapping one nonwoven layer of para-aramid fiber (thickness 0.020") onto seven woven layers of para-aramid fabric (thickness 0.070") each. The stack was needle-punched. The resulting bonded material had a yield of approximately 0.22 lb / ft². 2 It was weighed as (10% heavier than Example 7). Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0086] Example 7

[0087] Two woven layers of aramid copolymer fabric (thickness 0.070") each were laminated. The stack was hydro-entangled by a high-pressure water jet (pressure up to 6.9 MPa). The resulting fused material had a density of approximately 0.07 lb / ft². 2 It was weighed as . Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0088] Comparative Example 8

[0089] A stack was formed by overlapping one nonwoven layer of para-aramid fibers (thickness 0.02") onto two woven layers of aramid copolymer fabric (thickness 0.070") each. The stack was hydro-entangled by a high-pressure water jet (pressure up to 6.9 MPa). The resulting fused material had a yield of approximately 0.09 lb / ft². 2 It was weighed as (10% heavier than Example 7). Subsequently, V50 of the solidified material was tested against a 17-grain fragmentation mock projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0090] Table 1 shows the V50 performance of the solidified materials produced in Examples 1, 3, 5, 7 and Comparative Examples 2, 4, 6, and 8 using a 17-grain fragmentation simulated projectile according to MIL STD-662F. As shown, the solidified materials produced in Examples 1, 3, 5, and 7 exhibit similar ballistic performance at a weight 10% lower compared to Comparative Examples 2, 4, 6, and 8, respectively.

[0091] [Table 1]

[0092]

[0093] Example 9

[0094] Three bonded materials were formed individually according to Example 1 and stacked together. Subsequently, the edges of the stack of the three bonded materials were stitched together to approximately 0.57 lb / ft² 2 A ballistic plate (firing pack) weighing [value] was created. Subsequently, the V50 of the ballistic plate was tested against a 17-grain fragmentation simulated projectile according to MIL STD-662F. The V50 results are shown in Table 2.

[0095] Comparative Example 10

[0096] Three bonded materials were individually formed and stacked together according to Comparative Example 2. Subsequently, the edges of the stack of the three bonded materials were stitched together to obtain approximately 0.62 lb / ft²2 A ballistic plate (firing pack) weighing [value] was created. Subsequently, the V50 of the ballistic plate was tested against a 17-grain fragmentation simulated projectile according to MIL STD-662F. The V50 results are shown in Table 2.

[0097] Example 11

[0098] Ten solidified materials were individually formed and stacked together according to Example 7. The edges of the stack of the ten solidified materials were stitched together to produce approximately 0.70 lb / ft² 2 A ballistic plate (firing pack) weighing [value] was created. Subsequently, the V50 of the ballistic plate was tested against a 17-grain fragmentation simulated projectile according to MIL STD-662F. The V50 results are shown in Table 2.

[0099] Comparative Example 12

[0100] Ten solidified materials were individually formed and stacked together according to Comparative Example 8. The edges of the stack of the ten solidified materials were stitched together to produce approximately 0.90 lb / ft². 2 A ballistic plate (firing pack) weighing [value] was created. Subsequently, the V50 of the ballistic plate was tested against a 17-grain fragmentation simulated projectile according to MIL STD-662F. The V50 results are shown in Table 2.

[0101] Table 2 shows the V50 performance of ballistic plates produced in Examples 9 and 11 and Comparative Examples 10 and 12 using a 17-grain fragmentation simulated projectile according to MIL STD-662F. As shown, the ballistic plates (firing packs) produced in Examples 9 and 11 exhibit similar ballistic performance at lower weights compared to Comparative Examples 10 and 12, respectively.

[0102] [Table 2]

[0103]

[0104] Accordingly, the ballistic materials described herein are improved and have many advantages over mechanically woven ballistic materials using nonwoven fibers and materials, including, but not limited to, being lighter in weight while having similar ballistic performance, being less sensitive to absorbing undesirable liquids (e.g., water, sweat, etc.), requiring fewer fabric rolls to produce ballistic articles, being easier to manufacture and reducing manufacturing costs, and reducing the risk of error in manufacturing ballistic articles due to a smaller total number of layers.

[0105] Other embodiments of the present application

[0106] Embodiment 1. In some embodiments, the bonded material comprises a plurality of woven fabric layers mechanically intertwined together, said plurality of woven fabric layers comprises fibers, said plurality of woven fabric layers are mechanically intertwined with the fibers of the plurality of woven fabric layers without nonwoven fibers, and at least some of the fibers of said plurality of woven fabric layers extend in a Z direction perpendicular to the xy plane of the plurality of woven fabric layers.

[0107] Embodiment 2. The bonded material of Embodiment 1, wherein some fibers of at least one woven fabric layer among the plurality of woven fabric layers extend in the Z direction to at least one other woven fabric layer among the plurality of woven fabric layers.

[0108] Embodiment 3. The bonded material in Embodiment 1 or 2, wherein at least some fibers of one of the plurality of woven fabric layers extend in the Z direction to at least two other woven fabric layers among the plurality of woven fabric layers.

[0109] Embodiment 4. A bonded material in any one of embodiments 1 to 3, wherein some fibers of at least one woven fabric layer among the plurality of woven fabric layers are mechanically intertwined with some fibers of at least one other woven fabric layer among the plurality of woven fabric layers.

[0110] Embodiment 5. A bonded material in any one of embodiments 1 to 4, wherein some fibers of one woven fabric layer among the plurality of woven fabric layers are mechanically intertwined with some fibers of at least two other woven fabric layers among the plurality of woven fabric layers.

[0111] Embodiment 6. A bonded material in any one of embodiments 1 to 5, wherein the plurality of woven fabric layers are mechanically interwoven together by needle bonding.

[0112] Embodiment 7. In any one of Embodiments 1 to 6, the plurality of woven fabric layers are mechanically intertwined by hydraulic entanglement, the bonded material.

[0113] Embodiment 8. A bonded material in any one of embodiments 1 to 7, wherein the plurality of woven fabric layers are mechanically intertwined by air entanglement.

[0114] Embodiment 9. A solidified material in any one of embodiments 1 to 8, wherein the plurality of woven fabric layers has about 2 to about 100 layers.

[0115] Embodiment 10. The bonded material of Embodiment 9, wherein the plurality of woven fabric layers have about 2 to about 50 layers.

[0116] Embodiment 11. The bonded material of Embodiment 10, wherein the plurality of woven fabric layers have about 2 to about 25 layers.

[0117] Embodiment 12. The bonded material of Embodiment 11, wherein the plurality of woven fabric layers have about 2 to about 10 layers.

[0118] Embodiment 13. In any one of Embodiments 1 to 12, each woven fabric layer of the plurality of woven fabric layers is about 20 g / m² 2 Up to about 1500 g / m² 2 A solidified material having a basis weight of

[0119] Embodiment 14. In Embodiment 13, each woven fabric layer of the plurality of woven fabric layers is about 50 g / m² 2 Up to about 1000 g / m² 2 A solidified material having a basis weight of

[0120] Embodiment 15. In Embodiment 14, each woven fabric layer of the plurality of woven fabric layers is about 100 g / m² 2 Up to about 800 g / m² 2 A solidified material having a basis weight of

[0121] Embodiment 16. In Embodiment 15, each woven fabric layer of the plurality of woven fabric layers is approximately 130 g / m² 2 Up to about 500 g / m² 2 A solidified material having a basis weight of

[0122] Embodiment 17. A bonded material in any one of embodiments 1 to 16, wherein each of the plurality of woven fabric layers comprises a plurality of yarns.

[0123] Embodiment 18. In Embodiment 17, the yarn of at least one woven fabric layer among the plurality of woven fabric layers has a linear density of about 50 dtex to about 5600 dtex, a bonded material.

[0124] Embodiment 19. In Embodiment 18, the yarn of at least one woven fabric layer among the plurality of woven fabric layers has a linear density of about 50 dtex to about 1500 dtex, a bonded material.

[0125] Embodiment 20. In Embodiment 19, the yarn of at least one woven fabric layer among the plurality of woven fabric layers has a linear density of about 100 dtex to about 850 dtex, a bonded material.

[0126] Embodiment 21. In Embodiment 17 or 18, the yarn of at least one of the plurality of woven fabric layers has a linear density of about 1000 dtex to about 3500 dtex, a bonded material.

[0127] Embodiment 22. In any one of embodiments 17 to 21, the yarn of each of the plurality of woven fabric layers has the same linear density, a bonded material.

[0128] Embodiment 23. A bonded material in any one of embodiments 17 to 22, wherein the yarn of at least one woven fabric layer among the plurality of woven fabric layers has the same linear density as the yarn of at least one other woven fabric layer among the plurality of woven fabric layers.

[0129] Embodiment 24. A bonded material in any one of embodiments 17 to 21, wherein the yarn of at least one woven fabric layer among the plurality of woven fabric layers has a linear density different from the yarn of at least one other woven fabric layer among the plurality of woven fabric layers.

[0130] Embodiment 25. In any one of Embodiments 17 to 21 or 24, the yarn of each of the plurality of woven fabric layers has a different linear density, the bonded material.

[0131] Embodiment 26. A bonded material in any one of Embodiments 1 to 25, wherein the plurality of woven fabric layers are unidirectional in composition.

[0132] Embodiment 27. A bonded material in any one of Embodiments 1 to 25, wherein the plurality of woven fabric layers are composed of a quasi-unidirectional structure.

[0133] Embodiment 28. In any one of Embodiments 1 to 27, the fibers of the plurality of woven fabric layers are a solidified material having a toughness of at least 10 g / dtex.

[0134] Embodiment 29. In Embodiment 28, the fibers of the plurality of woven fabric layers are a solidified material having a toughness of at least 15 g / dtex.

[0135] Embodiment 30. In Embodiment 29, the fibers of the plurality of woven fabric layers are a solidified material having a toughness of at least 30 g / dtex.

[0136] Embodiment 31. In Embodiment 30, the fibers of the plurality of woven fabric layers are a solidified material having a toughness of at least 40 g / dtex.

[0137] Embodiment 32. The fibers of the plurality of woven fabric layers in Embodiment 31 are a solidified material having a toughness of at least 50 g / dtex.

[0138] Embodiment 33. In any one of Embodiments 1 to 32, the fibers of the plurality of woven fabric layers are a solidified material having a tensile modulus of at least about 100 g / dtex.

[0139] Embodiment 34. In any one of Embodiments 1 to 33, the fibers of the plurality of woven fabric layers are a solidified material having a tensile modulus of at least about 150 g / dtex to about 2700 g / dtex.

[0140] Embodiment 35. The composite material of Embodiment 34, wherein the fibers of the plurality of woven fabric layers have a tensile modulus of at least about 200 g / dtex to about 2200 g / dtex.

[0141] Embodiment 36. In any one of Embodiments 1 to 35, the fibers of the plurality of woven fabric layers are a solidified material having a linear density of about 0.1 dtex to about 5600 dtex.

[0142] Embodiment 37. In Embodiment 36, the fibers of the plurality of woven fabric layers are a solidified material having a linear density of about 0.1 dtex to about 2500 dtex.

[0143] Embodiment 38. In Embodiment 37, the fibers of the plurality of woven fabric layers are a solidified material having a linear density of about 0.1 dtex to about 1000 dtex.

[0144] Embodiment 39. The composite material of Embodiment 38, wherein the fibers of the plurality of woven fabric layers have a linear density of about 0.1 dtex to about 100 dtex.

[0145] Embodiment 40. In any one of Embodiments 1 to 39, the fibers of the plurality of woven fabric layers are a solidified material having an elongation at break of about 1 to about 550%.

[0146] Embodiment 41. In Embodiment 40, the fibers of the plurality of woven fabric layers are a solidified material having an elongation at break of about 1 to about 125%.

[0147] Embodiment 42. The fibers of the plurality of woven fabric layers in Embodiment 41 are a solidified material having an elongation at break of about 1 to about 10%.

[0148] Embodiment 43. In any one of Embodiments 1 to 42, the fibers of the plurality of woven fabric layers are polymeric, and the material is a solidified material.

[0149] Embodiment 44. In any one of Embodiments 1 to 43, the fibers of the plurality of woven fabric layers comprise one or more of the following types of fibers: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0150] Embodiment 45. In any one of Embodiments 1 to 44, the fibers of the plurality of woven fabric layers are composed of one or more of the following types of fibers: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multi-component fibers, and combinations thereof.

[0151] Embodiment 46. In any one of Embodiments 1 to 45, the fibers of the plurality of woven fabric layers are a bonded material selected from the group consisting of aramid fibers, polyethylene fibers, polypropylene fibers, polyazole fibers, polyester fibers, graphene fibers, spider silk fibers, carbon nanotube fibers, copolymer fibers, multi-component fibers, and combinations thereof.

[0152] Embodiment 47. In any one of Embodiments 1 to 44, the fibers of the plurality of woven fabric layers comprise aramid fibers, a bonded material.

[0153] Embodiment 48. In any one of Embodiments 1 to 44, 46 or 47, the fibers of the plurality of woven fabric layers comprise polyethylene fibers, a bonded material.

[0154] Embodiment 49. In any one of Embodiments 1 to 44 or 46 to 48, the fibers of the plurality of woven fabric layers comprise copolymer fibers, a bonded material.

[0155] Embodiment 50. A bonded material in any one of Embodiments 1 to 44 or 46 to 49, wherein the fibers of the plurality of woven fabric layers comprise multi-component fibers.

[0156] Embodiment 51. A bonded material in any one of Embodiments 1 to 46, wherein the fibers of the plurality of woven fabric layers are polyethylene fibers.

[0157] Embodiment 52. A bonded material in any one of Embodiments 1 to 46, wherein the fibers of the plurality of woven fabric layers are copolymer fibers.

[0158] Embodiment 53. A bonded material in any one of Embodiments 1 to 46, wherein the fibers of the plurality of woven fabric layers are multi-component fibers.

[0159] Embodiment 54. A solidified material having a thickness of about 0.025 in. to about 4.0 in. in any one of Embodiments 1 to 53.

[0160] Embodiment 55. The solidified material of Embodiment 54, having a thickness of about 0.10 in. to about 2.0 in.

[0161] Example 56. In any one of Examples 1 to 55, about 0.034 kg / m² 2 Up to about 9.8 kg / m² 2 A solidified material having a surface density.

[0162] Embodiment 57. In Embodiment 56, approximately 0.034 kg / m² 2 Up to about 3.1 kg / m² 2 A solidified material having a surface density.

[0163] Embodiment 58. In Embodiment 56, about 0.17 kg / m² 2 Up to about 9.8 kg / m² 2 A solidified material having a surface density.

[0164] Embodiment 59. In Embodiment 58, approximately 0.17 kg / m² 2 to about 2.2 kg / m² 2 A solidified material having a surface density.

[0165] Embodiment 60. In Embodiment 59, about 0.17 kg / m² 2 Up to about 0.85 kg / m² 2 A solidified material having a surface density.

[0166] Embodiment 61. A solidified material having a V50 according to MIL STD-662F of about 750 ft / s to about 3000 ft / s in any one of Embodiments 1 to 60.

[0167] Embodiment 62. A solidified material having a V50 according to MIL STD-662F of about 600 ft / s to about 4000 ft / s in any one of Embodiments 1 to 61.

[0168] Embodiment 63. A solidified material having a V50 according to MIL STD-662F of about 500 ft / s to about 20,000 ft / s in any one of Embodiments 1 to 62.

[0169] Embodiment 64. An article comprising at least one solidified material of any one of Embodiments 1 to 63.

[0170] Embodiment 65. A ballistic article comprising at least one solidified material of any one of Embodiments 1 to 63.

[0171] Embodiment 66. A ballistic article according to Embodiment 65, comprising 1 to 5 solidified materials.

[0172] Embodiment 67. A ballistic article according to Embodiment 65, comprising 1 to 50 solidified materials.

[0173] Embodiment 68. A ballistic article according to Embodiment 65, comprising 1 to 100 solidified materials.

[0174] Embodiment 69. In some embodiments, the bonded material comprises two or more woven fabric layers mechanically intertwined together without nonwoven fibers, and some fibers of at least one of the two or more woven fabric layers extend in the Z direction to at least one other woven fabric layer of the two or more woven fabric layers.

[0175] Embodiment 70. In some embodiments, the method for forming a bonded material includes the step of mechanically interlacing two or more layers of woven fabric together without using nonwoven fibers to form a bonded material.

[0176] Embodiment 71. The method of Embodiment 70, further comprising the step of arranging the two or more woven fabric layers in a stack before mechanically interlacing the two or more woven fabric layers.

[0177] Embodiment 72. A method according to Embodiment 70 or 71, further comprising the step of heat-treating and calendering the solidified material.

[0178] Embodiment 73. A method in any one of embodiments 70 to 72, further comprising the step of applying one or more secondary processing steps to the solidified material.

[0179] Embodiment 74. In some embodiments, a method for forming a bonded material comprises the step of mechanically interlocking a plurality of woven fabric layers together to form a bonded material, wherein the plurality of woven fabric layers include fibers, and the plurality of woven fabric layers are mechanically interlocked with the fibers of the plurality of woven fabric layers without non-woven fibers, and at least some of the fibers of the plurality of woven fabric layers extend in a Z direction perpendicular to the xy plane of the plurality of woven fabric layers.

[0180] Embodiment 75. The method of Embodiment 74, further comprising the step of arranging the plurality of woven fabric layers together in a stack before mechanically interlacing the plurality of woven fabric layers together.

[0181] Embodiment 76. The method of Embodiment 74 or 75, further comprising the step of heat-treating and calendering the solidified material.

[0182] Embodiment 77. A method in any one of embodiments 74 to 76, further comprising the step of applying one or more secondary processing steps to the solidified material.

[0183] Embodiment 78. A method in any one of embodiments 74 to 77, wherein some fibers of at least one woven fabric layer among the plurality of woven fabric layers extend in the Z direction to at least one other woven fabric layer among the plurality of woven fabric layers.

[0184] Embodiment 79. A method in any one of embodiments 74 to 78, wherein at least some fibers of one woven fabric layer among the plurality of woven fabric layers extend in the Z direction to at least two other woven fabric layers among the plurality of woven fabric layers.

[0185] Embodiment 80. A method in any one of embodiments 74 to 79, wherein some fibers of at least one woven fabric layer among the plurality of woven fabric layers are mechanically entangled with some fibers of at least one other woven fabric layer among the plurality of woven fabric layers.

[0186] Embodiment 81. A method in any one of embodiments 74 to 80, wherein some fibers of one woven fabric layer among the plurality of woven fabric layers are mechanically entangled with some fibers of at least two other woven fabric layers among the plurality of woven fabric layers.

[0187] Embodiment 82. A method in any one of embodiments 74 to 81, wherein the plurality of woven fabric layers are mechanically interwoven together by needle bonding.

[0188] Embodiment 83. A method in any one of embodiments 74 to 82, wherein the plurality of woven fabric layers are mechanically intertwined by hydraulic entanglement.

[0189] Embodiment 84. A method in any one of embodiments 74 to 83, wherein the plurality of woven fabric layers are mechanically intertwined by air entanglement.

[0190] Embodiment 85. A method in any one of embodiments 74 to 84, wherein the plurality of woven fabric layers comprises about 2 to about 100 layers.

[0191] Embodiment 86. The method of Embodiment 85, wherein the plurality of woven fabric layers comprises about 2 to about 50 layers.

[0192] Embodiment 87. The method of Embodiment 86, wherein the plurality of woven fabric layers comprises about 2 to about 25 layers.

[0193] Embodiment 88. The method of Embodiment 87, wherein the plurality of woven fabric layers comprises about 2 to about 10 layers.

[0194] Embodiment 89. In any one of Embodiments 74 to 88, each woven fabric layer of the plurality of woven fabric layers is about 20 g / m² 2 Up to about 1500 g / m² 2 A method having a basis weight.

[0195] Embodiment 90. In Embodiment 89, each woven fabric layer of the plurality of woven fabric layers is about 50 g / m² 2 Up to about 1000 g / m² 2 A method having a basis weight.

[0196] Embodiment 91. In Embodiment 90, each woven fabric layer of the plurality of woven fabric layers is about 100 g / m² 2 Up to about 800 g / m² 2 A method having a basis weight.

[0197] Embodiment 92. In Embodiment 91, each woven fabric layer of the plurality of woven fabric layers is about 130 g / m² 2 Up to about 500 g / m² 2 A method having a basis weight.

[0198] Embodiment 93. A method in any one of embodiments 74 to 92, wherein each woven fabric layer of the plurality of woven fabric layers comprises a plurality of yarns.

[0199] Embodiment 94. The method of Embodiment 93, wherein the yarn of at least one of the plurality of woven fabric layers has a linear density of about 50 dtex to about 5600 dtex.

[0200] Embodiment 95. The method of Embodiment 94, wherein the yarn of at least one of the plurality of woven fabric layers has a linear density of about 50 dtex to about 1500 dtex.

[0201] Embodiment 96. The method of Embodiment 95, wherein the yarn of at least one of the plurality of woven fabric layers has a linear density of about 100 dtex to about 850 dtex.

[0202] Embodiment 97. Method according to Embodiment 93 or 94, wherein the yarn of at least one of the plurality of woven fabric layers has a linear density of about 1000 dtex to about 3500 dtex.

[0203] Embodiment 98. A method in any one of embodiments 93 to 97, wherein the yarn of each of the plurality of woven fabric layers has the same linear density.

[0204] Embodiment 99. A method in any one of embodiments 93 to 98, wherein the yarn of at least one woven fabric layer among the plurality of woven fabric layers has the same linear density as the yarn of at least one other woven fabric layer among the plurality of woven fabric layers.

[0205] Embodiment 100. A method in any one of embodiments 93 to 97, wherein the yarn of at least one woven fabric layer among the plurality of woven fabric layers has a linear density different from the yarn of at least one other woven fabric layer among the plurality of woven fabric layers.

[0206] Embodiment 101. Method according to Embodiment 100, wherein the yarn of each of the plurality of woven fabric layers has a different linear density.

[0207] Embodiment 102. A method in any one of embodiments 74 to 101, wherein the plurality of woven fabric layers are unidirectionally configured.

[0208] Embodiment 103. A method in any one of embodiments 74 to 101, wherein the plurality of woven fabric layers are configured in a quasi-unidirectional manner.

[0209] Embodiment 104. A method in any one of embodiments 74 to 103, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 10 g / dtex.

[0210] Embodiment 105. Method according to Embodiment 104, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 15 g / dtex.

[0211] Embodiment 106. The method of Embodiment 105, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 30 g / dtex.

[0212] Embodiment 107. Method according to Embodiment 106, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 40 g / dtex.

[0213] Embodiment 108. Method according to Embodiment 107, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 50 g / dtex.

[0214] Embodiment 109. A method in any one of embodiments 74 to 108, wherein the fibers of the plurality of woven fabric layers have a tensile modulus of at least about 100 g / dtex.

[0215] Embodiment 110. Method of Embodiment 109, wherein the fibers of the plurality of woven fabric layers have a tensile modulus of at least about 150 g / dtex to about 2700 g / dtex.

[0216] Embodiment 111. Method according to Embodiment 110, wherein the fibers of the plurality of woven fabric layers have a tensile modulus of at least about 200 g / dtex to about 2200 g / dtex.

[0217] Embodiment 112. A method in any one of embodiments 74 to 111, wherein the fibers of the plurality of woven fabric layers have a linear density of about 0.1 dtex to about 5600 dtex.

[0218] Embodiment 113. Method of Embodiment 112, wherein the fibers of the plurality of woven fabric layers have a linear density of about 0.1 dtex to about 2500 dtex.

[0219] Embodiment 114. Method according to Embodiment 113, wherein the fibers of the plurality of woven fabric layers have a linear density of about 0.1 dtex to about 1000 dtex.

[0220] Embodiment 115. Method of Embodiment 114, wherein the fibers of the plurality of woven fabric layers have a linear density of about 0.1 dtex to about 100 dtex.

[0221] Embodiment 116. A method in any one of embodiments 74 to 115, wherein the fibers of the plurality of woven fabric layers have an elongation at break of about 1 to about 550%.

[0222] Embodiment 117. Method according to Embodiment 116, wherein the fibers of the plurality of woven fabric layers have an elongation at break of about 1 to about 125%.

[0223] Embodiment 118. Method of Embodiment 117, wherein the fibers of the plurality of woven fabric layers have an elongation at break of about 1 to about 10%.

[0224] Embodiment 119. A method in any one of embodiments 74 to 118, wherein the fibers of the plurality of woven fabric layers are polymeric.

[0225] Embodiment 120. In any one of Embodiments 74 to 119, the fibers of the plurality of woven fabric layers comprise one or more of the following types of fibers: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotube, copolymer, multicomponent fiber, and combinations thereof.

[0226] Embodiment 121. In any one of Embodiments 74 to 120, the fibers of the plurality of woven fabric layers comprise one or more of the following types of fibers: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotube, copolymer, multicomponent fiber, and combinations thereof.

[0227] Example 122. A method in any one of Examples 74 to 121, wherein the fibers of the plurality of woven fabric layers are selected from the group consisting of aramid fibers, polyethylene fibers, polypropylene fibers, polyazole fibers, polyester fibers, graphene fibers, spider silk fibers, carbon nanotube fibers, copolymer fibers, multicomponent fibers, and combinations thereof.

[0228] Embodiment 123. A method in any one of embodiments 74 to 120, wherein the fibers of the plurality of woven fabric layers comprise aramid fibers.

[0229] Embodiment 124. A method in any one of Embodiments 74 to 120 or 123, wherein the fibers of the plurality of woven fabric layers comprise polyethylene fibers.

[0230] Embodiment 125. A method in any one of embodiments 74 to 120, 123 or 124, wherein the fibers of the plurality of woven fabric layers comprise copolymer fibers.

[0231] Embodiment 126. A method in any one of embodiments 74 to 120 or 123 to 125, wherein the fibers of the plurality of woven fabric layers comprise multi-component fibers.

[0232] Embodiment 127. A method in any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are polyethylene fibers.

[0233] Embodiment 128. A method in any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are copolymer fibers.

[0234] Embodiment 129. A method in any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are multi-component fibers.

[0235] Embodiment 130. A method in any one of embodiments 74 to 129, wherein the solidified material has a thickness of about 0.025 in. to about 4.0 in.

[0236] Embodiment 131. The method of Embodiment 130, wherein the solidified material has a thickness of about 0.10 in. to about 2.0 in.

[0237] Embodiment 132. In any one of Embodiments 74 to 131, the solidified material is about 0.034 kg / m³ 2 Up to about 9.8 kg / m² 2 A method having a surface density of

[0238] Embodiment 133. In Embodiment 132, the solidified material is about 0.034 kg / m³ 2 Up to about 3.1 kg / m² 2 A method having a surface density of

[0239] Embodiment 134. In any one of Embodiments 74 to 132, the solidified material is about 0.17 kg / m³ 2 Up to about 9.8 kg / m² 2 A method having a surface density of

[0240] Embodiment 135. In Embodiment 134, the solidified material is about 0.17 kg / m³ 2 to about 2.2 kg / m² 2 A method having a surface density of

[0241] Embodiment 136. In Embodiment 135, the solidified material is about 0.17 kg / m³ 2 Up to about 0.85 kg / m² 2 A method having a surface density of

[0242] Embodiment 137. A method in any one of embodiments 74 to 136, wherein the solidified material has a V50 according to MIL STD-662F of about 750 ft / s to about 3000 ft / s.

[0243] Embodiment 138. A method in any one of Embodiments 74 to 136, wherein the solidified material has a V50 according to MIL STD-662F of about 600 ft / s to about 4000 ft / s.

[0244] Embodiment 139. A method in any one of embodiments 74 to 136, wherein the solidified material has a V50 according to MIL STD-662F of about 500 ft / s to about 20000 ft / s.

[0245] Although various embodiments of the present invention have been described above, it should be understood that such embodiments are presented as examples and are not limited thereto. It will be obvious to those skilled in the art that various modifications in form and detail may be made without departing from the spirit and scope of the present invention. Accordingly, although the present invention has been described with reference to the exemplary embodiments described above, it should be understood that other embodiments are also included in the claims. Furthermore, it should be understood that the exemplary embodiments described herein may be combined to form other embodiments. Through the foregoing description, those skilled in the art will clearly understand how to implement the present invention in alternative embodiments. Accordingly, the present invention should not be limited to any of the exemplary embodiments described above.

[0246] The following are claimed to be novel and sought to be protected by a U.S. patent certificate.

Claims

Claim 1 A bonded material comprising a plurality of woven fabric layers mechanically intertwined together, wherein the plurality of woven fabric layers comprise fibers, wherein the plurality of woven fabric layers are mechanically intertwined with the fibers of the plurality of woven fabric layers without non-woven fibers, wherein at least some fibers of the plurality of woven fabric layers extend in the Z direction perpendicular to the xy plane of the plurality of woven fabric layers, wherein the bonded material has a thickness of 0.254 cm (0.10 in.) to 5.08 cm (2.0 in.), wherein the bonded material has a V50 according to MIL STD-662F of 152 m / s (500 ft / s) to 6096.0 m / s (20000 ft / s), and wherein some fibers of at least one of the plurality of woven fabric layers extend in the Z direction to at least one other woven fabric layer among the plurality of woven fabric layers. Claim 2 In claim 1, the solidified material is a solidified material having a V50 according to MIL STD-662F of 183 m / s (600 ft / s) to 1219 m / s (4000 ft / s). Claim 3 A bonded material according to claim 1, wherein at least some fibers of one of the plurality of woven fabric layers extend in the Z direction to at least two other woven fabric layers among the plurality of woven fabric layers. Claim 4 In claim 1, the plurality of woven fabric layers are a bonded material that is mechanically interwoven together by needle bonding. Claim 5 A bonded material according to claim 1, wherein the plurality of woven fabric layers are mechanically entangled together by hydraulic entanglement or the plurality of woven fabric layers are mechanically entangled together by air entanglement. Claim 6 In claim 1, the plurality of woven fabric layers is a solidified material having 2 to 50 layers. Claim 7 In claim 1, each woven fabric layer of the plurality of woven fabric layers is 20 g / m² 2 Up to 1500 g / m² 2 A solidified material having a basis weight of Claim 8 A bonded material according to claim 1, wherein the plurality of woven fabric layers are unidirectional or the plurality of woven fabric layers are semi-unidirectional. Claim 9 A bonded material according to claim 1, wherein the fibers of the plurality of woven fabric layers have a toughness of at least 10 g / dtex, the fibers of the plurality of woven fabric layers have a tensile modulus of at least 100 g / dtex, or the fibers of the plurality of woven fabric layers have an elongation at break of 1 to 550%. Claim 10 In claim 1, the fibers of the plurality of woven fabric layers are polymeric, a solidified material. Claim 11 In claim 1, the fibers of the plurality of woven fabric layers comprise one or more of the types of fibers including aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof, in a bonded material. Claim 12 In paragraph 1, 0.034 kg / m² 2 up to 9.8 kg / m² 2 A solidified material having a surface density. Claim 13 An article comprising at least one of the solidified materials of paragraph 1. Claim 14 Article 13, a ballistic article that does not contain a solidified material having nonwoven fibers. Claim 15 delete Claim 16 delete Claim 17 delete Claim 18 delete Claim 19 delete Claim 20 delete

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