Three-dimensional fabric with interwoven warp yarns suitable for withstanding impacts, bulletproof vest for the female torso and method for manufacturing same

Abstract

The invention relates to a three-dimensional fabric (16) with interwoven warp yarns, suitable for withstanding impacts, the three-dimensional fabric (16) having a weave (22), the repeating pattern of which comprises at least a first weft yarn (Pa1) and a second weft yarn (Pb1) that form a first vertical column, a first weft yarn (Pa2) and a second weft yarn (Pb2) that form a second vertical column, and two bonding warp yarns (C11, C21) that move along a longitudinal pitch of a weft yarn, and across a vertical bonding depth of two weft yarns.

Description

[0001] DESCRIPTION

[0002] Title: Three-dimensional fabric with interwoven warp threads suitable for impact resistance and bulletproof vest for female torso and its manufacturing process

[0003] Field of invention

[0004] This patent application relates to the field of fabrics suitable for resisting impacts, and more particularly to three-dimensional fabrics with interwoven warp threads.

[0005] The present invention also relates to a female torso bulletproof vest made with such a fabric and its manufacturing method.

[0006] This invention may find application in the marine, aerospace, transport, sports, aeronautics and more generally in any field requiring a high-performance fabric that is deformable without compromising its ability to resist impacts.

[0007] State of the art

[0008] The ballistic protection industry has primarily focused on the design and manufacture of bulletproof vests for the male torso, using various ballistic impact fabrics, including two-dimensional fabrics, quasi-unidirectional wovens, unidirectional laminates, etc.

[0009] Also, efforts have been made to develop bulletproof vests adapted to the female torso. Indeed, it is known that the effectiveness of female bulletproof vests depends heavily on the fit of the vest to the body wearing it, and in particular on the fit of the ballistic protection panel that covers the torso.

[0010] In other words, the more the vest conforms to the shape of the body, the more effective the protection.

[0011] To give a bulletproof vest a shape close to a female bust, it is known to use "cut and sew" techniques on ballistic fabrics with different seams.

[0012] Although simple in design, this type of technique has weak points at the seams to resist ballistic impact.

[0013] Also known is a bulletproof vest which is made by folding and sewing, as described and shown in US4183097A.

[0014] This document describes a contoured fabric bulletproof vest for protecting a woman's torso, comprising a contoured frontal protective panel composed of a plurality of layers of aramid ballistic protective fabric. The fabric layers are folded upon themselves by angularly offsetting them from one direction to the other.

[0015] The protective panel is contoured by overlapping folded layers of fabric that are sewn to join two side sections to a center section of the panel so as to cause the protective panel to conform to the curvature of a woman's bust.

[0016] This method aims to distribute the added thickness evenly, avoid bulges and improve comfort.

[0017] However, a protective panel made using this folding design has excess thickness, causing itching, reduced personal mobility and some discomfort.

[0018] Also, a multi-layer laminated woven structure for ballistic protective clothing is known that can be molded to substantially conform to a female torso, as described in US6281149B1.

[0019] According to this document, the three-dimensional woven structure is used for the basic functional layer of the ballistic protective clothing.

[0020] Additionally, a thermoplastic material is used to fuse the fibers of the layers of the three-dimensional woven structure to each other in order to improve the strength of the woven structure.

[0021] However, the lack of flexibility of this type of woven and thermo-molded structure creates folds which can ultimately cause problems with fit and comfort.

[0022] Also known is a molded, curable resin-impregnated body armor panel designed to fit female torsos, as described in US2009255022A1.

[0023] This panel is made up of several layers of floating woven fabric, each layer of fabric being made with weft and warp yarns with long floats in one or more directions, to aid in molding and shaping the panel.

[0024] Additionally, the threads of each layer are impregnated with adhesive resin and several layers of ballistic fabric are placed on a preformed mold adapted to the desired body shape.

[0025] The layers of fabric, with the adhesive applied, are compressed in the mold to obtain the required shape thanks to the long weft floats of the fabric.

[0026] Although the loose woven fabric helps shape the body armor panel, such a panel may lack flexibility and comfort. Finally, another technique is to use a ballistic panel that is made from a three-dimensional fabric with interwoven warp threads, also known as three-dimensional warp interlock fabric.

[0027] This type of three-dimensional fabric has excellent moldability, allowing it to adapt to the contours of the female torso.

[0028] However, the ballistic performance of this type of fabric is inferior to that of their counterparts, two-dimensional fabrics, called 2D fabrics, or unidirectional laminates called "UD laminates".

[0029] The difference between a two-dimensional fabric and a three-dimensional fabric is that three-dimensional fabrics have threads running through the thickness of the fabric.

[0030] As shown in a study titled “Engineering of 3D warp interlock p-aramid fabric structure and its energy absorption capabilities against ballistic impact for body armor applications,” the ballistic performance of the three-dimensional warp interlock fabric is inferior to that of its counterparts, 2D fabrics or UD laminates.

[0031] Indeed, when the fabric deforms, the deformation stress may not be uniform over the entire protective panel, causing a problem for the final ballistic performance of the bulletproof vest.

[0032] Technical problem

[0033] As previously stated, there are various techniques for developing female bulletproof vests, including "cut and sew" techniques on ballistic fabrics with various seams, including butted and overlapped seams.

[0034] These techniques certainly improve the comfort and ease of use of the vest, but at the expense of protection at the seams.

[0035] To improve impact protection and user comfort, it is therefore advantageous to offer a bulletproof vest whose fabric protection panel is made without cutting or sewing, without stretch folding or folding.

[0036] Also, it is known that the effectiveness of female bulletproof vests depends heavily on the fit of the ballistic protection panel to the torso.

[0037] However, when developing streamlined female body armor, ballistic fabrics may have different mechanical properties, including surface shear angle, material strength values, and corresponding mechanical damage, which could affect the mechanical properties, including impact performance. Ballistic fabrics such as 2D woven fabric or unidirectional laminated fabric are composed of high-strength fibers and are used to develop ballistic protective equipment, including female body armor, due to their excellent mechanical properties and improved fatigue resistance.

[0038] However, due to the lack of flexibility of these fabrics, shaping techniques result in creases that pose problems with fit and final performance in the event of an impact. Finally, three-dimensional fabrics have excellent molding and shaping capabilities to adapt to the contours of the female torso, but their ballistic performance is inferior to that of their counterparts, 2D fabrics or unidirectional laminates.

[0039] Thus, the present invention aims to provide a three-dimensional fabric with interwoven warp threads, which has improved mechanical and dynamic performance in order to resist impacts on a flat or raised surface, and which can be shaped and adjusted to a female torso for the design of a female bulletproof vest, without compromising ballistic performance.

[0040] Statement of the invention

[0041] An object of the present invention is to provide a three-dimensional fabric with interwoven warp threads, suitable for resisting impacts, the fabric having a weave whose repeating pattern comprises at least:

[0042] - a first group of transverse weft threads comprising at least a first weft thread and a second weft thread which form a first vertical column,

[0043] - a second group of transverse weft threads comprising at least a first weft thread and a second weft thread which form a second vertical column, the first weft thread of the first group and the first weft thread of the second group forming a first layer of weft threads, and the second weft thread of the first group and the second weft thread of the second group forming a second layer of weft threads,

[0044] - a first group of binding warp yarns which comprises at least one first longitudinal binding warp yarn, and

[0045] - a second group of binding warp yarns which comprises at least one first longitudinal binding warp yarn,

[0046] Advantageously, each binding warp thread evolves along a longitudinal pitch of one weft thread, and along a vertical binding depth of two weft threads, so that the first binding warp thread of the first group extends longitudinally by taking at least the two weft threads of the first column and successively leaving the two weft threads of the second column, and the first binding warp thread of the second group extends longitudinally by leaving the two weft threads of the first column and taking at least the two weft threads of the second column.

[0047] Such a three-dimensional fabric according to the invention has good dimensional stability which is particularly suitable for use as an impact protection material.

[0048] The three-dimensional fabric according to the invention offers the possibility of being shaped without affecting its mechanical performance.

[0049] Also, the three-dimensional fabric according to the invention reduces the coupling of shock waves after impact at the connection points of the weft threads and the warp threads, which improves the resistance to delamination of the layers of the three-dimensional fabric 16, in particular in the case of multiple impacts. According to other optional characteristics of the invention, taken alone or in combination:

[0050] - the weave pattern has an orthogonal structure, with the warp threads being interwoven orthogonally with the weft threads;

[0051] - the first group of weft threads comprises at least five weft threads each belonging to the first vertical column, the second group of weft threads comprises at least five weft threads each belonging to the second vertical column, the first group of binding warp threads comprises at least four binding warp threads, the second group of binding warp threads comprises at least four binding warp threads, and each binding warp thread evolves following a longitudinal pitch of one weft thread, and following a vertical binding depth of two weft threads;

[0052] - the three-dimensional fabric comprises at least one reinforcing warp thread which extends longitudinally between each layer of weft threads;

[0053] - the proportion of binding warp yarns represents between fifty percent and seventy percent of the total formed by the binding warp yarns and the reinforcing warp yarns. However, it is observed that three-dimensional fabrics which comprise a rate of between fifty percent and seventy percent of binding warp yarns compared to the reinforcing warp yarns, have a better energy absorption capacity when the fabric is subjected to an impact, whether the fabric is flat or in relief. This characteristic contributes to providing optimal protection against impacts while minimizing defects during the manufacture of the fabric;

[0054] - the warp threads and the weft threads which make up the three-dimensional fabric are each made from one of the materials included in the following group: para-aramid, meta-aramid, para-aramid copolymer, high-performance polyester, high-density polyethylene, polybenzoxazole, polybenzothiazole, fiberglass. The invention also relates to a protective panel suitable for making a bulletproof vest for a female torso, said panel comprising a plurality of layers of three-dimensional fabric with interwoven warp threads of the type described above.

[0055] The invention also relates to a bulletproof vest for a female torso comprising at least one protective panel of the type described above.

[0056] The invention also relates to a method for manufacturing a bulletproof vest for a female torso of the type described above, said vest comprising at least one protective panel which is adapted to cover a female torso and which comprises a plurality of layers of three-dimensional fabric with interwoven warp threads, characterized in that it successively comprises at least:

[0057] - a step of forming the panel which consists of arranging a plurality of layers of said three-dimensional fabric in a bust-shaped mold and exerting pressure on said layers of fabric by means of the mold for a predetermined time to form a raised part intended to fit the shapes of a female torso,

[0058] - a step of demolding the panel formed by said layers, and

[0059] - a step of applying an elastomer-based resin to at least the raised part of the panel. The forming step has the advantage of being carried out at room temperature, i.e. without the addition of additional heat.

[0060] Also, the method according to the invention comprises at least one heat treatment step which is carried out following the resin application step and which consists of heating the molded panel for a predetermined time, to promote cohesion between the resin and the wires which make up the panel.

[0061] Brief description of the drawings

[0062] Other characteristics, aims and advantages of the invention will appear on reading the detailed description which follows, for the understanding of which reference will be made to the appended drawings in which:

[0063] [Fig. 1] is a perspective view of a bulletproof vest comprising a molded front panel, according to the invention;

[0064] [Fig. 2] is a schematic view of a portion of the front panel of Figure 1, comprising eight layers of three-dimensional fabric according to the invention;

[0065] [Fig. 3] is a schematic cross-sectional view of the three-dimensional fabric of Fig. 2, which illustrates the repeating pattern of the weave of the three-dimensional fabric; [Fig. 4] is a reading table of the repeating pattern of the weave of the three-dimensional fabric according to the invention;

[0066] [Fig. 5] is a table for reading the repeat pattern of the weave of the three-dimensional fabric according to the invention;

[0067] [Fig. 6] is a schematic perspective view of a mold for implementing the method of manufacturing a front panel for a bulletproof vest of Figure 1, according to the invention.

[0068] In the description and claims, the terminology longitudinal, vertical and transverse will be adopted without limitation with reference to the trihedron L, V, T indicated in Figure 3, considering that the thickness of the three-dimensional fabric extends vertically.

[0069] Throughout these figures, identical or similar elements are identified by identical or similar reference signs.

[0070] Detailed description of embodiments of the invention

[0071] Figure 1 shows a bulletproof vest 10 adapted to the shape of a female torso.

[0072] The bulletproof vest 10 comprises a front panel 12 for protection against ballistic impacts which has a raised portion 13 which conforms to the shape of the female torso illustrated in FIG. 1. According to an exemplary embodiment of the bulletproof vest 10 according to the invention illustrated schematically in FIG. 2, the front panel 12 comprises eight layers 14, or plies, of a three-dimensional fabric 16 with interlaced warp threads, with an arrangement of the layers 14 at zero degrees.

[0073] The front panel 12 has an inner face 18 where the trauma is created and an outer face 20 where the projectile hits the front panel 12.

[0074] The three-dimensional fabric 16 with interlaced warp threads according to the invention, commonly called three-dimensional “interlock” warp fabric, or “3D interlock” warp fabric, designates a fabric which has threads evolving in the thickness of the fabric, unlike a two-dimensional fabric, or “2D fabric”.

[0075] The present invention aims in particular to propose a three-dimensional fabric 16 with interlaced warp threads which has a weave 22, shown in a box in Figure 3, adapted to distribute the forces in different directions and promote the mechanical properties of the fabric. The weave of a fabric designates the mode of interlacing of the warp threads and the weft threads which compose it.

[0076] According to an exemplary embodiment illustrated in Figures 3 to 5, the repeating pattern of the weave 22 of the three-dimensional fabric 16 according to the invention comprises a first group P1 of transverse weft threads, a second group P2 of transverse weft threads, a first group C1 of longitudinal binding warp threads, a second group C2 of binding warp threads and a third group C3 of reinforcing warp threads which each extend longitudinally between a layer of weft threads.

[0077] The first group PI of weft yarns comprises five transverse weft yarns Pal, Pbl, Pci, Pdl, Pel which form a first column extending vertically along the thickness of the three-dimensional fabric 16.

[0078] Likewise, the second group P2 of weft yarns comprises five transverse weft yarns Pa2, Pb2, Pc2, Pd2, Pe2 which form a second column extending vertically along the thickness of the three-dimensional fabric 16.

[0079] The first weft yarn Pal of the first group PI and the first weft yarn Pa2 of the second group P2 form a first layer of weft yarns which extends longitudinally.

[0080] Also, the second weft yarn Pbl of the first group P1 and the second weft yarn Pb2 of the second group P2 form a second layer of weft yarns which extends longitudinally, and so on, so that the three-dimensional fabric 16 comprises five layers of weft yarns. Still according to an exemplary embodiment of the invention, the first group C1 of binding warp yarns comprises four binding warp yarns C11, C12, C13, C14, each shown in solid lines in Figure 3.

[0081] Similarly, the second group C2 of binding warp yarns comprises four binding warp yarns C21, C22, C23, C24, each shown in broken lines in Figure 3.

[0082] As can be seen in Figure 2, generally speaking, each binding warp thread C11, C12, C13, C14, C21, C22, C23, C24 evolves following a longitudinal pitch of one weft thread, and following a vertical binding depth of two weft threads.

[0083] More particularly, the first binding warp yarn Cl 1 of the first group Cl undulates longitudinally by taking the five weft yarns Pal, Pbl, Pci, Pdl, Pel of the first column and leaving the first two weft yarns Pa2, Pb2 of the second column.

[0084] Each binding warp yarn of the first group Cl evolves in the same way as the first binding warp yarn Cil, with a vertical shift of one weft yarn in the thickness of the three-dimensional fabric 16.

[0085] Thus, the C12 binding warp yarn takes four weft yarns Pbl, Pci, Pdl, Pel from the first column and leaves the first three weft yarns Pa2, Pb2, Pc2 from the second column, the C13 binding warp yarn takes three weft yarns Pci, Pdl, Pel from the first column and leaves the first four weft yarns Pa2, Pb2, Pc2, Pd2 from the second column and the C14 binding warp yarn takes two weft yarns Pci, Pdl from the first column and leaves the five weft yarns Pa2, Pb2, Pc2, Pd2, Pe2 from the second column. The binding warp yarns of the second group C2 undulate longitudinally in an “out-of-phase” manner with respect to the binding warp yarns of the first group Cl.

[0086] Thus, the binding warp yarn C21 of the second group C2 leaves the first two weft yarns Pal, Pbl of the first column and takes the five weft yarns Pa2, Pb2, Pc2, Pd2, Pe2 of the second column, the binding warp yarn C22 leaves the first three weft yarns Pal, Pbl, Pci of the first column and takes four weft yarns Pb2, Pc2, Pd2, Pe2 of the second column, the binding warp yarn C23 leaves the first four weft yarns Pal, Pbl, Pci, Pdl of the first column and takes three weft yarns Pc2, Pd2, Pe2 of the second column, the binding warp yarn C24 leaves the five weft yarns Pal, Pbl, Pci, Pdl, Pel of the first column and takes two weft yarns Pd2, Pe2 of the second column.

[0087] It will be noted that the binding warp threads C11, C12, C13, C14 of the first group C1 evolve symmetrically to the binding warp threads C21, C22, C23, C24 of the second group C2, following a vertical plane of symmetry S illustrated in figure 3.

[0088] It will also be noted that the pattern of the weave 22 has an orthogonal structure, which means that the binding warp threads are interlaced orthogonally with the layers of weft threads.

[0089] Finally, the third group C3 of reinforcing warp yarns comprises four reinforcing warp yarns C31, C32, C33, C34 which each extend longitudinally between a layer of weft yarns and which are each represented in dotted lines in Figure 3.

[0090] More specifically, the first reinforcing warp yarn C31 extends between the first layer of weft yarns formed by the yarns Pal, Pa2 and the second layer of weft yarns formed by the yarns Pbl, Pb2, the second reinforcing warp yarn C32 extends between the second layer of weft yarns formed by the yarns Pbl, Pb2 and the third layer of weft yarns formed by the yarns Pci, Pc2, the third reinforcing warp yarn C33 extends between the third layer of weft yarns formed by the yarns Pci, Pc2 and the fourth layer of weft yarns formed by the yarns Pdl, Pd2 and the fourth reinforcing warp yarn C34 extends between the fourth layer of weft yarns formed by the yarns Pdl, Pd2 and the fifth layer of weft yarns formed by the yarns Pel, Pe2.

[0091] It will be understood that the pattern of the weave 22 is repeated in the transverse direction and in the longitudinal direction to form the three-dimensional fabric 16.

[0092] In the upper portion of the table of Figure 5, the designations "UWp" and "LWp" refer to the raising and lowering actions of the frames of the weaving machine (not shown) which is used in the manufacture of the three-dimensional fabric 16.

[0093] Also, the designations "UWp" and "LWp" correspond to the high or low position of the selected warp threads and the weft threads respectively, the designations "UWp" and "LWp" representing respectively the warp threads above the weft threads considered and the warp threads below the weft threads considered.

[0094] The lower part of the table in Figure 5 shows the number of weft threads left by the warp thread in question.

[0095] Also, the lower table of Figure 4, which includes ten lines, shows the weaving pattern of the weave 22 of the three-dimensional fabric 16, a black box representing a weft thread which is taken by the binding warp thread considered, a white box representing a weft thread which is left by the warp thread considered and a gray box representing a weft thread which is taken by the reinforcing warp thread considered.

[0096] The upper table of Figure 4 which includes two first represents the lifting plan of the frames of the weaving machine (not shown) which is used for the manufacture of the three-dimensional fabric 16.

[0097] Advantageously, the three-dimensional fabric 16 according to the invention comprises eight binding warp threads C11, C12, C13, C14, C21, C22, C23, C24 and four reinforcing warp threads C31, C32, C33, C34, so that the three-dimensional fabric 16 comprises twice as many binding warp threads as reinforcing warp threads C31, C32, C33, C34.

[0098] The proportion of binding warp yarns represents between fifty percent and seventy percent of the total formed by the binding warp yarns and the reinforcing warp yarns. However, it is observed that three-dimensional fabrics which comprise a rate of between fifty percent and seventy percent of binding warp yarns compared to the reinforcing warp yarns, have a better energy absorption capacity when the fabric is subjected to an impact, whether the fabric is flat or in relief.

[0099] This feature helps provide optimal impact protection while minimizing defects during fabric manufacturing.

[0100] In addition, each binding warp thread C11, Cl 2, C13, C14, C21, C22, C23, C24 forms a binding stitch by taking two weft threads, which corresponds to one binding stitch out of two, or fifty percent of binding stitches.

[0101] This bonding rate ensures good dimensional stability of the three-dimensional fabric 16 used as impact protection material, and ensures the possibility of being shaped without affecting its mechanical performance.

[0102] Also, this bonding rate significantly reduces the coupling of shock waves to the bonding points after impact, which improves the resistance to delamination of the layers of the three-dimensional fabric 16, especially in the case of multiple impacts. The reinforcing warp yarns C31, C32, C33, C34 do not have a bonding point but contribute to the rigidity of the three-dimensional fabric 16.

[0103] The yarns that constitute the three-dimensional fabric 16 according to the invention are preferably yarns made from high-density, high-performance yarns derived from the families of inorganic, mineral and organic polymers in the form of single or mixed yarns.

[0104] These yarns include, for example, aromatic polyamides such as para-aramid of the poly(p-phenyleneterephthalamide) type, meta-aramid of the poly(m-phenylene isophthalamide) type, para-aramid copolymers, high-performance polyesters, high-density polyethylene (HDPE), or polybenzoxazoles such as PBO (p-phenylene benzobisoxazole) and PIPD (polypropylene dobisimidazole), or polybenzothiazoles, or glass fibers.

[0105] For example, the yarns have a minimum modulus of elasticity of 2.52 gigapascal (GPa), 2.31 gigapascal (GPa) and 62 gigapascal (GPa) respectively. In addition, the aforementioned fibers also have a minimum modulus of elasticity of 2.52 gigapascal (GPa), 2.31 gigapascal (GPa) and 62 gigapascal (GPa) respectively.

[0106] The linear mass of the yarns that make up the three-dimensional fabric 16 is determined so that the three-dimensional fabric 16 has a surface mass of between 800 and 900 grams per square meter (g / m 2 ).

[0107] Thus, the panel 12, which comprises eight layers of three-dimensional fabric 16, has a surface mass of the order of approximately 7,200 grams per square meter (g / m 2 ).

[0108] The surface mass of the warp and weft yarns contributes in equal proportions to the total surface mass of the three-dimensional fabric 16.

[0109] The three-dimensional fabric 16 according to the invention has a thickness of approximately two to three millimeters, for example.

[0110] The invention also relates to a method for manufacturing a front panel 12 for a bulletproof vest 10 for a female torso, of the type described above.

[0111] The method comprises a step of forming the panel 12 which consists of arranging the layers 14 of the three-dimensional fabric 16 described previously in a mold 24 in the shape of a bust of a forming machine (not shown).

[0112] The mold 24 comprises a first upper part 26a which delimits a female impression corresponding to the shape of a female bust and a second complementary part 26b which delimits a male impression.

[0113] During the forming step, pressure is exerted on the layers 14 by means of the closed mold 24 for a predetermined time to form the panel 12 and give it the shape delimited by the mold 24, and in particular to form the raised part 13 which matches the shape of the chest of the female torso.

[0114] Preferably, pressure is exerted on the layers 14 for at least four hours.

[0115] Also, the forming step is carried out dry and at room temperature, i.e. without additional heat input.

[0116] The method comprises a step of demolding the panel 12 which is carried out following the forming step.

[0117] The demolding step is followed by a step of applying a resin to the molded panel 12. The resin is preferably applied to the entire panel 12, but without limitation, it may be applied only to the raised portion 13 of the molded panel 12.

[0118] The resin aims to maintain the shape of the panel 12 given by the molding throughout the lifetime of the panel 12 equipping the bulletproof vest 10.

[0119] Preferably, the resin is a low viscosity elastomer-based resin, for example polyurethane-based, which promotes the impregnation of the resin into the threads of the three-dimensional fabric 16.

[0120] The resin application step is followed by a heat treatment step which consists of heating the molded panel 12 for a determined duration and at a determined temperature, to promote cohesion between the resin and the wires which make up the panel 12 and to allow the resin to harden.

[0121] The heat treatment stage lasts a maximum of thirteen minutes, for example.

[0122] The temperature of the heat treatment is set below the transition temperature of the threads which make up the layers 14 of three-dimensional fabric 16 of the panel 12 in order to avoid degradation of the threads, for example between 240 and 260 degrees Celsius for para-aramid type threads.

[0123] Such crosslinking of the resin makes it possible to maintain the final deformed shape of the panel 12, while retaining sufficient flexibility and therefore satisfactory comfort for the wearer of the vest.

[0124] It will be noted that the layers 14 of the panel 12 are linked together without recourse to assembly techniques such as fusion, sewing, gluing or stitching.

[0125] Naturally, the invention is described in the above by way of example.

[0126] It is understood that a person skilled in the art is able to carry out different variant embodiments of the invention without departing from the scope of the invention.

[0127] For example, the first group P1 of weft yarns and the second group P2 of weft yarns of the repeating pattern of the three-dimensional fabric 16 may comprise a number greater than five weft yarns, depending on the capabilities of the weaving machine.

Claims

Claims 1. Three-dimensional fabric (16) with interwoven warp threads, suitable for resisting impacts, the three-dimensional fabric (16) having a weave (22) whose repeating pattern comprises at least: - a first group (PI) of transverse weft threads comprising at least a first weft thread (Pal) and a second weft thread (Pbl) which form a first vertical column, - a second group (P2) of transverse weft threads comprising at least a first weft thread (Pa2) and a second weft thread (Pb2) which form a second vertical column, the first weft thread (Pal) of the first group and the first weft thread (Pa2) of the second group forming a first layer of weft threads, and the second weft thread (Pbl) of the first group and the second weft thread (Pb2) of the second group forming a second layer of weft threads, - a first group (Cl) of binding warp yarns which comprises at least one first longitudinal binding warp yarn (Cil), and - a second group (C2) of binding warp yarns which comprises at least one first longitudinal binding warp yarn (C21), characterized in that each binding warp yarn (C11, C21) evolves following a longitudinal pitch of one weft yarn, and following a vertical binding depth of two weft yarns, so that the first binding warp yarn (C11) of the first group (C1) extends longitudinally by taking at least the two weft yarns (Pal, Pbl) of the first column and successively leaving the two weft yarns (Pa2, Pb2) of the second column, and the first binding warp yarn (C21) of the second group (C2) extends longitudinally by leaving the two weft yarns (Pal, Pbl) of the first column and taking at least the two weft yarns (Pa2, Pb2) of the second column.

2. Three-dimensional fabric (16) with interlaced warp threads according to claim 1, characterized in that said pattern of the weave (22) has an orthogonal structure, the binding warp threads (Cil, C21) being interlaced orthogonally with the weft threads (Pal, Pbl, Pa2, Pb2).

3. Three-dimensional fabric (16) with interlaced warp threads according to any one of the preceding claims, characterized in that the first group (PI) of weft threads comprises at least five weft threads (Pal, Pbl, Pci, Pdl, Pel) each belonging to the first vertical column, - the second group (P2) of weft threads comprises at least five weft threads (Pa2, Pb2, Pc2, Pd2, Pe2) each belonging to the second vertical column, - the first group (Cl) of binding warp yarns comprises at least four binding warp yarns (C11, C12, C13, C14), and - the second group (C2) of binding warp threads comprises at least four binding warp threads (C21, C22, C23, C24), and in that each binding warp thread (Cl 1, Cl 2, Cl 3, Cl 4, C21, C22, C23, C24) evolves according to a longitudinal pitch of one weft thread, and according to a vertical binding depth of two weft threads.

4. Three-dimensional fabric (16) with interlaced warp threads according to any one of the preceding claims, characterized in that it comprises at least one reinforcing warp thread (C31, C32, C33, C34) which extends longitudinally between each layer of weft threads.

5. Three-dimensional fabric (16) with interlaced warp threads according to claim 1, characterized in that the proportion of the binding warp threads (C11, C12, C13, C14, C21, C22, C23, C24) represents between fifty percent and seventy percent of the whole formed by the binding warp threads (C11, C12, C13, C14, C21, C22, C23, C24) and the reinforcing warp threads (C31, C32, C33, C34).

6. Three-dimensional fabric (16) with interlaced warp threads according to any one of the preceding claims, characterized in that said threads (Ci l, C12, C13, C14, C21, C22, C23, C24, C31, C32, C33, C34, Pal, Pbl, Pci, Pdl, Pel, Pa2, Pb2, Pc2, Pd2, Pe2) which make up the three-dimensional fabric (16) are each made from one of the materials included in the following group: para-aramid, meta-aramid, para-aramid copolymer, high-performance polyester, high-density polyethylene, polybenzoxazole, polybenzothiazole, glass fiber.

7. Protective panel (12) suitable for making a bulletproof vest (10) for a female torso, said panel (12) comprising a plurality of layers (14) of three-dimensional fabric (16) with interwoven warp threads according to any one of the preceding claims.

8. Bulletproof vest (10) for female torso comprising at least one protective panel (12) according to claim 7.

9. Method for manufacturing a bulletproof vest (10) for a female torso according to claim 8, said bulletproof vest (10) comprising at least one protective panel (12) which is adapted to cover a female torso and which comprises a plurality of layers (14) of three-dimensional fabric (16) with interwoven warp threads, characterized in that it successively comprises at least: - a step of forming the panel (12) which consists of arranging a plurality of layers (14) of said three-dimensional fabric (16) in a mold (24) in the shape of a bust and exerting pressure on said layers (14) by means of the mold (24) for a predetermined time to form a raised part (13) intended to fit the shapes of a female torso, - a step of demolding the panel (12) formed by said layers (14), and - a step of applying an elastomer-based resin to at least the raised part of the panel (12).

10. Method according to claim 9, characterized in that it comprises at least one heat treatment step which is carried out following the step of applying the resin and which consists of heating the molded panel (12) for a predetermined time, to promote cohesion between the resin and the wires which make up the panel (12).

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