Bulletproof material made from mechanically entangled woven fabric without nonwoven fibers and its manufacturing method

Abstract

A unified material and a method of forming the unified material. The unified material includes a plurality of woven layers mechanically entangled with one another. The plurality of woven layers includes fibers. The plurality of woven layers are mechanically entangled with one another without fibers of the plurality of woven layers and without non-woven fibers. At least some of the fibers of the plurality of woven layers extend in a Z direction perpendicular to an xy plane of the plurality of woven layers. A method of forming the unified material is also provided.

Description

[Technical field]

[0001] The disclosed embodiments relate generally to ballistic materials, and more particularly to ballistic materials made from mechanically entangled woven fabrics without nonwoven fibers, and methods of making such materials. [Background technology]

[0002] It is well known in the art to mechanically entangle woven fabrics with each other using nonwoven fibers, for example by needle punching, to form ballistic materials. This involves mechanically forcing nonwoven fibers into the woven fabric by mechanical means such as barbed needles, water jets, air jets, etc. The mechanical means repeatedly penetrates the woven fabric and threads the nonwoven fibers through the woven fabric such that the nonwoven fibers are woven into and mechanically entangled with the fibers of the woven fabric. This mechanically integrates the woven fabric. See, for example, U.S. Pat. Nos. 7,101,818 and 7,631,405, and U.S. Patent Publication Nos. 2017 / 0191803 and 2020 / 0025530, which describe ballistic materials and methods of mechanically entangling the fibers of a nonwoven material in the interstices of a woven fabric material to reinforce the woven fabric material and form an integrated multi-layer ballistic material.

[0003] However, nonwoven materials used to form mechanically entangled ballistic materials introduce additional weight that is undesirable. For example, nonwoven materials and the nonwoven fibers therein generally do not provide ballistic performance benefits in themselves and are considered "parasitic weight" in the mechanically entangled ballistic material. Weight is an important factor for ballistic materials because the weight of ballistic applications (e.g., vests, helmets, etc.) contributes to and results in fatigue for the wearer of the ballistic application after extended use. Weight also affects the performance and durability of certain ballistic applications, such as helicopters and other aircraft in which the ballistic material is used. Thus, it is desirable to reduce weight while maintaining or improving performance. In addition, nonwoven materials absorb more liquids (e.g., water, sweat, etc.) compared to woven materials, which is undesirable in ballistic applications.

[0004] Thus, there is a need and desire for a mechanically entangled ballistic material that is lightweight, has reduced liquid absorption, and has the same or improved ballistic performance, but is more efficient to manufacture. Summary of the Invention [Means for solving the problem]

[0005] In one aspect, the present disclosure provides an integrated material. The integrated material includes a plurality of woven layers mechanically entangled with each other. The plurality of woven layers includes fibers. The plurality of woven layers are mechanically entangled with each other without fibers of the plurality of woven layers and non-woven fibers. At least some of the fibers of the plurality of woven layers extend in a Z direction perpendicular to the xy plane of the plurality of woven layers.

[0006] In another aspect, the present disclosure provides an integrated material, the integrated material comprising two or more woven layers mechanically entangled with each other without non-woven fibers, wherein some fibers of at least one of the two or more woven layers extend in the Z direction into at least one other of the two or more woven layers.

[0007] In another aspect, the present disclosure provides a method of forming an integrated material, the method comprising mechanically entangling two or more woven layers together to form the integrated material without the use of nonwoven fibers.

[0008] In one embodiment, the method of forming the integrated material further comprises placing the two or more woven fabric layers in a stack prior to mechanically entangling the two or more woven fabric layers. In another embodiment, the method of forming the integrated material further comprises heat treating and calendaring the integrated material. In another embodiment, the method of forming the integrated material further comprises applying one or more secondary processing steps to the integrated material.

[0009] In another aspect, a method of forming an integrated material includes mechanically entangling a plurality of woven fabric layers to form an integrated material. The plurality of woven fabric layers include fibers. The plurality of woven fabric layers are mechanically entangled 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 an xy plane of the plurality of woven fabric layers.

[0010] In one embodiment, the method of forming the integrated material further comprises placing the multiple woven fabric layers on top of one another prior to mechanically entangling the multiple woven fabric layers with one another. In another embodiment, the method of forming the integrated material further comprises heat treating and calendaring the integrated material. In another embodiment, the method of forming the integrated material further comprises subjecting the integrated material to one or more secondary processing steps. [Brief description of the drawings]

[0011] [Figure 1] 1 is a cross-sectional front view of a ballistic material in accordance with an illustrative embodiment; [Diagram 2] 1 is a flowchart of a method of forming a ballistic material in accordance with an illustrative embodiment. [Diagram 3] 1 is a perspective view of a ballistic resistant article in accordance with an illustrative embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] In the following detailed description, reference is made to the accompanying drawings, which form a part of this specification and which illustrate exemplary embodiments of the present invention. These embodiments are described in sufficient detail to enable those skilled in the art to make and use the embodiments. It will also be understood that structural, logical, or procedural changes can be made to the exemplary embodiments disclosed herein without departing from the spirit or scope of the present invention.

[0013] As used herein, "needle consolidation" refers to the process of consolidating woven fabrics using needles without the use of non-woven fibers by forcing barbed needles through the fabric and withdrawing them to mechanically entangle the fibers of the woven fabric to form a consolidated material.

[0014] As used herein, a "fiber" is an elongated body having a lengthwise dimension that is much greater than the transverse dimensions of width and thickness. The term fiber includes monofilaments, multifilaments, ribbons, strips, staples, and other forms such as chopped, cut, or discontinuous fibers having regular or irregular cross sections. The term fiber also includes a plurality of any of the foregoing or combinations thereof. Fibers may be in the form of split films or tapes.

[0015] As used herein, a "yarn" is a continuous strand of many fibers, the same or two or more different fibers, including natural or man-made fibers. A yarn may also be referred to as a "tow" or "end."

[0016] As used herein, a "layer" is an object that can be rigidly or flexibly curved in three dimensions, but that when laid flat on a plane has length and width dimensions that are much greater than their thickness dimensions.

[0017] As used herein, a "tape" is a flat, narrow, monolithic strip of material having a length greater than its width and an average cross-sectional aspect ratio, i.e., the ratio of the largest to the smallest cross-sectional dimension averaged over the length of the tape article, of at least about 3:1. The cross-section of the tapes of the present disclosure may be rectangular, oval, polygonal, irregular, or any shape that meets the width, thickness, and aspect ratio requirements outlined herein. An example of a commercially available tape is Tensylon® from DuPont, Wilmington, Delaware.

[0018] As used herein, a "woven fabric" is any structure that includes a plurality of the same or two or more different types of fibers or yarns interwoven. Generally, such woven fabrics are produced by interweaving a set of yarns, called the cross or filling yarns. Woven fabrics can have essentially any weave, such as plain weave, staggered weave, leno weave, twill weave, basket weave, satin weave, twill weave, unbalanced weave, and the like, and combinations thereof. Plain and twill weaves are the most common and preferred.

[0019] As used herein, "coverage" refers to the degree (eg, percentage) to which an area of ​​a woven fabric is covered by yarns or fibers.

[0020] As used herein, "V50" is a standard test of ballistic performance and refers to the velocity at which 50 percent of bullets fired at a ballistic target will penetrate the target. Thus, a higher V50 indicates better ballistic performance. The V50 data presented herein was obtained in accordance with NIJ Standard-0101.06 (Law Enforcement Projectile Testing) 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" are 9 / 10 times a decitex, specifically the weight in grams of 9000 meters of yarn.

[0022] As used herein, the terms "initial tensile modulus," "tensile modulus," and "modulus" refer to the modulus as measured by ASTM D2256 (Standard Test Method for Tensile Properties of Yarns by Single Strand Method).

[0023] As used herein, the singular forms "a," "an," and "the" include the plurals, and reference to a particular numerical value includes at least that particular value unless the context clearly dictates otherwise. When a range of values ​​is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, it will be understood that the particular value forms another embodiment by use of the antecedent "about." All ranges are inclusive and combinable.

[0024] An exemplary ballistic resistant material is shown in Figure 1. The ballistic resistant material 100 comprises two or more woven fabric layers 120 (e.g., 120 ) that are mechanically entangled with each other without nonwoven fibers or materials, such that the fibers 130 of the woven fabric layers 120 are mechanically entangled in the interstices of the woven fabric layers 120 to form an integrated material without nonwoven fibers and materials. 1 , 120 2 , 120 3 …120 n ) stack 110. During mechanical entanglement, some of the fibers 130 of the woven fabric layer 120 extend in a Z direction perpendicular to the xy plane of the woven fabric layer 120. In some embodiments, some of the fibers 130 of at least one woven fabric layer 120 extend in the Z direction into at least one other woven fabric layer 120. In some embodiments, some of the fibers 130 of at least one woven fabric layer 120 extend in the Z direction into at least two other woven fabric layers 120. In some embodiments, some of the fibers 130 of at least one woven fabric layer 120 are mechanically entangled with some of the fibers 130 of at least one other woven fabric layer 120. In some embodiments, some of the fibers 130 of at least one woven fabric layer 120 are mechanically entangled with some of the fibers 130 of at least two other woven fabric layers 120.

[0025] Any method of mechanical entanglement known in the art that can be used to mechanically entangle woven fabrics without nonwoven fibers, such as (but not limited to) needle consolidation or the use of hydroentangling or air jets (e.g., air entanglement), can be used to mechanically entangle and consolidate the stack 110 of woven layers 120 without nonwoven fibers. Such mechanical entanglement helps to lock the fibers 130 in place and prevent the stack 110 of woven layers 120 from shearing apart and / or delaminating from one another. In addition, such mechanical entanglement increases the dimensional stability and overall strength of the stack 110 of woven layers 120 (e.g., mechanical entanglement increases the density of the material, thereby engaging more fibers per unit volume), while also imparting some flexibility to the stack 110 of woven layers 120.

[0026] A preferred method of mechanical entanglement is needle consolidation. A needle loom is used during needle consolidation to consolidate the stack 110 of woven fabric layers 120. Needle looms are manufactured, for example, by Oskar Dilo Maschinenfabrik KG, Eberbach / N, Germany, Ferher AG, Linz, Austria, and Asselin, Elbeuf, France. During needle consolidation, barbed needles are pushed into the stack 110 of woven fabric layers 120 and pulled out, entangling the fibers 130 of the woven fabric layers 120.

[0027] Woven fabric layer Woven fabric layer 120 can include any number of layers. In some embodiments, woven fabric layer 120 has from about 2 to about 1000 layers, in other embodiments from about 2 to about 500 layers, in other embodiments from about 2 to about 100 layers, in other embodiments from about 2 to about 50 layers, in other embodiments from about 2 to about 25 layers, and in other embodiments from about 2 to about 10 layers.

[0028] In some embodiments, each woven fabric layer 120 has a thickness of about 20 g / m 2 ~About 1500g / m 2 and in another embodiment about 50 g / m 2 ~About 1000g / m2 and in another embodiment about 100 g / m 2 ~about 800g / m 2 and in another embodiment about 130 g / m 2 ~about 500g / m 2 The sheet has a basis weight of 1.0 g.

[0029] Each woven fabric layer 120 is made of yarns 140 (e.g., warp yarns 140 a and weft 140 b ). 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 yarns 140 of at least one woven fabric layer 120 have a linear density of from about 50 dtex to about 5600 dtex, in other embodiments from about 500 dtex to about 5000 dtex, in other embodiments from about 50 dtex to about 1500 dtex, in other embodiments from about 100 dtex to about 850 dtex, and in other embodiments from about 1000 dtex to about 3500 dtex.

[0030] In some embodiments, the yarns 140 of each woven layer 120 have the same linear density, in other embodiments, the yarns 140 of at least one woven layer 120 have the same linear density as the yarns of another woven layer 120, in other embodiments, the yarns 140 of at least one woven layer 120 have a different linear density than the yarns 140 of another woven layer 120, and in other embodiments, the yarns 140 of each woven layer 120 have a different linear density. In some embodiments, the yarns 140 of at least one woven layer 120 have a linear density that is at least 15% greater than the yarns 140 of another woven layer 120, in some embodiments at least 35% greater than the yarns of another woven layer 120, and in some embodiments 50% greater than the yarns 140 of another woven layer 120. In some embodiments, the yarns 140 of one or more woven layers 120 have a linear density that is at least 15% greater than the yarns 140 of one or more other woven layers 120, in some embodiments at least 35% greater than the yarns 140 of one or more other woven layers 120, and in some embodiments at least 50% greater than the yarns 140 of one or more other woven layers 120.

[0031] In some embodiments, each woven fabric layer 120 has a warp yarn count of from about 2 to about 39 ends per inch (5.08 to 99.06 ends per centimeter), in other embodiments from about 3 to about 24 ends per inch (7.62 to 60.96 ends per centimeter), in other embodiments from about 4 to about 18 ends per inch (10.16 to 45.72 ends per centimeter), and in other embodiments from about 18 to about 39 ends per inch (45.72 to 99.06 ends per centimeter). In some embodiments, each woven fabric layer 120 has a weft or filling yarn count of from about 2 to about 39 ends per inch (5.08 to 99.06 ends per centimeter), in other embodiments from about 3 to about 24 ends per inch (7.62 to 60.96 ends per centimeter), in other embodiments from about 4 to about 18 ends per inch (10.16 to 45.72 ends per centimeter), and in other embodiments from about 18 to about 39 ends per inch (45.72 to 99.06 ends per centimeter).

[0032] In some embodiments, the woven layer 120 is a unidirectional construction having yarns 140 running in the same direction. In some embodiments, the woven layer 120 is a quasi-unidirectional construction having yarns 140 that may be arranged in multiple directions. As used herein, "unidirectional" encompasses both unidirectional and quasi-unidirectional fabrics, unless the context requires otherwise.

[0033] fiber Each woven layer 120 has a plurality of fibers 130. The fibers 130 may be threads 140. The fibers 130 may be of any length or texture.

[0034] In some embodiments, fiber 130 has a tenacity of at least 10 g / dtex (11.1 grams per denier (gpd)), in other embodiments at least 15 g / dtex (16.7 grams per denier (gpd)), in other embodiments at least 30 g / dtex (33.3 grams per denier (gpd)), in other embodiments at least 35 g / dtex (38.9 grams per denier (gpd)), in other embodiments at least 40 g / dtex (44.4 grams per denier (gpd)), and in other embodiments at least 50 g / dtex (55.5 grams per denier (gpd)). In some embodiments, the fiber has a strength 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 other embodiments, the fiber 130 has a tensile modulus of about 150 g / dtex to about 2700 g / dtex, and in other embodiments about 200 g / dtex to about 2200 g / dtex. In some embodiments, fiber 130 has a linear density of from about 0.1 dtex to about 5600 dtex, in other embodiments from about 0.1 dtex to about 2500 dtex, in other embodiments from about 0.1 dtex to about 1000 dtex, in other embodiments from about 0.1 dtex to about 100 dtex, and in other embodiments from about 0.5 dtex to about 25 dtex. In some embodiments, fiber 130 has an elongation to break of from about 1 to about 550 percent, in other embodiments from about 1 to about 125 percent, in other embodiments from about 1 to about 10 percent, and in other embodiments from about 2 to about 6 percent.

[0035] The fibers can be made from any polymer known in the art to produce high strength fibers, such as, but not limited to, polyamides, polyolefins, polyazoles, or blends / mixtures thereof. In some embodiments, the fibers 130 can be aramids, polyethylenes, polypropylenes, polyazoles, polyesters, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0036] When the polymer is a polyamide, aramid is preferred. As used herein, "aramid" refers to a polyamide polymer in which at least 85% of the amide (-CONH-) bonds are directly attached to two aromatic rings. A para-aramid polymer is an aramid polymer in which the amide bonds are in the para position relative to each other. One preferred para-aramid polymer is poly(paraphenylene terephthalamide) or PPD-T. It has been found that additives can be used with aramid, and in fact, up to as much as 10% by weight of other polymeric materials can be blended with aramid, or copolymers can be used in which the diamine of the aramid is replaced by as much as 10% of other diamines or the diacid chloride of the aramid is replaced by as much as 10% of other diacid chlorides. Suitable aramid fibers are described in Man-Made Fibers-Science and Technology, Volume 2, Section titled Fiber-Forming Aromatic Polyamides, page 297, W. Black et al., Interscience Publishers, 1968. Aramid fibers and their production are also disclosed in U.S. Pat. Nos. 3,767,756; 4,172,938; 3,869,429; 3,869,430; 3,819,587; 3,673,143; 3,354,127; and 3,094,511.

[0037] Other useful para-aramids include aramid copolymers resulting from the incorporation and / or substitution of other aromatic diamines and other aromatic diacid chlorides, such as 2,6-naphthaloyl chloride or chloro- or dichloroterephthaloyl chloride or 3,4'-diaminodiphenyl ether. Other preferred para-aramids include aramid copolymers 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), such as those in U.S. Patent Application Publication No. 2014 / 0357834, Russian Patent Application Publication No. 2,045,586, and other such polymers shown, for example, in Sugak et al., Fibre Chemistry Vol 31, No 1, 1999; U.S. Patent No. 4,018,735; WO 2008 / 061668, and U.S. Patent Application Publication No. 2014 / 357834.

[0038] Examples of commercially available para-aramid fibers include Kevlar® from DuPont of Wilmington, Delaware and Twaron® from Teijin Aramid of Arnhem, Netherlands. Examples of aramid copolymer fibers include Armos® and Rusar® from Kamenskvolokno Company of Kamensk-Shakhtinskii, Russia.

[0039] When the fiber is a polyolefin, polyethylene or polypropylene is preferred. The term "polyethylene" refers to a predominantly linear polyethylene-based material, preferably of molecular weight above 1 million, which may contain small amounts of chain branching or comonomers, not exceeding 5 modifying units per 100 carbon atoms of the main chain, and may also contain up to about 50% by weight of one or more polymeric additives, such as alkene-1-polymers, especially low density polyethylene, propylene, etc., or low molecular weight additives, such as antioxidants, lubricants, UV filters, colorants, etc., as commonly incorporated. Such are commonly known as extended chain polyethylene (ECPE) or ultra-high molecular weight polyethylene (UHMWPE). The preparation of polyethylene fibers is described in U.S. Pat. Nos. 4,478,083, 4,228,118, 4,276,348, and JP-B-60-047,922 and JP-B-64-008,732. High molecular weight linear polyolefin fibers are commercially available. The preparation of polyolefin fibers is described in U.S. Patent No. 4,457,985. Commercially available examples of polyethylene fibers include Spectra® fibers from Honeywell International Inc. of Morristown, NJ, USA, and Dyneema® from Koninklijke DSM NV of Heerlen, Netherlands.

[0040] When the fiber is a polyazole, polybenzazoles and polypyridazoles are preferred. Suitable polyazoles include homopolymers as well as copolymers. Additives can be used with the polyazoles, and up to 10% by weight of other polymeric materials can be blended with the polyazoles. Copolymers can also be used in which more than 10 percent of the polyazole monomers are replaced by other monomers. Suitable polyazole homopolymers and copolymers can be prepared by known procedures, such as those described in or derived from U.S. Pat. Nos. 4,533,693 (Wolfe et al., Aug. 6, 1985), 4,703,103 (Wolfe et al., Oct. 27, 1987), 5,089,591 (Gregory et al., Feb. 18, 1992), 4,772,678 (Sybert et al., Sept. 20, 1988), 4,847,350 (Harris et al., Aug. 11, 1992), and 5,276,128 (Rosenberg et al., Jan. 4, 1994).

[0041] Preferred polybenzazoles are polybenzimidazole, polybenzothiazole, and polybenzoxazole. When the polybenzazole is polybenzothiazole, it is preferably poly(p-phenylenebenzobisthiazole). When the polybenzazole is polybenzoxazole, it is preferably poly(p-phenylenebenzobisoxazole), more preferably poly(p-phenylene-2,6-benzobisoxazole), also called PBO.

[0042] Preferred polypyridazoles are polypyridiimidazoles, polypyridothiazoles, and polypyridoxazoles. In some embodiments, preferred polypyridazoles are polypyridobisazoles. A preferred poly(pyridobisozazole) is poly(1,4-(2,5-dihydroxy)phenylene-2,6-pyrido[2,3-d:5,6-d']bisimidazole, also known as PIPD. Suitable polypyridazoles, including polypyridobisazoles, can be prepared by known procedures, such as those described in U.S. Pat. No. 5,674,969. An example of a paraphenylene benzobisoxazole (PBO) fiber is Zylon® (Toyobo Co., Ltd., Osaka).

[0043] Other useful aromatic polymers include aromatic unsaturated polyesters such as polyethylene terephthalate, aromatic polyimides, aromatic polyamideimides, aromatic polyesteramideimides, aromatic polyetheramideimides, and aromatic polyesterimides. Copolymers of any of the above classes of materials can also be used.

[0044] When the fibres are polyesters, vinyl ester and ortho polyester resins are preferred. Vinyl ester resins are the reaction product of an epoxy resin with an unsaturated fatty acid such as methacrylic acid or acrylic acid. Most preferably, the epoxy resins used are of the diglycidyl ether / bisphenol A type. Other epoxy resins such as epoxy novolacs and halogenated epoxies are also preferred. Ortho polyesters are the 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 may be used. The unsaturated dibasic acid or anhydride is usually maleic acid, fumaric acid, or maleic anhydride, but may be other similar acids or anhydrides. The ortho aromatic acid or anhydride is preferably ortho phthalic acid or anhydride, but may also be other saturated ortho aromatic acids and acids modified by halogenation with chlorine. Vinyl ester resins and ortho- and isophthalic polyester resins are generally cured by reaction with monomers such as styrene or substituted styrenes, e.g., vinyl toluene or α-methyl styrene, but also with other monomers such as methyl methacrylate, methyl acrylate, diallyl phthalate, triallyl cyanurate, etc.

[0045] When the fibers are graphene, multiple layers of single sheets of carbon atoms bonded together in a honeycomb pattern are preferred.

[0046] When the fibres are carbon nanotubes, they consist of single-walled carbon nanotubes, which have diameters in the nanometre range. Single-walled carbon nanotubes are an allotrope of carbon and are intermediate between fullerene cages and flat graphene.

[0047] When the fiber is spider silk, natural or synthetic silk can be used. Natural silk is a protein fiber spun into silk by spiders, usually to make webs. Synthetic silk consists of fibers derived from other organisms, such as, but not limited to, Bombyx mori silkworms, E. coli, goats, tobacco plants, and potato plants.

[0048] Bulletproof materials The thickness and weight of the ballistic material 100 can vary depending on a variety of factors, including, but not limited to, the type and number of layers of the woven fabric layer 120, the degree of mechanical entanglement, the fabric structure of the woven fabric layer 120, the areal density, and the woven fabric coverage.

[0049] The ballistic material 100 may be of any thickness or weight. In some embodiments, the thickness of the ballistic material 100 is from about 0.025 inches (0.0635 cm) to about 4.0 inches (10.06 cm), and in other embodiments, from about 0.10 inches (0.254 cm) to about 2.0 inches (5.03 cm). In some embodiments, the ballistic material 100 has a thickness of about 0.034 kg / m 2 (0.0070lb / ft 2 ) ~ approx. 9.8kg / m 2 (2.0lb / ft 2 ), and in another embodiment about 0.034 kg / m 2 (0.0070lb / ft 2 ) ~ approx. 3.1kg / m 2 (0.63 lb / ft 2 ), and in another embodiment about 0.17 kg / m 2 (0.035lb / ft 2 ) ~ approx. 9.8kg / m 2 (2.0lb / ft 2 ), and in another embodiment about 0.17 kg / m 2 (0.035lb / ft 2 ) ~ approx. 2.2kg / m 2 (0.45lb / ft 2 ), and in another embodiment about 0.17 kg / m 2 (0.035lb / ft 2 ) ~ approx. 0.85kg / m 2(0.17lb / ft 2 ) areal density.

[0050] In some embodiments, the ballistic material 100 has a V50 in the range of about 750 ft / s to about 3000 ft / s, in other embodiments about 600 ft / s to about 4000 ft / s, and in other embodiments about 500 ft / s to about 20,000 ft / s when struck by either a 9 mm projectile per NIJ Standard-0101.06 (Law Enforcement Projectile Testing) or a projectile simulating a 17 grain fragment per MIL STD-662F (Fragment Testing).

[0051] In addition to the performance advantages, the ballistic material 100 does not require further assembly of the woven fabric layer 120. For example, if a ballistic vest manufacturer uses the ballistic material 100 to manufacture a ballistic vest, the manufacturer can cut units of the ballistic material 100 from a single roll that has been tested to meet specific ballistic requirements. In this manner, the additional labor of cutting, stacking, counting, and quilting or sewing together multiple layers of ballistic fabric is avoided. Thus, the ballistic material 100 is an "off-the-shelf" ballistic material that provides economic and performance advantages, which can then be used as a building block to create a variety of structures in a multitude of potential products for ballistic applications.

[0052] Manufacturing method 2 is a flow chart of an exemplary method of forming a ballistic material. In step 21, two or more woven fabric layers 120 are arranged in a stack 110.

[0053] The threads 140 of the woven fabric layer 120 are preferably cross-laminated at 90 degree angles to each other and held in place by lightly stitching, sewing, or interweaving the lightweight threads so that the woven fabric layer 120 does not separate and the individual tows or threads 140 do not bend and remain easy to handle during the manufacturing process.

[0054] In step 22, the stack 110 of woven layers 120 are mechanically entangled with one another without nonwoven fibers to form a unified material by any method of mechanical entanglement known in the art that can be used to mechanically entangle woven fabrics without nonwoven fibers, such as, but not limited to, needle consolidation, or hydroentangling or the use of air jets (e.g., air entanglement). Thus, the fibers 130 of the woven layers 120 are mechanically entangled in the interstices of the woven layers 120 to form a unified material that is free of nonwoven fibers and materials.

[0055] In step 23, the consolidated material may be heat treated and calendered. The heat treating and calendering are performed to increase the density of the consolidated material. In some embodiments, the density of the consolidated 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 about 40%.

[0056] In step 24, one or more secondary processing steps may be applied to the integrated material, which may include any steps known in the art, such as, but not limited to, applying one or more treatments or coatings (e.g., a water repellent coating), as well as sewing and / or laminating the integrated material.

[0057] Steps 21, 22, 23, and 24 are preferably performed in this order, however, these steps may be performed in any order and / or in combination with other steps.

[0058] Bulletproof articles and industrial applicability An exemplary ballistic resistant article is shown in FIG. 3. Ballistic resistant article 300 includes one or more ballistic materials 305 (e.g., 305 1 …305 n Each ballistic material 305 includes yarns 340 (e.g., warp yarns 340 ) of the woven fabric layer 320 . a and weft 340 bThe present invention includes a stack 310 of two or more woven layers 320 that are mechanically entangled with each other without nonwoven fibers or materials, such that the fibers 330 of the woven layers 320 are mechanically entangled in the interstices of the woven layers 320 to form an integrated material that is free of nonwoven fibers and materials.

[0059] The one or more ballistic materials 305 can include any number of individual ballistic materials, in some embodiments, the one or more ballistic materials 305 include between 1 and 5 ballistic materials, in other embodiments between 1 and 50 ballistic materials, in other embodiments between 1 and 100 ballistic materials, and in other embodiments between 1 and 500 ballistic materials.

[0060] When the one or more ballistic materials 305 include 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. When 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, flat stitching, quilt stitching, and cross stitching.

[0061] The articles and ballistic materials disclosed herein are useful in a wide variety of applications and can be used in any ballistic application known in the art, including, but not limited to, protective or ballistic clothing for protecting body parts from projectiles, such as vests and jackets; rigid or rigid composite armor; rigid and soft containment structures; bomb containment structures; mitigation panels; and aircraft. The term "projectile" is used herein to mean a bullet or other object, such as one fired from a gun, or fragments thereof.

[0062] Test Method In the examples below, the following test methods were used:

[0063] Linear Density: The linear density of a yarn or fiber is determined by measuring the weight of a known length of yarn or fiber according to the procedure set forth in ASTM D1907-97.

[0064] Areal density: The areal density of a fabric layer is determined by measuring the weight of each single layer of a selected size, e.g. 10 cm x 10 cm. The areal density of a composite structure is determined by the sum of the areal densities of the individual layers.

[0065] Ballistic Penetration Performance: Ballistic testing of the multi-layered integrated material was performed in accordance with NIJ Standard-0101.06 (projectile testing) and MIL STD-662F (military fragmentation testing). Four targets were tested for each example, with 6-9 shots fired at 0 degrees cant against each dry target. The reported V50 values ​​are the average for the number of shots for each example.

[0066] The following examples are presented to illustrate exemplary embodiments of the invention and should not be construed as limiting thereof in any way. EXAMPLES

[0067] Example 1 Seven woven plies of aramid copolymer, each 0.070 inches thick, were stacked and needle consolidated. The resulting consolidated material weighed approximately 0.19 lb / ft 2 The integrated material was then tested for V50 against a 17 grain simulated fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 1.

[0068] Comparative Example 2 One nonwoven layer of para-aramid fiber (0.02 inch thick) was layered over seven woven layers of aramid copolymer (each 0.070 inch thick) to form a stack. The stack was then needle punched. The resulting consolidated material weighed approximately 0.21 lb / ft 2 (10% heavier than Example 1). The consolidated material was then tested for V50 against a 17 grain simulated fragment projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0069] Example 3 Seven woven layers of UHMWPE polymer, each 0.050 inches thick, were stacked and needle consolidated. The resulting consolidated material weighed approximately 0.15 lb / ft 2 The integrated material was then tested for V50 against a 17 grain simulated fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 1.

[0070] Comparative Example 4 One nonwoven layer of para-aramid (0.020 inch thick) was layered over seven woven layers of UHMWPE polymer (each 0.050 inch thick) to form a stack. The stack was then needle punched. The resulting consolidated material weighed approximately 0.16 lb / ft. 2 (10% heavier than Example 3). The consolidated material was then tested for V50 against a 17 grain simulated fragment projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0071] Example 5 Seven woven plies of para-aramid, each 0.070 inches thick, are stacked. The stack is needle consolidated. The resulting consolidated material weighs approximately 0.20 lb / ft 2 The integrated material is then tested for V50 against a 17 grain simulated fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 1.

[0072] Comparative Example 6 One nonwoven layer of para-aramid fiber (0.020 inch thick) was layered over seven woven layers of para-aramid (each 0.070 inch thick) to form a stack. The stack was then needle punched. The resulting consolidated material weighed approximately 0.22 lb / ft 2 (10% heavier than Example 7). The consolidated material is then tested for V50 against a 17 grain simulated fragment projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0073] Example 7 Two woven layers of aramid copolymer, each 0.070 inches thick, are stacked together. The stack is hydroentangled using high pressure water (maximum pressure 6.9 MPa). The resulting consolidated material weighs approximately 0.07 lb / ft 2 The integrated material is then tested for V50 against a 17 grain simulated fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 1.

[0074] Comparative Example 8 One nonwoven layer of para-aramid fiber (0.02 inches thick) is layered over two woven layers of aramid copolymer (each 0.070 inches thick) to form a stack. The stack is hydroentangled using high pressure water (maximum pressure 6.9 MPa). The resulting consolidated material weighs approximately 0.09 lb / ft. 2 (10% heavier than Example 7). The consolidated material is then tested for V50 against a 17 grain simulated fragment projectile according to MIL STD-662F. The V50 results are shown in Table 1.

[0075] Table 1 shows the V50 performance of the consolidated materials obtained in Examples 1, 3, 5, 7 and Comparative Examples 2, 4, 6, 8 using a simulated 17 grain fragment projectile according to MIL STD-662F. As shown, the consolidated materials obtained in Examples 1, 3, 5, and 7 exhibit similar ballistic performance at 10% lower weight when compared to Comparative Examples 2, 4, 6, and 8, respectively.

[0076] [Table 1]

[0077] Example 9 Three integrated materials were formed separately according to Example 1 and stacked together. The stack of three integrated materials was then sewn together at the corners to produce a sewn construction weighing approximately 0.57 lb / ft.2 The panels were then tested for V50 against a simulated 17 grain fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 2.

[0078] Comparative Example 10 Three integrated materials were formed separately according to Comparative Example 2 and stacked together. The stack of three integrated materials was then sewn together at the corners to a weight of approximately 0.62 lb / ft 2 The panels were then tested for V50 against a simulated 17 grain fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 2.

[0079] Example 11 Ten pieces of the integrated material are formed separately according to Example 7 and stacked together. The stack of ten integrated materials is sewn together at the corners to a weight of approximately 0.70 lb / ft 2 The panels are then tested for V50 against a simulated 17 grain fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 2.

[0080] Comparative Example 12 Ten pieces of consolidated material are formed separately according to Comparative Example 8 and stacked together. The stack of ten consolidated materials is sewn together at the corners to a weight of approximately 0.90 lb / ft 2 The panels are then tested for V50 against a simulated 17 grain fragment projectile in accordance with MIL STD-662F. The V50 results are shown in Table 2.

[0081] Table 2 shows the V50 performance of the ballistic panels obtained in Examples 9 and 11 and Comparative Examples 10 and 12 using a simulated 17 grain fragment projectile according to MIL STD-662F. As shown, the ballistic panels (shoot packs) obtained in Examples 9 and 11 exhibit similar ballistic performance at a lighter weight when compared to Comparative Examples 10 and 12, respectively.

[0082] [Table 2]

[0083] Thus, the ballistic resistant materials described herein are an improvement and have many advantages over ballistic resistant materials that are mechanically entangled using nonwoven fibers and materials, including, but not limited to, lighter weight while having similar ballistic performance, less absorption of undesirable liquids (e.g., water, sweat, etc.), fewer rolls of fabric required to manufacture a ballistic application, easier and lower cost to manufacture, and reduced risk of error in manufacturing a ballistic application due to fewer overall layers.

[0084] Another embodiment of the present application Embodiment 1. In some embodiments, an integrated material includes a plurality of woven fabric layers mechanically entangled with one another, the plurality of woven fabric layers including fibers, the plurality of woven fabric layers being mechanically entangled with one another without fibers of the plurality of woven fabric layers being non-woven fibers, and at least some of the fibers of the plurality of woven fabric layers extending in a Z direction perpendicular to an xy plane of the plurality of woven fabric layers.

[0085] Embodiment 2. The integrated material of embodiment 1, wherein some fibers of at least one of the plurality of woven fabric layers extend in the Z direction into at least one other of the plurality of woven fabric layers.

[0086] Embodiment 3. An integrated material as described in embodiment 1 or 2, wherein at least some of the fibers of one of the plurality of woven fabric layers extend in the Z direction into at least two other of the plurality of woven fabric layers.

[0087] Embodiment 4. An integrated material according to any one of embodiments 1 to 3, wherein some fibers of at least one of the plurality of woven fabric layers are mechanically entangled with some fibers of at least one other of the plurality of woven fabric layers.

[0088] Embodiment 5. An integrated material described in any one of embodiments 1 to 4, wherein some fibers of one of the plurality of woven fabric layers are mechanically entangled with some fibers of at least two other woven fabric layers of the plurality of woven fabric layers.

[0089] Embodiment 6. The integrated material of any one of embodiments 1 to 5, wherein the multiple woven fabric layers are mechanically entangled with each other by needle integration.

[0090] Embodiment 7. The integrated material of any one of embodiments 1 to 6, wherein the plurality of woven fabric layers are mechanically entangled with one another by hydroentanglement.

[0091] Embodiment 8. The integrated material of any one of embodiments 1 to 7, wherein the multiple woven fabric layers are mechanically entangled with one another by air entanglement.

[0092] Embodiment 9. The integrated material according to any one of embodiments 1 to 8, wherein the plurality of woven fabric layers has from about 2 layers to about 100 layers.

[0093] Embodiment 10. The integrated material of embodiment 9, wherein the plurality of woven fabric layers has from about 2 layers to about 50 layers.

[0094] Embodiment 11. The integrated material of embodiment 10, wherein the plurality of woven fabric layers has about 2 layers to about 25 layers.

[0095] Embodiment 12. The integrated material of embodiment 11, wherein the plurality of woven fabric layers has about 2 layers to about 10 layers.

[0096]

[0023] Embodiment 13. Each of the plurality of woven fabric layers has a thickness of about 20 g / m 2 ~About 1500g / m 2 13. The consolidated material of any one of embodiments 1 to 12, having a basis weight of

[0097]

[0023] Embodiment 14. Each of the plurality of woven fabric layers has a thickness of about 50 g / m 2 ~about 1000g / m 2 14. The consolidated material of embodiment 13, having a basis weight of

[0098]

[0023] Embodiment 15. Each of the plurality of woven fabric layers has a thickness of about 100 g / m 2 ~about 800g / m 2 15. The consolidated material of embodiment 14, having a basis weight of

[0099]

[0036] Embodiment 16. Each of the plurality of woven fabric layers has a thickness of about 130 g / m 2 ~about 500g / m 2 16. The consolidated material of embodiment 15, having a basis weight of

[0100] Embodiment 17. The integrated material of any one of embodiments 1 to 16, wherein each of the plurality of woven fabric layers comprises a plurality of yarns.

[0101] Embodiment 18. The integrated material of embodiment 17, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 50 dtex to about 5600 dtex.

[0102] Embodiment 19. The integrated material of embodiment 18, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 50 dtex to about 1500 dtex.

[0103] Embodiment 20. The integrated material of embodiment 19, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 100 dtex to about 850 dtex.

[0104] Embodiment 21. The integrated material of embodiment 17 or 18, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 1000 dtex to about 3500 dtex.

[0105] Embodiment 22. The integrated material of any one of embodiments 17 to 21, wherein the yarns of each of the plurality of woven fabric layers have the same linear density.

[0106] Embodiment 23. An integrated material according to any one of embodiments 17 to 22, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have the same linear density as the yarns of at least one other woven fabric layer of the plurality of woven fabric layers.

[0107] Embodiment 24. An integrated material according to any one of embodiments 17 to 21, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a different linear density than the yarns of at least one other woven fabric layer of the plurality of woven fabric layers.

[0108] Embodiment 25. The integrated material of any one of embodiments 17-21 or 24, wherein the yarns of each of the plurality of woven fabric layers have different linear densities.

[0109] Embodiment 26. An integrated material according to any one of embodiments 1 to 25, wherein the multiple woven fabric layers are of unidirectional construction.

[0110] Embodiment 27. An integrated material described in any one of embodiments 1 to 25, wherein the multiple woven fabric layers are in a quasi-unidirectional configuration.

[0111] Embodiment 28. An integrated material according to any one of embodiments 1 to 27, wherein the fibers of the multiple woven fabric layers have a tenacity of at least 10 g / dtex.

[0112] Embodiment 29. The integrated material of embodiment 28, wherein the fibers of the plurality of woven layers have a tenacity of at least 15 g / dtex.

[0113] Embodiment 30. The integrated material of embodiment 29, wherein the fibers of the plurality of woven layers have a tenacity of at least 30 g / dtex.

[0114] Embodiment 31. The integrated material of embodiment 30, wherein the fibers of the plurality of woven layers have a tenacity of at least 40 g / dtex.

[0115] Embodiment 32. The integrated material of embodiment 31, wherein the fibers of the multiple woven layers have a tenacity of at least 50 g / dtex.

[0116] Embodiment 33. An integrated material according to any one of embodiments 1 to 32, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 100 g / dtex.

[0117] Embodiment 34. An integrated material according to any one of embodiments 1 to 33, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 150 g / dtex to about 2700 g / dtex.

[0118] Embodiment 35. The integrated material of embodiment 34, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 200 g / dtex to about 2200 g / dtex.

[0119] Embodiment 36. An integrated material according to any one of embodiments 1 to 35, wherein the fibers of the plurality of woven layers have a linear density of at least about 0.1 g / dtex to about 5600 g / dtex.

[0120] Embodiment 37. The integrated material of embodiment 36, wherein the fibers of the plurality of woven layers have a linear density of at least about 0.1 g / dtex to about 2500 g / dtex.

[0121] Embodiment 38. The integrated material of embodiment 37, wherein the fibers of the plurality of woven layers have a linear density of at least about 0.1 g / dtex to about 1000 g / dtex.

[0122] Embodiment 39. The integrated material of embodiment 38, wherein the fibers of the plurality of woven layers have a linear density of at least about 0.1 g / dtex to about 100 g / dtex.

[0123] Embodiment 40. The integrated material of any one of embodiments 1 to 39, wherein the fibers of the plurality of woven fabric layers have an elongation to break of about 1 to about 550 percent.

[0124] Embodiment 41. The integrated material of embodiment 40, wherein the fibers of the plurality of woven layers have an elongation to break of about 1 to about 125 percent.

[0125] Embodiment 42. The integrated material of embodiment 41, wherein the fibers of the plurality of woven layers have an elongation to break of about 1 to about 10 percent.

[0126] Embodiment 43. An integrated material according to any one of embodiments 1 to 42, wherein the fibers of the plurality of woven fabric layers are polymeric.

[0127] Embodiment 44. An integrated material described in any one of embodiments 1 to 43, wherein the fibers of the multiple woven layers include one or more of the following fiber types: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0128] Embodiment 45. An integrated material described in any one of embodiments 1 to 44, wherein the fibers of the multiple woven layers are made of one or more of the following fiber types: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0129] Embodiment 46. An integrated material described in any one of embodiments 1 to 45, wherein the fibers of the multiple 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.

[0130] Embodiment 47. An integrated material described in any one of embodiments 1 to 44, wherein the fibers of the multiple woven fabric layers comprise aramid fibers.

[0131] Embodiment 48. An integrated material according to any one of embodiments 1 to 44, 46, or 47, wherein the fibers of the plurality of woven fabric layers comprise polyethylene fibers.

[0132] Embodiment 49. An integrated material according to any one of embodiments 1 to 44, or 46 to 48, wherein the fibers of the multiple woven fabric layers comprise copolymer fibers.

[0133] Embodiment 50. The integrated material of any one of embodiments 1-44, or 46-49, wherein the fibers of the multiple woven fabric layers comprise multicomponent fibers.

[0134] Embodiment 51. An integrated material described in any one of embodiments 1 to 46, wherein the fibers of the multiple woven fabric layers are polyethylene fibers.

[0135] Embodiment 52. An integrated material according to any one of embodiments 1 to 46, wherein the fibers of the multiple woven fabric layers are copolymer fibers.

[0136] Embodiment 53. An integrated material according to any one of embodiments 1 to 46, wherein the fibers of the multiple woven fabric layers are multicomponent fibers.

[0137] Embodiment 54. The integrated material of any one of embodiments 1 to 53, having a thickness of about 0.025 inches to about 4.0 inches.

[0138] Embodiment 55. The integrated material of embodiment 54, having a thickness of about 0.10 inches to about 2.0 inches.

[0139] Embodiment 56. Approximately 0.034 kg / m 2 ~Approx. 9.8kg / m 2 56. The integrated material of any one of embodiments 1 to 55, having an areal density of

[0140] Embodiment 57. Approximately 0.034 kg / m 2 ~Approx. 3.1kg / m 2 57. The integrated material of embodiment 56, having an areal density of

[0141] Embodiment 58. Approximately 0.17 kg / m 2 ~Approx. 9.8kg / m 2 57. The integrated material of embodiment 56, having an areal density of

[0142] Embodiment 59. Approximately 0.17 kg / m 2 ~Approx. 2.2kg / m 2 59. The integrated material of embodiment 58, having an areal density of

[0143] Embodiment 60. Approximately 0.17 kg / m 2 ~about 0.85kg / m 2 60. The integrated material of embodiment 59, having an areal density of

[0144] Embodiment 61. An integrated material according to any one of embodiments 1 to 60, having a V50 according to MIL STD-662F of about 750 ft / s to about 3000 ft / s.

[0145] Embodiment 62. An integrated material according to any one of embodiments 1 to 61, having a V50 according to MIL STD-662F of about 600 ft / s to about 4000 ft / s.

[0146] Embodiment 63. An integrated material according to any one of embodiments 1 to 62, having a V50 according to MIL STD-662F of about 500 ft / s to about 20,000 ft / s.

[0147] Embodiment 64. An article comprising at least one integrated material according to any one of embodiments 1 to 63.

[0148] Embodiment 65. A ballistic article comprising at least one integrated material according to any one of embodiments 1 to 63.

[0149] The ballistic article of embodiment 65, comprising 1 to 5 integrated materials.

[0150] The ballistic article of embodiment 65, comprising 1 to 50 integrated materials.

[0151] The ballistic article of embodiment 65, comprising 1 to 100 integrated pieces of material.

[0152] Embodiment 69. In some embodiments, the integrated material comprises two or more woven fabric layers mechanically entangled with each other without nonwoven fibers, and some fibers of at least one of the two or more woven fabric layers extend in the Z direction into at least one other of the two or more woven fabric layers.

[0153] Embodiment 70. In some embodiments, a method of forming an integrated material includes mechanically entangling two or more woven layers with one another to form an integrated material without the use of nonwoven fibers.

[0154] Embodiment 71. The method of embodiment 70, further comprising placing the two or more woven fabric layers on top of each other prior to mechanically entangling the two or more woven fabric layers.

[0155] Embodiment 72 The method of embodiment 70 or 71, further comprising heat treating and calendaring the consolidated material.

[0156] Embodiment 73. The method of any one of embodiments 70-72, further comprising subjecting the integrated material to one or more secondary processing steps.

[0157] Embodiment 74. In some embodiments, a method of forming an integrated material includes mechanically entangling a plurality of woven fabric layers to form an integrated material, the plurality of woven fabric layers including fibers, the plurality of woven fabric layers being mechanically entangled with one another without fibers of the plurality of woven fabric layers and without non-woven fibers, and at least some of the fibers of the plurality of woven fabric layers extending in a Z direction perpendicular to an xy plane of the plurality of woven fabric layers.

[0158] Embodiment 75. The method of embodiment 74, further comprising placing the plurality of woven fabric layers in a stack prior to mechanically entangling the plurality of woven fabric layers with one another.

[0159] Embodiment 76 The method of embodiment 74 or 75, further comprising heat treating and calendering the consolidated material.

[0160] Embodiment 77. The method of any one of embodiments 74-76, further comprising subjecting the integrated material to one or more secondary processing steps.

[0161] Embodiment 78. The method of any one of embodiments 74 to 77, wherein some fibers of at least one woven fabric layer of the plurality of woven fabric layers extend in the Z direction into at least one other woven fabric layer of the plurality of woven fabric layers.

[0162] Embodiment 79. The method of any one of embodiments 74 to 78, wherein at least some of the fibers of one woven fabric layer of the plurality of woven fabric layers extend in the Z direction into at least two other woven fabric layers of the plurality of woven fabric layers.

[0163] Embodiment 80. The method of any one of embodiments 74 to 79, wherein a portion of the fibers of at least one woven fabric layer of the plurality of woven fabric layers is mechanically entangled with a portion of the fibers of at least one other woven fabric layer of the plurality of woven fabric layers.

[0164] Embodiment 81. The method of any one of embodiments 74 to 80, wherein some fibers of one woven fabric layer of the plurality of woven fabric layers are mechanically entangled with some fibers of at least two other woven fabric layers of the plurality of woven fabric layers.

[0165] Embodiment 82. The method of any one of embodiments 74-81, wherein the multiple woven fabric layers are mechanically entangled with one another by needle consolidation.

[0166] Embodiment 83. The method of any one of embodiments 74-82, wherein the plurality of woven layers are mechanically entangled with one another by hydroentanglement.

[0167] Embodiment 84. The method of any one of embodiments 74-83, wherein the plurality of woven fabric layers are mechanically entangled with one another by air entanglement.

[0168] Embodiment 85. The method of any one of embodiments 74 to 84, wherein the plurality of woven fabric layers has from about 2 layers to about 100 layers.

[0169] Embodiment 86. The method of embodiment 85, wherein the plurality of woven fabric layers has from about 2 layers to about 50 layers.

[0170] Embodiment 87. The method of embodiment 86, wherein the plurality of woven fabric layers has from about 2 layers to about 25 layers.

[0171] Embodiment 88. The method of embodiment 87, wherein the plurality of woven fabric layers has about 2 layers to about 10 layers.

[0172]

[0046] Embodiment 89. Each of the plurality of woven fabric layers has a thickness of about 20 g / m 2 ~About 1500g / m 2 The method of any one of embodiments 74 to 88, wherein the sheet has a basis weight of

[0173]

[0046] Embodiment 90. Each of the plurality of woven fabric layers has a thickness of about 50 g / m 2 ~About 1000g / m 2 90. The method of embodiment 89, wherein the sheet has a basis weight of

[0174]

[0046] Embodiment 91. Each of the plurality of woven fabric layers has a thickness of about 100 g / m 2 ~about 800g / m 2 91. The method of embodiment 90, wherein the sheet has a basis weight.

[0175]

[0046] Embodiment 92. Each of the plurality of woven fabric layers has a thickness of about 130 g / m 2 ~about 500g / m 2 92. The method of embodiment 91, wherein the sheet has a basis weight.

[0176] Embodiment 93. The method of any one of embodiments 74-92, wherein each woven layer of the plurality of woven fabric layers comprises a plurality of yarns.

[0177] Embodiment 94. The method of embodiment 93, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 50 dtex to about 5600 dtex.

[0178] Embodiment 95. The method of embodiment 94, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 50 dtex to about 1500 dtex.

[0179] Embodiment 96. The method of embodiment 95, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 100 dtex to about 850 dtex.

[0180] Embodiment 97. The method of embodiment 93 or 94, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a linear density of about 1000 dtex to about 3500 dtex.

[0181] Embodiment 98. The method of any one of embodiments 93 to 97, wherein the yarns of each woven layer of the plurality of woven fabric layers have the same linear density.

[0182] Embodiment 99. The method of any one of embodiments 93 to 98, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have the same linear density as yarns of at least one other woven fabric layer of the plurality of woven fabric layers.

[0183] Embodiment 100. The method of any one of embodiments 93-97, wherein the yarns of at least one woven fabric layer of the plurality of woven fabric layers have a different linear density than yarns of at least one other woven fabric layer of the plurality of woven fabric layers.

[0184] Embodiment 101. The method of embodiment 100, wherein the yarns of each woven layer of the plurality of woven layers have different linear densities.

[0185] Embodiment 102. The method of any one of embodiments 74 to 101, wherein the plurality of woven fabric layers are of unidirectional construction.

[0186] Embodiment 103. The method of any one of embodiments 74 to 101, wherein the plurality of woven layers is in a quasi-unidirectional configuration.

[0187] Embodiment 104. The method of any one of embodiments 74 to 103, wherein the fibers of the plurality of woven layers have a tenacity of at least 10 g / dtex.

[0188] Embodiment 105. The method of embodiment 104, wherein the fibers of the plurality of woven layers have a tenacity of at least 15 g / dtex.

[0189] Embodiment 106. The method of embodiment 105, wherein the fibers of the plurality of woven layers have a tenacity of at least 30 g / dtex.

[0190] Embodiment 107. The method of embodiment 106, wherein the fibers of the plurality of woven layers have a tenacity of at least 40 g / dtex.

[0191] Embodiment 108. The method of embodiment 107, wherein the fibers of the plurality of woven layers have a tenacity of at least 50 g / dtex.

[0192] Embodiment 109. The method of any one of embodiments 74 to 108, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 100 g / dtex.

[0193] Embodiment 110. The method of embodiment 109, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 150 g / dtex to about 2700 g / dtex.

[0194] Embodiment 111. The method of embodiment 110, wherein the fibers of the plurality of woven layers have a tensile modulus of at least about 200 g / dtex to about 2200 g / dtex.

[0195] Embodiment 112. The method of any one of embodiments 74 to 111, wherein the fibers of the plurality of woven layers have a linear density of from about 0.1 g / dtex to about 5600 g / dtex.

[0196] Embodiment 113. The method of embodiment 112, wherein the fibers of the plurality of woven layers have a linear density of about 0.1 g / dtex to about 2500 g / dtex.

[0197] Embodiment 114. The method of embodiment 113, wherein the fibers of the plurality of woven layers have a linear density of about 0.1 g / dtex to about 1000 g / dtex.

[0198] Embodiment 115. The method of embodiment 114, wherein the fibers of the plurality of woven layers have a linear density of about 0.1 g / dtex to about 100 g / dtex.

[0199] Embodiment 116. The method of 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 percent.

[0200] Embodiment 117. The method of embodiment 116, wherein the fibers of the plurality of woven fabric layers have an elongation to break of about 1 to about 125 percent.

[0201] Embodiment 118. The 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 percent.

[0202] Embodiment 119. The method of any one of embodiments 74 to 118, wherein the fibers of the plurality of woven fabric layers are polymeric.

[0203] Embodiment 120. The method of any one of embodiments 74 to 119, wherein the fibers of the plurality of woven layers comprise one or more of the following fiber types: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0204] Embodiment 121. The method of any one of embodiments 74 to 120, wherein the fibers of the plurality of woven layers are comprised of one or more of the following fiber types: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multicomponent fibers, and combinations thereof.

[0205] Embodiment 122. The method of any one of embodiments 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.

[0206] Embodiment 123. The method of any one of embodiments 74 to 120, wherein the fibers of the plurality of woven fabric layers comprise aramid fibers.

[0207] Embodiment 124. The method of any one of embodiments 74 to 120, or 123, wherein the fibers of the plurality of woven fabric layers comprise polyethylene fibers.

[0208] Embodiment 125. The method of any one of embodiments 74-120, 123, or 124, wherein the fibers of the plurality of woven fabric layers comprise copolymer fibers.

[0209] Embodiment 126. The method of any one of embodiments 74-120, or 123-125, wherein the fibers of the plurality of woven fabric layers comprise multicomponent fibers.

[0210] Embodiment 127. The method of any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are polyethylene fibers.

[0211] Embodiment 128. The method of any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are copolymer fibers.

[0212] Embodiment 129. The method of any one of embodiments 74 to 121, wherein the fibers of the plurality of woven fabric layers are multicomponent fibers.

[0213] Embodiment 130. The method of any one of embodiments 74 to 129, wherein the thickness is from about 0.025 inches to about 4.0 inches.

[0214] Embodiment 131. The method of embodiment 130, wherein the thickness is from about 0.10 inches to about 2.0 inches.

[0215] Embodiment 132. Approximately 0.034 kg / m 2 ~Approx. 9.8kg / m 2 The method of any one of embodiments 74 to 131, having an areal density of

[0216] Embodiment 133. Approximately 0.034 kg / m 2 ~Approx. 3.1kg / m 2 133. The method of embodiment 132, having an areal density of

[0217] Embodiment 134. Approximately 0.17 kg / m 2 ~Approx. 9.8kg / m 2 The method of any one of embodiments 74 to 132, having an areal density of

[0218] Embodiment 135. Approximately 0.17 kg / m 2 ~Approx. 2.2kg / m 2 135. The method of embodiment 134, having an areal density of

[0219] Embodiment 136. Approximately 0.17 kg / m 2 ~about 0.85kg / m 2 136. The method of embodiment 135, having an areal density of

[0220] Embodiment 137. The method of any one of embodiments 74 to 136, wherein the V50 according to MIL STD-662F is from about 750 ft / s to about 3000 ft / s.

[0221] Embodiment 138. The method of any one of embodiments 74 to 136, wherein the V50 according to MIL STD-662F is from about 600 ft / s to about 4000 ft / s.

[0222] Embodiment 139. The method of any one of embodiments 74 to 136, wherein the V50 according to MIL STD-662F is from about 500 ft / s to about 20,000 ft / s.

[0223] While various embodiments of the present invention have been described above, it should be understood that they are presented by way of example, not limitation. It will be apparent to one skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the present invention. Thus, although the present invention has been described with reference to the exemplary embodiments above, it should be understood that other embodiments are within the scope of the claims. It should further be understood that the exemplary embodiments described herein may be combined to form other embodiments. After reading the above description, it will be apparent to one skilled in the art how to implement the present invention in alternative embodiments. Thus, the present invention should not be limited by any of the exemplary embodiments described above.

Claims

1. An integrated material, a plurality of woven fabric layers mechanically entangled with one another; the plurality of woven fabric layers comprising fibers; the plurality of woven fabric layers are mechanically entangled 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 an xy plane of the plurality of woven fabric layers; the combined material has a thickness of about 0.1 inches to about 2.0 inches; V50 according to MIL STD-662F is about 152 m / s (500 ft / s) to about 6096.0 m / s (20,000 ft / s), some fibers of at least one of the plurality of woven fabric layers extend in the Z direction into at least one other of the plurality of woven fabric layers; Integrated material.

2. The integrated material described in claim 1, having a V50 according to MIL STD-662F of about 183 m / s (600 ft / s) to about 1219 m / s (4000 ft / s).

3. 2. The integrated material of claim 1, wherein at least some fibers of at least one woven fabric layer of the plurality of woven fabric layers extend in the Z direction into at least two other woven fabric layers of the plurality of woven fabric layers.

4. The consolidated material of claim 1 , wherein the plurality of woven fabric layers are mechanically entangled with one another by needle consolidation.

5. the plurality of woven fabric layers are mechanically entangled with one another by hydroentanglement; or The consolidated material of claim 1 , wherein the plurality of woven fabric layers are mechanically entangled with one another by air entanglement.

6. The integrated material of claim 1 , wherein the plurality of woven fabric layers comprises from about 2 to about 50 layers.

7. Each of the plurality of woven fabric layers has a thickness of about 20 g / m 2 ~Approx. 1500g / m 2 10. The consolidated material of claim 1 having a basis weight of

8. the plurality of woven fabric layers are unidirectional; or The integrated material of claim 1 , wherein the plurality of woven fabric layers are in a quasi-unidirectional configuration.

9. the fibers of the plurality of woven fabric layers have a tenacity of at least 10 g / dtex; or the fibers of the plurality of woven fabric layers have a tensile modulus of at least about 100 g / dtex; or The integrated material of claim 1 , wherein the fibers of the plurality of woven fabric layers have an elongation to break of from about 1 to about 550 percent.

10. The integrated material of claim 1 , wherein the fibers of the plurality of woven fabric layers are polymeric.

11. 10. The integrated material of claim 1, wherein the fibers of the plurality of woven fabric layers comprise one or more of the following fiber types: aramid, polyethylene, polypropylene, polyazole, polyester, graphene, spider silk, carbon nanotubes, copolymers, multi-component fibers, and combinations thereof.

12. Approximately 0.034kg / m 2 ~Approx. 9.8kg / m 2 10. The integrated material of claim 1 having an areal density of

13. An article comprising at least one integrated material according to claim 1.

14. The article described in claim 13, wherein the article is a ballistic article that does not include materials integrated using nonwoven fibers.

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