Knitted penetration-resistant protective fabric

Abstract

A penetration protective fabric, or portions thereof, having a first region with a first percent elongation, a second region with a second percent elongation, and a transition region from the first region to the second region that defines a gradient of percent elongation, wherein at least one of the first region or second region has a knitted construction.

Description

KNITTED PENETRATION-RESISTANT PROTECTIVE FABRICCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application is related to and claims the benefit of priority of U.S. Provisional Application 68 / 636,050, filed on April 18, 2024, and U.S. Provisional Application 63 / 636,038, filed on April 18, 2024, the entire contents of which are incorporated by reference.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH ORDEVELOPMENT

[0002] This invention was made with government support under Contract ID: W911NF2020069 awarded by the U.S. Army Research Laboratory. The government has certain rights in the invention.FIELD

[0003] Embodiments relate to apparatuses, methods, and systems configured to provide ballistic protective (or other puncture or cut resistant) fabric. In particular, embodiments relate to a penetration resistant protective fabric having a first region with a first percent elongation, a second region with a second percent elongation, and a transition region from the first region to the second region defining a gradient of percent elongation, and at least one of the first or second regions being knitted.BACKGROUND

[0004] Soft body armor, also known as ballistic or bulletproof vests, include personal protective equipment designed to safeguard individuals from ballistic or other penetration threats (i.e. from knives, picks, etc.). Development and evolution over time have significantly improved the safety and effectiveness of law enforcement, military personnel,prison guards, and other professionals and working animals operating in potentially hazardous environments.

[0005] In the 1970s, the National Institute of Justice (NIJ) in the United States established standardized testing and performance criteria for body armor. These standards provided a framework for evaluating the effectiveness of soft body armor in stopping bullets of various calibers and velocities. The US military requires soft body armor to stop handgun bullets, as well as fragments that might arise from bursting munitions or as debris from an explosive event.

[0006] The present disclosure is directed to a knitted ballistic system. Generally, knitted fabric may be considered as superior to other fabrics manufactured using different techniques. A key advantage of knits for worn garments is that the interlocking, looped structure of a knit allows for significant in-plane fabric stretching, which is accommodated by unbending of the yam loops. Knit fabric in-plane stretch under uniaxial force conditions can be significant, for example with elongations of 10%, or 20%, or 50%, or 100%, or 200%, or even higher depending on the construction of the knit.

[0007] Knits have other properties that are desirable for worn garments. The stretchability of knits makes them more flexible to bending, and therefor, more conformable to complex 3D shapes, compared to other constructions. Additionally, the intricate interlocking of yarn loops typically render knitted fabric highly breathable, promoting air circulation and moisture- wicking properties, which can contribute to temperature regulation and moisture management. Moreover, knitted fabrics are known for their durability, as they tend to resist tearing and fraying due to their construction. These qualities, coupled with the versatility ofknitted textiles in terms of design and pattern possibilities, make them a superior choice for a wide range of applications including soft body armor.

[0008] Continuous research and development efforts have led to the creation of advanced materials and designs, such as aramid fibers (like Kevlar® and Twaron®), high-density or ultrahigh molecular weight polyethylene (UHMWPE) such as Dyneema® and Spectra®, nylon, and polyphenylene benzobisoxazole (PBO). There is a continued desire to deploy these materials in a way that provides ballistic protection while improving flexibility and comfort.SUMMARY

[0009] Manufacturing soft body armor using advanced knitting methods as described herein provides for a ballistic system that is lightweight and conformable, allowing for ease of movement and comfort during prolonged wear.

[0010] One aspect of the invention relates to a penetration protective fabric, or portion thereof. The penetration protective fabric, or portion thereof, has a first region having a first percent elongation, a second region having a second percent elongation, and a transition region from the first region to the second region defining a gradient of percent elongation. At least one of the first region or the second region has a knitted construction.

[0011] In some embodiments, the first region has a recoverable in-plane stretchability of at least 50%, the second region has an in-plane stretchability of less than 10%, and the transition region defines a seamless gradient of in-plane stretchability from at least 50% to less than 10%.

[0012] In some embodiments, the penetration protective fabric, or portion thereof, defines a tubular body. The tubular body can be configured to be worn by a human or animal wearer, suchas in the form of a pant leg or shirt sleeve. In embodiments, a first region is aligned with a first body part of the wearer, such as a musculoskeletal joint, and a second region is aligned with a second body part of the wearer, such as a long bone region connected to the musculoskeletal joint.

[0013] The tubular body may have an unstretched diameter in a range of 1 cm to 50 cm.

[0014] The tubular body may have an unstretched diameter in a range of 2 cm to 20 cm.

[0015] The first region may have a greater degree of ballistic protection than the second region. The greater degree of ballistic protection may be based upon a difference in one or more of areal density, yarn denier, yarn count, or layer count in the first region relative to the second region.

[0016] In some embodiments, at least one of the first region or the second region may include a plain weave, basket weave, rib weave, satin weave, twill weave, sateen weave, point twill weave, royal oxford weave, houndstooth weave, oxford weave, or herringbone weave.

[0017] In some embodiments, the penetration protective fabric, or portion thereof, may be a stab- , puncture-, and / or cut threat-specific protective fabric or portion thereof.

[0018] In some embodiments, the penetration protective fabric or portion thereof may be a ballistic-specific fabric or portion thereof.

[0019] In some embodiments, at least one of the first region or the second region may include one or more fabric coatings. The one or more fabric coatings may include at least one of a thermoplastic coating, thermosetting polymer coating, urethane coating, chemical resistance coating, hydrophobic coating, fluoropolymer coating, coloration coating, abrasive coating, hard particle coating, latex coating, or shear thickening fluid coating.

[0020] A second aspect of the invention relates to a penetration protective fabric, or portion thereof. The penetration protective fabric, or portion thereof, has a knit fabric having a ballisticyarn defining a first plurality of stitches having a first stitch architecture defining a first percent elongation in a first region and a second plurality of stitches having a second stitch architecture, defining a second percent elongation in a second region. A transition region defines a gradient in percent elongation from the first region to the second region having the first plurality of stitches interlocked with the second plurality of stitches.

[0021] In some embodiments, the ballistic yarn may include at least one of aramid, ultrahigh molecular weight polyethylene, nylon, or polyphenylene benzobisoxazole.

[0022] In some embodiments, the ballistic yarn that defines the first plurality of stitches and the second plurality of stitches may be a single, continuous ballistic yarn.

[0023] In some embodiments, the first stitch architecture may be one of a front stitch, a back stitch, a front-back stitch, and a float stitch.

[0024] In some embodiments, at least one of the first region or the second region may include a transfer stitch, miss stitch, float stitch, tuck stitch, or spread stitch.

[0025] In some embodiments, at least one of the first region or the second region may include a single jersey knit, knit welt, interlock knit, rib knit, tricot, sweater knit, pique knit, purl knit, cable fabric, bird's eye, cardigan, milano rib, pointelle, intarsia, jacquard jersey, knitted terry, knitted velour, sliver knit, fleece, raschel knit, weft knit, or warp knit.

[0026] In some embodiments, the penetration protective fabric, or portion thereof, includes at least one plied yarn. The at least one plied yarn may include at least one ballistic yarn and at least one non-ballistic yarn. In embodiments, the at least one non-ballistic yarn may include at least one of an elastic yarn, a rayon yarn, a silk yarn, a natural fiber yarn, or a staple fiber yarn.

[0027] In some embodiments, at least one of the first region or the second region includes a double knit. The double knit may be a double jersey knit.

[0028] In some embodiments, at least one of the first region or the second region includes a double layer knit.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 shows an exemplary embodiment of a penetration protective fabric.

[0030] FIG. 2 shows an exemplary embodiment of a penetration protective fabric.

[0031] FIG. 3 shows an exemplary embodiment of a penetration protective fabric.

[0032] FIG. 4 shows an exemplary embodiment of a penetration protective fabric.

[0033] FIG. 5 illustrates exemplary stitch and knit architectures for a penetration protective fabric.

[0034] FIG. 6 illustrates exemplary stitch and knit architectures for a penetration protective fabric.

[0035] FIG. 7 illustrates exemplary stitch and knit architectures for a penetration protective fabric.

[0036] FIG. 8A illustrates exemplary knit architectures for a penetration protective fabric.

[0037] FIG. 8B illustrates exemplary knit architectures for a penetration protective fabric.

[0038] FIG. 9 illustrates an exemplary embodiment of a penetration protective fabric vest.

[0039] FIG. 10 illustrates an exemplary embodiment of a penetration protective fabric vest.DETAILED DESCRIPTION

[0040] Objects, aspects, features, advantages and possible applications of the present innovation will be more apparent from the following description thereof, presented in conjunction with the drawings. Like reference numbers used in the drawings identify like components.

[0041] The following description of exemplary embodiments presently contemplated for carrying out aspects of the present invention is made merely for the purpose of describing general principles, examples, and features of embodiments of the present invention. The scope of the present invention is not limited to the embodiments as described in detail herein.

[0042] In various embodiments, knitted ballistic protective fabric (e.g., fabric produced with Kevlar® or similar aramid yarns, Dyneema® or similar high-density or ultrahigh molecular weight polyethylene (UHMWPE) yarns, nylon yams, and / or polyphenylene benzobisoxazole (PBO) yams) may be formed into various shapes and or volumes. While the term “ballistic” is frequently used herein, it should be understood that this term is not intended to be limited only to fabrics, garments, and yarns that are intended to protect only against projectiles (e.g. bullets, shrapnel, etc.), unless expressly stated to be so limited, but this term is also used interchangeably to mean “puncture resistant,” generally, to encompass any fabric, garment, yarn, or the like intended to resist not only ballistic threats but also stabbing threats, such as from puncture or cutting (e.g. from knives, picks, swords, etc.). A penetration protective fabric may comprise a ballistic yam (e.g., aramid yam, polyethylene (UHWMPE) yam, nylon yarn, polyphenylene benzobisoxazole (PBO) yam) knitted into a first region, a transition region and a second region. The first region may comprise a plurality of first stitches. The plurality of first stitches may have a first stitch architecture. The second region may comprise a plurality of second stitches. The plurality of second stitches may have a second stitch architecture. The transition region may be defined by the first plurality of stitches being interlocked with each respective stitch of the second plurality of stitches.

[0043] Tn various embodiments, the knitted ballistic, or penetration protective, fabric may contain rows or sections of different stitch architecture. The different stitch architectures may produce a fabric that comprises similar properties across each region having a same or similar stitch architecture. The denier (linear density) of the yarn used to make the fabric may contribute to the fabric properties.

[0044] In various embodiments, the knitted ballistic, or penetration protective, fabric, or portion thereof, may comprise one or more ballistic yarns and one or more non-ballistic yams. The non-ballistic yarns may comprise yams that enhance or increase the comfortability, durability, and / or aesthetics of the knitted ballistic fabric. For example, non- ballistic yams may include elastic yarn, rayon yam, silk yarn, natural fiber yarn (e.g. derived from plants, animals, or minerals without chemical treatment or altering, including but not limited to cotton, linen, hemp, jute, ramie, abaca, sisal, bamboo, wool, silk, mohair, cashmere, alpaca, and the like), staple fiber yam, and similar yarns for enhancing comfort, durability, and / or aesthetics of the knitted ballistic, or penetration protective, fabric.

[0045] In various embodiments, the knitted ballistic, or penetration protective, fabric, or portion thereof, may comprise one or more plied yarns. The plied yam comprises two or more yarns twisted together, or placed side-by-side prior to knitting, as is known in the art, to form a plied yarn. The plied yam may comprise two or more ballistic yarns. The plied yam may comprise two or more non-ballistic yarns. The plied yarn may comprise one or more ballistic yams and one or more non-ballistic yarns.

[0046] The stretch of any ballistic or penetration protective fabric is controlled primarily by the fabric architecture. Yarns are composed of multiple fibers or filaments typically having an inherent strain-to-failure of only around 3%. As used herein, the term yam may refer to amultifilament or multifiber yarn. Textiles with yarns that are substantially straight, such as a plain-woven textile, tend to have a very small stretch (less than 10% or even less than 5%) along the textile's warp and weft directions. Knits, in contrast, accommodate stretch via straightening of yarn loops in the knit structure, resulting in stretchability (elongation) of 10%, or 20%, or 50%, or 100%, or up to 200% or more, and any values in between any of the foregoing.

[0047] The ballistic properties of a textile armor are generally evaluated as the ability of the armor to resist or prevent penetration from a fast-moving projectile. The projectile can be a bullet, such as a lead-core copper-clad handgun bullet, or a piece of shrapnel such as a steel fragment that results from a bursting munition. The velocity of the bullets or fragments can range from 100-5000 ft / s; the mass of the bullets or fragments can range from 1 g to 10 g, or even up to 100 g or more.

[0048] The ballistic performance of an armor is usually normalized by the mass per unit area, or areal density, of the armor. For a given ballistic threat (projectile and impact velocity), armors that can stop the ballistic threat at lowest areal density are typically considered to be more desirable than armors that require higher areal density to stop the same threat. For some applications, thickness and bulk are more critical than armor weight; in these cases, the thinnest armor material that can stop a given ballistic threat is considered the best. In other applications, particularly for body armor, the "comfort" of the armor is highly important. For armored sleeves and pants, it is critical that the armor does not restrict the wearer's range of motion, or their ability to walk, run, jump or reposition their body quickly. Therefore, for sleeves and pants, body armor should be protective, lightweight, and thin, but should also be designed for minimal resistance to user motion.

[0049] Studies on ballistic materials have shown that materials that have high-stretch, such as knits, tend to be less efficient as armor materials compared to low-stretch textiles, such as woven fabrics. In other words, a higher areal density and / or thickness of armor may be required when stretchability is important. Higher weight may be achieved by using higher denier (linear density) yams; knitting or weaving the textile so that the yarns are packed more closely together, resulting in a higher yam count or wale count or course count; or by knitting, weaving, or stacking textiles into multiple layers.

[0050] For pants and sleeves, stretchability may be most needed locally at the wearer's musculoskeletal joints: e.g., elbows, shoulders, hips, knees, etc. Stretchability between joints, along long bones, etc., may be less critical. Therefore, one approach for creating an efficient annored sleeve or pant - a design that minimizes weight and thickness - is to use low-stretch, highly efficient materials such as woven fabrics to protect long bone sections; while using high-stretch constructions such as knits at joints. Furthermore, to achieve balanced protection along the entire sleeve, the high-stretch sections can be designed with higher areal density to offset their lower ballistic efficiency.

[0051] For example, an exemplary sleeve may protect the elbow with a high-stretch fabric using high denier yarns, a high yam count, and / or multiple layers; while protecting the long bones with lower-stretch fabric using lower denier yarns, lower yam count, and / or fewer layers.

[0052] Ballistic injuries to the joints tend to be more debilitating, and often require more extensive surgical repair and rehabilitation, as compared to injuries to the long bones. Therefore, it may be desirable to design a ballistic armor sleeve or pant in which the high-stretch regions at the joints have considerably higher ballistic protection than the regions protecting the long bones.In such a design, the high-stretch region(s) may have dramatically higher areal density, yarn deniers, yam counts, and / or layer counts compared to the low-stretch regions.

[0053] A method for constructing such armored sleeves or pants may include cutting sections of high-stretch fabric (such as knit) and low-stretch fabric (such as woven textile) and then sewing these sections together into a garment. However, stitches are known to become a weak point during ballistic events, particularly in the presence of blast overpressure and debris flows, which can lead to premature failure and vulnerability to the underlying tissue. Furthermore, sewn seams can be points of irritation when worn tight and / or close to the skin.

[0054] A superior approach can be creating a single textile sleeve or pant, in which the high stretch and low stretch regions are seamlessly integrated. For example, the high stretch region and the low stretch region can be connected with a transition section of knit stitches without the need for a sewn seam. Furthermore, the transition from high stretch to low stretch regions is preferably gradual. A gradual transition may reduce stress and strain concentrations during loading and stretching, which may reduce the likelihood of failure during general use and ballistic impact. In embodiments, seamless designs may be manufactured using a fully automatic machine and may tend to be more comfortable due to a lack of raised seams rubbing against the skin.

[0055] In various embodiments, areal density can be tied to fabric thickness. In some embodiments, areal density can also be influenced by yarn size and stitch patterns. Utilizing different stitch types, such as the double welt pattern, can enable the creation of a two-sided fabric with varying areal densities. This versatility can allow for tailored fabric properties to suit-specific applications.

[0056] Referring to FIG. 1, in an exemplary embodiment, penetration protective fabric 100, or portion(s) thereof, includes a first region 102 having a first percent elongation, e.g., 1%, 10%, 20%, 50%, 100%, 200%, or any value between 1-200%. A second region 104 has a second percent elongation, typically different from the first percent elongation. Transition region 106 extends between the first region 102 and the second region 104, and defines a gradient of percent elongation. For example, in an embodiment in which transition region 106 defines a gradient from a first percent elongation of 50% to a second percent elongation of 10%, transition region 106 defines a seamless gradient 108 transitioning from the first region 102 to the second region 104 (i.e. from 50% elongation to 10% elongation). The seamless gradient 108 may be a linear or non-linear gradient and may occur within a single row of knit stitches or may occur across a plurality of rows of knit stitches.

[0057] In some embodiments, the first region 102 has a different degree of ballistic protection as compared to the second region 104. For example, in some embodiments, first region 102 has a lesser degree of ballistic protection than second region 104. In other embodiments, the first region 102 has a greater degree of ballistic protection than second region 104. In still other embodiments, the first region 102 and the second region 104 may have the same degree of ballistic protection. It should be understood that the number of regions is merely exemplary, and that, in some embodiments, the penetration protective fabric 100 may include any suitable number of regions and corresponding transition regions therebetween.

[0058] For example, in an embodiment in which the first region 102 has a first degree of ballistic protection and the second region 104 has a second degree of ballistic protection different from the first degree of ballistic protection, the degree of ballistic protection may be based upon adifference in density, e g., yarn linear density (denier), areal density, yarn count, and / or layer count in the first region 102, as compared to the second region 104.

[0059] In some embodiments, the first region 102, the second region 104, and / or the transition region 106 may have a recoverable in-plane stretchability. For example, the first region 102 may have a 50% recoverable in-plane stretchability, the second region 104 may have a 10% recoverable in-plane stretchability, and the transition region 106 may define a gradient of in-plane stretchability, such as a seamless gradient of in-plane stretchability from 50% to 10% recoverable in-plane stretchability where loops of the knit in the first region 102 are arranged to interlock with the second region 104 across the transition region 106. It is understood that the above values of percent elongation and / or recoverable in-plane stretchability are merely exemplary, and that the penetration protective fabric 100, and / or portions thereof (e.g., first, second, and / or transition regions 102, 104, and / or 106, respectively), may have any suitable percent elongation and / or recoverable in-plane stretchability.

[0060] In some embodiments, the penetration protective fabric 100 may include a knit of ballistic fabric that comprises a ballistic yam. The ballistic yarn may define a first plurality of stitches 110 and a second plurality of stitches 112. In some embodiments, the first plurality of stitches 110 has a first stitch architecture and the second plurality of stitches 112 has a second stitch architecture, as further described below. In such embodiments, the transition region 106 may define a gradient (e.g., gradient 108) including the first plurality of stitches 110 interlocked with the second plurality of stitches 112. In some embodiments, the aramid yarn defining the first plurality of stitches 110 and the second plurality of stitches 112 may be defined by a single aramid yarn. As used herein, the term “interlocked” meansthat following the path of the yarn (or portion thereof) that defines the first plurality of stitches, the yarn has an interlocking relationship with at least one yam (or portion thereof) that defines the second plurality of stiches. For example, referring to FIG. 8 A, and considering the dark yam to define a row, the dark yarn can be characterized as “interlocked” with the stiches defined by the white yams with which it makes contact in the rows above and below the dark yarn row. Although FIG. 8A shows, e.g., each of the three adjacent rows of 316 including the dark yarn as having the same architecture, the term interlocked also applies to embodiments in which the dark yam may bridge between different stitch architectures above and below and may have a different architecture than either of the architectures above or below.

[0061] Referring to FIGS. 2-4, in some embodiments, a penetration protective fabric 200, or portion(s) thereof, may define a body, such as tubular body 202 configured to be worn by a human or animal (FIGS. 3-4, 9-10), such as, for example, a sleeve or pant leg. Penetration protective fabric 200 has a first region 204, a second region 206, and a transition region 208. As described above in relation to penetration protective fabric 100, the regions of the penetration protective fabric 200, such as first region 204, second region 206, and / or transition region 208, has varying degrees of ballistic protection, percent elongation, and / or recoverable in-plane stretchability. In some embodiments, at least one of the first region 204 and / or the second region 206 has a knitted construction. Penetration protective fabric 200 may include any suitable number of regions, transition regions, etc.

[0062] In some embodiments, the first region 204 is aligned with a first body part 210, such as a musculoskeletal joint (for example, an elbow joint, shoulder joint, knee joint, etc.), and the second region 206 is aligned with a second body part 212 , such as a long bone region(for example, a forearm region, upper arm region, shin region, thigh region, etc.)connected to the musculoskeletal joint. For example, first body part 210 (elbow) is connected to second body part 212 (forearm), as shown in FIGS. 3-4. The penetration protective fabric 100 / 200 may be deployed as a base layer for a ballistic system, as a cover for other structures, or as a standalone protective garment.

[0063] As described above, in some embodiments, the penetration protective fabric 100 and / or 200 can include one or more ballistic yarns and one or more non-ballistic yams. The penetration protective fabric 100 and / or 200 can include one or more plied yarns. The plied yams may each include a plurality of ballistic yarns, a plurality of non-ballistic yams, or a combination thereof.

[0064] FIGS. 5-8 depict a variety of stitch and knit architectures 300. In some embodiments, the penetration protective fabric(s) 100 and / or 200 can include one or more knit and / or stitch architecture(s). For example, referring now to FIG. 5, in some embodiments, the penetration protective fabric(s) 100 and / or 200 can include one or more of a front stitch 302, back stitch 304, and front-back stitch 306.

[0065] Table 310 is a machine-agnostic representation of a double knit array of stitch architecture, such as might be used for programming an automated knitting machine, representing an exemplary gradient for a transition region as described herein. It should be understood that the rows above and below those shown in the table may be any type of stitch known in the art, including but not limited to a combination of front stitches and back stitches without any front-back stitches.

[0066] In table 310, black yarn 320 represents a first side (e.g. outer facing) of a fabric (e.g., a double knit fabric) comprising a first yarn (e.g. a front side comprising a ballistic yarn) and whiteyarn 322 represents a second side (e.g. inner facing) of the fabric. Light colored blocks (e.g. green in a color version) represent those with a front stitch architecture 302, medium dark blocks (e.g. pink in a color version) represent those with a back stitch architecture 304, and darkest blocks (e.g. yellow in a color version) represent those with a front-back stitch architecture 306. For clarity, in view of the limited information that can be conveyed by a grayscale drawing, each block in rows 344a, 344b, and 344c are blocks 304, except for the expressly noted blocks 306. The medium tone yarn 324 (where shown) corresponding to block 306 represents a portion of yarn 322 having the representative stitch in that block. It should be understood that while not shown for block 306 in row 344a, a similar stitch would be present here as in blocks 306 in rows 344b and 344c.

[0067] Considering table 310 shown in FIG. 5 as having five rows and five columns, numbered from first to fifth going left to right and top to bottom, table 310 shows a front-back stitch in the first row (344a) second column, third row (344b) fourth column, and fourth row (344c) second column, with front stitches in all other blocks of the first, third, and fifth rows and back stitches in all blocks of the second, fourth, and sixth rows. Although not shown, columns to the left or right of those shown in the table may follow the same pattern (e g. the first row may have another front-back stitch two columns to the right of the fifth column (i .e. in the seventh column) and the third row might have another front-back stitch in left-adjacent column (not shown) relative to the first column.

[0068] In general, a front-back stitch has greater percent elongation relative to the front stitch and back stitches. Thus, in table 310, the different stitch architecture block 306 (e.g., having a greater percent elongation) is interposed every fifth column along the same row, with the location of the different stitch architecture block in alternating rows of the same type (e.g. 344a,344b, 344c) offset (e.g. centered) between the different stitch architecture blocks of the adj cent same-type rows. It should be understood that different gradients having different percent elongation can be achieved by providing a different spacing between the different stitch architecture blocks (e.g. relatively greater spacing between stitches having relatively greater percent elongation will provide a gradient region with a generally lesser percent elongation relative to a region having a relatively lesser spacing).

[0069] The invention is not limited to any particular spacing or pattern of different stitches. While shown and described herein in an example in which the black yam may be a ballistic yam, and the white yarn may be a non-ballistic yarn, the composition of each yarn and relative location (e.g. front or back) is not limited to any particular construction. Likewise, the invention is not limited to any particular stitch architecture in each of the blocks as described, nor to only a total of three stitch architectures, nor to embodiments in which the different stitch has a greater percent elongation. In some embodiments, the different stitch may have a lesser percent elongation, for relatively greater protection. Although shown in an embodiment in which the different stitch architecture is deployed in the non-ballistic yarn, the invention is not limited to such constructions, although such constructions may be generally more preferable. Although shown as a 5x5 table, it should be understood that the number of columns may extend nearly indefinitely, including in an arrangement in which the columns are arranged to form a circumference, such as in a sleeve. Likewise, the number of rows may extend for as long as the gradient is desired, and the rows may change from row to row. For example, in transitioning the percent elongation between a first to a second value, each row may have a different spacing and number (per unit area) of the relatively greater (or lesser) percent elongation stitches. Depending on the areal density of the knit, the transition may define a relatively linear gradient from firstrow to last row, or the gradient may be stepwise from row to row, or the gradient may follow a non-linear curve in values from first row to last row.

[0070] Table 312 in Fig. 6 is a machine-agnostic representation of a double layer knit array of stitch architecture, such as might be used for programming an automated knitting machine, representing another exemplary gradient for a transition region as described herein. It should be understood that the rows above and below those shown in the table may be any type of stitch known in the art, including but not limited to a combination of front stitches and back stitches without any front-back stitches. In embodiments, the rows above or below may conform to the pattern depicted in table 310 or a version thereof as described above.

[0071] In table 312, black yarn 330 represents a first side, or first layer (e.g. outer facing) of a fabric (e.g., a double layer knit fabric) comprising a first yarn (e g. a front side comprising a ballistic yarn) and white yam 332 represents a second side, or second layer (e.g. inner facing) of the fabric. Light colored blocks (e.g. green in a color version) represent those with a front stitch architecture 302, medium dark blocks (e.g. pink in a color version) represent those with a back stitch architecture 304, and darkest blocks (e.g. yellow in a color version) represent those with a front-back stitch architecture 306. For clarity, in view of the limited information that can be conveyed by a grayscale drawing, each block in rows marked 304 conform to a back stitch architecture 304, each block in rows marked 302 conform to a back stitch architecture 302, and each block in lines marked 306 conform to a front-back stitch architecture 306. The medium tone yarn 334 corresponding to block 306 represents yarn having a front-back stitch, which may be a same type as yarn 330 or 332 or may be a different type of yarn. The different type of yarn may have a greater or lesser percent elongation than yarn 330 or 332, and may comprise a different composition in whole or in part. For example, in an embodiment in which yarn 330 or 332comprises a multi-fiber (or multi-ply) yarn comprising both ballistic and non-ballistic fibers, yarn 334 may have a different number of fibers or plies or a different relative composition of fibers or plies (including a greater percentage of ballistic or non-ballistic fibers, different materials for one or all types of fibers, or the same materials in different relative concentration). In embodiments, yarn 334 may be identical to one or both of 330 or 332, with the only difference being the difference in stitch architecture. Although depicted as starting in a row adjacent a back stich row, row 306 may start in a row adjacent a front stitch row. Although depicted as only 1 row, multiple rows of different stitch architecture may be provided, with each next adjacent row (e.g. seventh, eighth, etc.) having a same architecture, or each having a progressively different architecture (e.g. each yarn having a progressively greater (or lesser) percent elongation). The gradient as a whole may be linear, non-linear, or stepwise.

[0072] Table 314 of FIG. 7 is another machine-agnostic representation of a “B” or float 1*1 alternate array of stitch architecture, in which black yarn 350 represents a first side (e.g. outer facing) of a fabric (e.g. a front side comprising a ballistic yarn) and white yam 352 represents a second side (e.g. inner facing) of a fabric. Light colored blocks (e.g. blue in a color version) represent those with a float or miss stitch architecture 308 and dark blocks (e.g. red in a color version) represent those with a front stitch architecture 302. Float or miss stitches 308 may be used to connect stitch architectures and / or alter (e.g., increase or decrease) dimensions of a fabric, for example, to create specific fabric shapes. In table 314, as depicted, stitches 308 and 302 alternate from column to column and row to row, with the float stitch in the second side centered between adjacent float stitches on the first side. The incorporation of float stitches may be further spaced rowwise and / or columnwise, as needed to provide the desired degree ofgradient. In embodiments, the gradient shown in table 314 may be used in combination with the gradients depicted in one or both of tables 310 or 312.

[0073] In some embodiments, the penetration protective fabric(s) 100 and / or 200 can include one or more of a double knit 310, a double layer knit 312, a B or float 1*1 alternate array 314, a face-loop-on-surface weft knit 316 (FIG. 8A), and / or a back-loop-on-surface weft knit 318 (FIG 8B). As described above, the variety of stitch and knit architectures 300 is merely exemplary, and the penetration protective fabrics 100 and / or 200 may include any suitable knit and / or stitch architectures in various permutations and combinations.

[0074] As described above, in some embodiments, the penetration protective fabric 100 and / or 200 can include one or more stitch architectures and / or knit architectures. For example, the first region 102 may have a first stitch architecture and / or first knit architecture, and the second region may have a second stitch architecture and / or second knit architecture different than first stitch and / or knit architectures. In some embodiments, the first region 102 and the second region 104 may have the same stitch and / or knit architectures. Referring now to FIGS. 9 and 10, in some embodiments, a ballistic (e.g., penetration protective) harness or vest 400 is shown as an exemplary application of a penetration protective fabric 100. The ballistic vest 400 may be deployed as a base layer for a ballistic system, as a cover for other structures, or as a standalone protective garment.

[0075] As depicted in FIGS. 9 and 10, the back of the vest 402 and the front of the vest 424 have an overall contour that matches the general anatomy of a working dog or K-9. The vest 400 may be divided into multiple portions each portion having a stitch pattern and / or a yam denier that can impart features and / or functionalities in the penetration protective fabric 100. For example,portions 404a-c may comprise 600 denier yarn 420, which can be made using a series of front knit stitch architecture, back knit stitch architecture, and / or front-back stitch architecture(s).

[0076] The various stitch architectures may be deployed in a double knit array and / or a double layer knit array, as shown in FIGS. 5-6. These arrays can provide for a tighter or bunched structure corresponding to openings 408 and 410 in the vest or at points where the anatomy of the working dog may benefit from a tighter fit. For example, the tighter arrays may be located at or near the collar area 412 of the working dog allowing for a tighter or tailored fit adjacent the dog's head. A tighter or more tailored structure may also be used at the base of the working dog's neck 414 before the transition to the dog's chest 416. A tighter or more tailored structure may also be used at or before the hind quarters of the dog 418. These tighter or more tailored structure may also be positioned to hold the vest or harness in place on the anatomy to keep vital regions (e.g., the trunk of the dog) ballistically protected.

[0077] In some embodiments, the regions 406a-b may be made of 1500 denier yarn 422. These regions may be formed into a ballistic fabric made of an array of alternating front stitch architectures and float or miss stitch architectures (FIG. 7). These regions can be a "B" or float 1* 1 alternate array (FIG. 7). The array regions can be knitted in large portions that can cover larger portions of the dog's anatomy with ballistic fabric. That ballistic fabric may be less tailored allowing the dog to move more freely, breathe, and still be protected.

[0078] In some embodiments, the front of the vest 424 may employ similar stitch architecture(s) and / or arrays relative to the back of the vest 402. The front of the vest 424 can be adapted to meet the requirements of a dog’s anatomy, such as with one or more openings 426 to accommodate the front and / or rear legs of the dog. One or more stitched portions of the ballistic vest 400 may be non-uniform and can transition along a variety of gradients between variousstitch architectures and / or arrays. For example, the interfaces between each region having different properties (e.g. between some or all of regions 406b and 404c, 406b and 404b, 404b and 406a, 406a and 404a) may comprise a transition or gradient as described and claimed herein. One or more of the stitched portions may include uniform and / or non-uniform stitch voids that allow for openings that can be sized for any suitable application. Such portions may be formed into volumes that can receive anatomy or otherwise provide three-dimensional ballistic protection.

[0079] Aspects of the invention also relate to a method of making a penetration protective, or ballistic (e.g. aramid), fabric, comprising: knitting a ballistic yarn (e.g. an aramid yam, , polyethylene (UHWMPE) yarn, nylon yarn, polyphenylene benzobisoxazole (PBO) yarn) into a first region comprising a plurality of first stitches of a first stitch architecture; a second region comprising a plurality of second stitches of a second stitch architecture, wherein a transition region (e.g., a gradient) is defined by the first plurality of stitches being interlocked with each respective stitch of the second plurality of stitches. The first stitch architecture may be one of a front stitch, a back stitch, a front-back stitch, and a float stitch. The first region may be a jersey knit. The percent elongation of the ballistic fabric may be in the range of 0 to 100 percent. The ballistic yarn may comprise a plurality of ballistic yams, or at least one ballistic yarn and at least one non-ballistic yam, or a single ballistic yarn.

[0080] Another aspect of the invention relates to making a ballistic (e.g. aramid, polyethylene (UHWMPE), nylon, polyphenylene benzobisoxazole (PBO)) fabric, comprising: knitting a ballistic (e.g. aramid, polyethylene (UHWMPE), nylon, polyphenylene benzobisoxazole (PBO)) yarn into a structure defining a volume, the yarn comprising a first region comprising a plurality of first stitches and a first percent elongation, and a second region comprising aplurality of second stitches and a second percent elongation, wherein a transition region (e g., a gradient) is defined by the first plurality of stitches being interlocked with each respective stitch of the second plurality of stitches. One or both of the first percent elongation and the second percent elongation may be in a range from 0 to 100 percent. The volume may be an irregular volume. In embodiments, the volume may be configured to engage a wearer’s anatomy. The ballistic fabric may comprise at least one ballistic yam and at least one non-ballistic yam. The ballistic fabric may comprise a single ballistic yarn. The ballistic fabric may comprise one or more plied yams. The one or more plied yarns may comprise a plurality of ballistic yams. The one or more plied yams may comprise one or more ballistic yarns and one or more non-ballistic yarns.

[0081] Yet another aspect of the invention relates to a seamless, textile tubular body comprising yarns with high stiffness and strength, wherein the body contains one or more regions with recoverable in-plane stretchability of at least 50%; and the body contains one or more regions with recoverable in-plane stretchability of less than 10%; and the body contains a transition region, from the at least one high stretchability region to the at least one low stretchability region, comprising a smooth gradient in stretchability; and at least one region is knitted. The yarns have an ultimate tensile strength of at least 1 GPa, preferably of at least 3 GPa. The yams have a tensile Young’s modulus of at least 10 GPa, preferably at least 50 GPa. In embodiments, the yams may comprise at least one of aramid, polyethylene (UHMWPE), nylon, or polyphenylene benzobi soxazole (PBO). In embodiments, at least one region may have a recoverable in-plane stretchability of at least 100% in one or more directions. In embodiments, at least one region may have a recoverable in-plane stretchability of less than 5% in one or more directions.

[0082] In embodiments, all cross-sections of the tubular body have an unstretched diameter between 1 cm and 50 cm, preferably between 2 cm and 20 cm. The body may be part of a garment, such as a sleeve or pant leg. The garment may be body armor, such as for use for military or law enforcement purposes. The garment may be worn by an animal. The garment may be resistant to penetration by ballistic projectiles. In a sleeve or pant leg embodiment, the high stretch region is located on the textile body on or near the wearer's one or more musculoskeletal joints, and the low stretch regions are located on the textile body on or near the wearer's one or more long bone sections between musculoskeletal joints. The one or more regions may comprise a front stitch, a back stitch, a front-back stitch, and a float stitch. The one or more regions may comprise a single jersey knit, double jersey knit, double knit, double layer knit, knit welt, interlock knit, rib knit, tricot, sweater knit, pique knit, purl knit, cable fabric, bird's eye, cardigan, milano rib, pointelie, intarsia, jacquard jersey, knitted terry, knitted velour, sliver knit, fleece, raschel knit, weft knit, or warp knit. At least one region may contain a transfer stitch, miss stitch, float stitch, tuck stitch, or spread stitch. One or more regions may comprise a plain weave, basket weave, rib weave, satin weave, twill weave, sateen weave, point twill weave, royal oxford weave, houndstooth weave, oxford weave, or herringbone weave. In embodiments, one or more regions contain highly elastic fibers, such as spandex, to reduce recovery times after stretching.

[0083] The one or more low stretch regions may contain one or more inlay yarns, such as inlay yarns having a tensile Young’s modulus greater than 50 GPa, an ultimate tensile strength greater than 1 GPa, or a combination thereof. The inlay yarns may comprise at least one of aramid, polyethylene (e.g. UHMWPE), nylon, or benzobisoxazole (PBO). The areal density, linear density, or a combination thereof, of one or more of the high stretch regions may be greater thanthe areal density of one or more of the low stretch regions. The yarn count, yams per unit length, wales per unit length, or courses per unit length, may be higher in one or more of the high stretch regions than in one or more of the low stretch regions. The number of fabric layers in one or more of the high stretch regions may be higher than the number of fabric layers in one or more of the low stretch regions. In embodiments, the areal density of one or more of the high stretch regions is higher than 200 g / m2.

[0084] The textile body may also have functional coatings. Coatings of a tough polymer, such as a polyurethane, can enhance the ballistic properties of the textile. Other coatings may be added to improve the hydrophobicity, resistance to chemical or biological hazards, abrasion resistance, or appearance of the garment. For example, the coatings may include thermoplastic polymer coatings, thermosetting polymer coatings, urethane coatings, chemical resistance coatings, hydrophobic coatings, fluoropolymer coatings, colorations, abrasive coatings, hard particle coatings, latex coatings, and / or shear thickening fluid coatings. The coatings may be sprayed, dipped, or hot-melted onto the textile body.

[0085] The present invention may also be used to build protective garments to resist stab and puncture. In prisons, and in countries with restrictive handgun laws, the threats to law enforcement are commonly stabbing threats. These stabbing threats can include cutting, slashing, stabbing, and puncture weapons to include knives, ice picks, and improvised weapons. High performance ballistic textiles, such as those composed of aramids, polyethylene (UHMWPE), nylon, and PBO are known to also provide good protection against stab and cut threats.Therefore, it should be understood that while the term “ballistic” is used herein, the protective fabrics as disclosed herein are not limited to protection only against bullets or other projectiles but may also provide protection against penetration or cutting threats of any sort, such as withknives, spikes, picks, or the like. Accordingly, the term “ballistic protective fabric” is not intended to be limited to fabrics dedicated to protecting against ballistic threats unless specifically stated herein, and may be used as a shorthand to refer to protective fabrics, generally. In portions of the disclosure or claims where specificity is intended, the term “penetration protective fabric” may be used to refer to embodiments that have no specific emphasis for ballistic or stab / cutting threats, where as “ballistic-specific” or “stab-, puncture-, and / or cut threat-specific” may be used to refer to designs intended for specifically enhanced protection against one or the other. Those of skill in the art understand the differences in overall design that may be implemented in garments for such specific, enhanced protection, the details of which are not discussed herein further. The aspects of the invention as described herein are equally applicable to any type of penetration protective fabric design, regardless of emphasis.

[0086] It should be understood that the disclosure of a range of values is a disclosure of every numerical value within that range, including the end points. It should also be appreciated that some components, features, and / or configurations may be described in connection with only one particular embodiment, but these same components, features, and / or configurations can be applied or used with many other embodiments and should be considered applicable to the other embodiments, unless stated otherwise or unless such a component, feature, and / or configuration is technically impossible to use with the other embodiment. Thus, the components, features, and / or configurations of the various embodiments can be combined together in any manner and such combinations are expressly contemplated and disclosed by this statement.

[0087] It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible considering the above teachings of the disclosure. The disclosed examples and embodiments are presented for purpose of illustrationonly. Other alternate embodiments may include some or all of the features disclosed herein. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention, which is to be given the full breadth thereof.

[0088] It should be understood that modifications to the embodiments disclosed herein can be made to meet a particular set of design criteria. Therefore, while certain exemplary embodiments of the compositions, materials, apparatuses, and methods of using and making the same disclosed herein have been discussed and illustrated, it is to be distinctly understood that the invention is not limited thereto but may otherwise be variously embodied and practiced within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1. A penetration protective fabric or portion thereof comprising: a first region with a first percent elongation; a second region with a second percent elongation; and a transition region, from the first region to the second region, defining a gradient of percent elongation; wherein at least one of the first region or the second region is knitted.

2. The penetration protective fabric or portion thereof of claim 1, wherein the first region has a recoverable in-plane stretchability of at least 50% and the second region has recoverable in-plane stretchability of less than 10%; and the transition region defines a seamless gradient of in-plane stretchability from at least 50% to less than 10%.

3. The penetration protective fabric or portion thereof of claim 2, wherein the penetration protective fabric or portion thereof defines a tubular body configured to be worn by a human or animal wearer as a pant leg or shirt sleeve with the first region aligned with a first body part of the wearer comprising a musculoskeletal joint, and the second region aligned with a second body part of the wearer comprising a long bone region connected to the musculoskeletal joint.

4. The penetration protective fabric or portion thereof of claim 3, wherein the first region has a greater degree of penetration protection than the second region.

5. The penetration protective fabric or portion thereof of claim 4, wherein the greater degree of ballistic protection is based upon a difference in one or more of areal density, yarn denier, yarn count, or layer count in the first region relative to the second region.

6. The penetration protective fabric or portion thereof of claim 1, wherein at least one of the first region or the second region comprises a plain weave, basket weave, rib weave, satin weave, twill weave, sateen weave, point twill weave, royal oxford weave, houndstooth weave, oxford weave, or herringbone weave.

7. The penetration protective fabric or portion thereof of claim 3, wherein the tubular body has an unstretched diameter in a range of 1 cm to 50 cm.

8. The penetration protective fabric or portion thereof of claim 3, wherein the tubular body has an unstretched diameter in a range of 2 cm to 20 cm.

9. The penetration protective fabric or portion thereof of claim 1, wherein the penetration protective fabric or portion thereof comprises a stab-, puncture-, and / or cut threat-specific protective fabric or portion thereof.

10. The penetration protective fabric or portion thereof of claim 1 , wherein the penetration protective fabric or portion thereof comprises a ballistic-specific protective fabric or portion thereof.11 . The penetration protective fabric or portion thereof of claim 1 , wherein at least one of the first region or the second region comprises one or more fabric coatings.

12. The penetration protective fabric or portion thereof of claim 11, wherein the one or more fabric coatings comprise at least one of a thermoplastic coating, thermosetting polymer coating, urethane coating, chemical resistance coating, hydrophobic coating, fluoropolymer coating, coloration coating, abrasive coating, hard particle coating, latex coating, or shear thickening fluid coating.

13. A penetration protective fabric or portion thereof, comprising: a knit fabric comprising a ballistic yarn, and: the ballistic yarn defines a first plurality of stitches having a first stitch architecture defining a first percent elongation in a first region; the ballistic yam defines a second plurality of stitches having a second stitch architecture defining a second percent elongation in a second region, and a transition region defines a gradient in percent elongation from the first region to the second region, comprising the first plurality of stitches interlocked with the second plurality of stitches.

14. The penetration protective fabric or portion thereof of claim 13, wherein the ballistic yarn comprises at least one of aramid, ultrahigh molecular weight polyethylene, nylon, or polyphenylene benzobisoxazole.

15. The penetration protective fabric or portion thereof of claim 13, wherein the ballistic yarn that defines the first plurality of stitches and the second plurality of stitches consists of a single, continuous ballistic yarn.

16. The penetration protective fabric or portion thereof of claim 13, wherein the first stitch architecture is one of a front stitch, a back stitch, a front-back stitch, and a float stitch.

17. The penetration protective fabric or portion thereof of claim 13, wherein at least one of the first region or the second region comprises a transfer stitch, miss stitch, float stitch, tuck stitch, or spread stitch.

18. The penetration protective fabric or portion thereof of claim 13, wherein at least one of the first region or the second region comprises a single jersey knit, knit welt, interlock knit, rib knit, tricot, sweater knit, pique knit, purl knit, cable fabric, bird's eye, cardigan, milano rib, pointelle, intarsia, jacquard jersey, knitted terry, knitted velour, sliver knit, fleece, raschel knit, weft knit, or warp knit.

19. The penetration protective fabric or portion thereof of claim 13, wherein the penetration protective fabric or portion thereof comprises at least one plied yarn.

20. The penetration protective fabric or portion thereof of claim 18, wherein the at least one plied yam comprises at least one ballistic yarn and at least one non-ballistic yam, wherein the atleast one non-ballistic yam comprises at least one of an elastic yarn, a rayon yarn, a silk yam, a natural fiber yarn, or a staple fiber yarn.

21. The penetration protective fabric or portion thereof of claim 13, wherein at least one of the first region or the second region comprises a double knit.

22. The penetration protective fabric or portion thereof of claim 21, wherein the double knit comprises a double jersey knit.

23. The penetration protective fabric or portion thereof of claim 13, wherein at least one of the first region or the second region comprises a double layer knit.

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