Materials for personal protection against bullets, shrapnel, sharp implements, such as knives, spikes, bayonets, etc. are well known. Such conventional protective devices take the form of multiple layers of material sewn together to create a thick vest-like garment or the lining of helmets, etc. Such thick garments are heavy, thick, rigid, stiff, cumbersome, restrictive and impede movement of the individual wearing the garment and are uncomfortable. This leads to less than optimal compliance with those intended to be protected.
To overcome the problems inherent in thick, heavy and uncomfortable personal protective clothing, the inventor have devised a product and method that affords equal, if not better, levels of protections using far fewer layers of material and is thus thinner, lighter and more flexible than conventional products.
In a first embodiment an impact dissipating fabric system comprises a first fabric layer formed using a first weave pattern, and a second fabric layer formed using a second weave pattern different from the first wave pattern. The first and second fabric layers are disposed on one another and coupled together.
In a second embodiment an impact dissipating fabric system comprises a first fabric layer formed with fibers having a first denier, and a second fabric layer formed with fibers having a second denier different from the first denier. The first and second fabric layers are disposed on one another and coupled together.
In a third embodiment an impact dissipating fabric system comprises a first fabric layer formed using a first weave from fibers having a first denier, and a second fabric layer formed using a second weave from fibers having a second denier. In this embodiment at least one of i) the first weave and the second weave are different types of weaves and ii) the first denier and the second denier are different from one another, and the first and second fabric layers are disposed on one another and coupled together.
In one aspect of the invention the first and second fabric layers are formed from a high tensile strength fiber.
In another aspect of the invention the high tensile strength fiber is an aramid fiber.
In a further aspect of the invention a further fabric layer is formed using either the first weave pattern, the second weave pattern or a third weave pattern different from both the first and second weave patterns. The further fabric layer is disposed on and coupled to either the first or second fabric layer based on the type of weave pattern used for the third fabric layer.
In yet a further aspect of the invention i) when the third weave pattern is the same as the first weave pattern, the third fabric layer is disposed on an exposed face of the second fabric layer, and ii) when the third weave pattern is the same as the second weave pattern, the third fabric layer is disposed on an exposed face of the first fabric layer.
In one aspect of the invention the weave patterns are selected from the group consisting of i) a plain weave, ii) a basket weave, iii) a leno weave, iv) a crowfoot weave, v) a twill weave and vi) an eight harness satin weave.
In another aspect of the invention the fabric system may be used in protection equipment selected from the group consisting of vests, helmets, footwear, body armor, vehicle lining, abrasion resistant gear, impact resistant gear, trauma gear, sports gear, blast protection, ballistic protection, stab protection, fragment protection, electronic casings and protective facings, and protection of other goods.
In still another aspect of the invention the first and second fabric layers are coupled together by one of stitching with tack yarn, needle punch to comingle fibers from the adjacent fabric layers with one another, a lamination film, or a resin.
In a further aspect of the invention an elastomer coating may be disposed on at least one of the exposed major surfaces of the fabric layer after the fabric layers are coupled to one another.
These and other aspects are described in detail below with reference to the drawings.
The invention is best understood from the following detailed description when read in connection with the accompanying drawings. Included in the drawings are the following figures:
The inventor has determined that by using two layers of material, with a first one of the layers having a first type of weave, and the second layer having a second type of weave different from the first type of weave, an impact dissipating fabric results that is at least as effective at impeding a projectile as is a material having more than two layers. The inventor has further determined that an impact dissipating fabric may be formed by using two or more layers of non-woven material. Thus, a light weight, more comfortable garment is feasible that will be more readily accepted and worn by those it is intended to protect.
Before continuing a listing of definitions for terms used herein will be useful.
Decitex—also called Detex (and will used herein as such)—is a measure of fiber density, and indirectly of yarn size. Decitex is determined by weighing 10,000 meters of a single thread and recording the mass in grams (or by weighing 100 meters and multiplying the mass in grams by 100). The higher the Detex the larger the diameter of the fiber becomes.
Denier—is a measure of fiber density, and indirectly of yarn size. Denier is determined by weighing 9,000 meters of a single thread and recording the mass in grams (or by weighing 90 meters and multiplying the mass in grams by 100). The higher the Denier the larger the diameter of the fiber becomes.
Fabric—As used herein, the term “fabric” refers to any structure comprising one or more woven or non-woven layers of yards or other elongated material. “Fabric” includes, by way of non-limiting example, knitted fabrics, laminates, micro-laminates, natural fibers (such as cotton), aramid fibers, metal fibers, synthetic fibers (including polypropylene and/or polyethylene), and high-tensile strength fibers.
In traditional ballistics and stab protection, multiple layers are encased with hard plastics, epoxies and hardening resins thereby locking the layers into place making them rigid, hard and stiff. One of the limitations of this method is that when a projectile or object strikes it, only a small area actually dissipates the joules of energy, force and trauma. An aspect of the invention teaches that when double and triple layers of fabric are joined together by means that enable mobility and flexibility and then the joined layers are coated with a flexible, malleable elastomeric coating, the entire surface area absorbs, confuses and dissipates the joules, force and trauma instead of just a small area, thereby reducing the number of layers needed to stop the projectile, thus making the protective gear thinner, lighter, and flexible. This invention will also work well with sport protection, helmets and other protective gear.
A first exemplary embodiment of the present invention is illustrated in
Referring again to
The reason for using different types of weaves and/or yarn diameters for immediately adjacent fabric layers is because as a projectile moves through the first layer it may begin to penetrate at a gap where two adjacent yarns meet. However, as the bullet, stab device, knife, spike, shrapnel, fragment or impact force generated by a foreign object including but not limited to: person, ball, bat, stick, weapon (“Projectile”) continues toward the second fabric layer, because of the different yarn diameter, the Projectile will strike the face of the yarn and thus be impeded. The intent is to disrupt and confuse the Projectile upon impact with the material.
Fabric A may be comprised of a weave using fibers having a first detex or denier while fabric B is comprised of weave having a second detex or denier different from the fabric A. For example, fabric A may be formed from a 750 Detex yarn and fabric B may be formed using 930 Detex yarn. In addition, the density of the different layer may also vary. It is contemplated that the density may range from 10×10 yarns/inch to 70×70 yarns/inch for these different materials to provide the desired ballistic resistance. It is also contemplated that the fibers used to form these various layers are a high tensile strength fibers including but not limited to an aramid fiber.
For a double weave fabric, for example, the weaving machine will use tack yarns 10 to join the double fabrics together into one piece of woven fabric. Corner Tack 12 and Bar Tack 14 may also be used as desired. In one exemplary embodiment, the stitching will be between 2 to 10 tack yarns per square inch. Popular conventional stitching designs include, but are not limited to, T-Bar, Corner Tack, Border Stitch, 1-2 Quilt Stitch and 1-2 Box Stitch.
The invention is not limited to two layers. It is contemplated that a third layer of material may be included. In such an embodiment, the third layer may be comprised of a fabric formed from a weave and/or denier that is different from weave and/or denier of the layer upon which it is disposed. In other words, if adding a fabric layer C on top of fabric layer A, fabric layer C may have the same denier as fabric layer B. It is also contemplated that fabric layer C could have a weave pattern and/or denier different that those of fabric layers A and B.
For example, due to the present invention when a bullet hits the different patterns it slows down and starts to tumble. Once the bullet is not spinning left to right but end over end, the effectiveness of the bullet is reduced if not entirely eliminated. When it hits this double pattern the bullet starts to go end over end, mushrooms out, gets confused and starts to lose its momentum. Further, as a Projectile continues toward the double pattern it will encounter greater resistance per square inch and thus be impeded. The intent is to disrupt and confuse the Projectile upon impact with the material.
As mentioned above, however, the different material layers formed using these various weaves may have different denier or detex than that of the immediately adjacent material layer.
Referring now to
Referring now to
In an exemplary embodiment fabric layers 130 and 132 comprise unidirectional non-woven fabric, as shown in
Intermediary layer 134 bonds fabric layer 130 to fabric layer 132. Intermediary layer 134 may comprise a lamination film or film resin that may be bonded in the manner described above with respect to intermediary layer 50. Suitable film resins for use as intermediary layer 134 will be known to one of ordinary skill in the art. Where more than two fabric layers are used, multiple intermediary layers 134 may be used such that at least one intermediary layer 134 exists between each adjacent pair of fabric layers. As shown in
Once fabric layers 130 and 132 are bonded using intermediary layer(s) 134, they may be coated with an elastomeric layer 136, substantially as described above with respect to elastomeric layer 60. As described above, such an elastomeric coating will further absorb and dissipate the impact from a bullet, shrapnel, knife or other life threatening projectile. The elastomeric coating will also improve durability of the material, including improved atmospheric protection (including temperature, moisture, and UV protection), and improved protection against wear and tear (or other physical degradation). The coating is preferably provided on both major surfaces but the invention is not so limited in that only one major surface may be coated if desired for a particular application. As used herein, a major surface is the planar surface of the fabric layer as opposed to the thin edges (ends) of the fabric.
It is contemplated that the aforementioned fabrics and materials can stand alone or be mixed together such as:
Referring now to
The invention is contemplated for use as a clothing material for use as bullet resistant vests and penetration resistant knee pads, military and riot helmets, other types of body armor, footwear, vehicle lining, casings and other types of protective linings for electronics and other goods, trauma, abrasion resistance for sports gear, motorcycle gear, impact resistance, stab resistance, fragment resistance, ballistic trauma, etc.
In an experimental application, the inventor constructed a bullet resistant vest using the approach above with one of the double layer of fabric that replaced several traditional layers. The result was a vest having equal or better ballistic performance with an apx. 40% weight reduction. Specifically, the experimental vest had a weight of 1 lb/sq. ft. This experimental vest was tested by an independent testing laboratory in accordance with National Institute of Justice (NIJ) testing standards. As those skilled in the art would readily recognize achieving such weight reductions while providing adequate protection is significant and unexpected given the fact that the experimental vest not only met but exceeded the NIJ testing standards.
Another test was conducted for stab protocol. The following Table 1 summarizes NIJ stab test standards
In one set of tests, the experimental vest was subjected to stab tests in accordance with NIJ standards. Considering the reduced weight of the subject vest, the results were extraordinary. Specifically, six separate tests were performed on a test panel in accordance with sections 5.7 and 5.8 of the NIJ Standard comprising two spike tests and 4 stab tests using energy levels E1 and E2. Of the six tests, three of the tests were at energy level E1 (one spike and two stab tests). Although under the NIJ standard, penetration of 7 mm for a vest under test is considered acceptable, applicants' vest demonstrated zero penetration. The remaining three tests were performed at energy level E2 (again, one spike and two stab tests). Under the NIJ standard penetration of 20 mm is considered acceptable. Applicants' vest, however, demonstrated zero penetration in two of the tests (the spike test and one stab test) and only 9 mm penetration in the last stab test. Conventional vests cannot provide this type of protection with such low mass. Accordingly, applicants' vest provided results that would be unexpected by those skilled in the art.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
This application is a Continuation-in-Part of U.S. patent application Ser. No. 13/331,004, filed Dec. 20, 2011 and claims benefit of priority to U.S. Provisional Patent Application No. 61/714,279, filed Oct. 16, 2012, the contents of such applications being incorporated by reference herein.
Number | Date | Country | |
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61714279 | Oct 2012 | US |
Number | Date | Country | |
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Parent | 13331004 | Dec 2011 | US |
Child | 13975447 | US |