Fiber Network Layers and Flexible Penetration Resistant Articles Comprising Same

Abstract

The present invention is directed to a fiber network layer for use in penetration resistant articles having a first plurality of yarns and a second plurality of yarns, each of the first and second yarns arranged in a first direction parallel or substantially parallel to the other first and second yarns and a third plurality of yarns, each of the third yarns arranged in a second direction parallel or substantially parallel to the other third yarns; the second direction transverse to the first direction. The third yarns and either the first yarns or the second yarns are made of a first polymer. Each of the first, second and third yarns having a tenacity of at least 15 g/dtex. The layers are such that either (i) the second yarns are made of a second polymer which is different than the first polymer, or (ii) the first yarns have a different average linear density than the average linear density of the second yarns, or (iii) the first and second yarns comprise multifilament yarns with filaments and the filaments of the first yarns have an average linear density different from the filaments in the second yarns, or (iv) combinations thereof.

1 . A fiber network layer for use in penetration resistant articles, comprising:
 a first plurality of yarns and a second plurality of yarns, each of the first and second yarns arranged in a first direction parallel or substantially parallel to the other first and second yarns;   a third plurality of yarns, each of the third yarns arranged in a second direction parallel or substantially parallel to the other third yarns, the second direction transverse to the first direction, the third yarns and either the first yarns or the second yarns made of a first polymer; and   each of the first, second and third yarns having a tenacity of at least 15 g/dtex;   wherein (i) the second yarns are made of a second polymer which is different than the first polymer, or (ii) the first yarns have a different average linear density than the average linear density of the second yarns, or (iii) the first and second yarns comprise multifilament yarns with filaments and the filaments of the first yarns have an average linear density different from the filaments in the second yarns, or (iv) combinations thereof.   
   
   
       2 . The fiber network layer of  claim 1 , further comprising:
 a fourth plurality of yarns, each of the fourth yarns arranged in the second direction parallel or substantially parallel to the third yarns,   wherein (i) the fourth yarns are made of the second polymer or a third polymer, or (ii) the third yarns have a different average linear density than the average linear density of the fourth yarns, or (iii) the third and fourth yarns comprise multifilament yarns with filaments and the filaments of the third yarns have an average linear density different from the filaments in the fourth yarns, or (iv) combinations thereof.   
   
   
       3 . The fiber network layer of  claim 1 , wherein:
 the first yarns comprise at least 35% of the total number of yarns in the first direction, and   the second yarns comprise at least 35% of the total number of yarns in the first direction.   
   
   
       4 . The fiber network layer of  claim 2 , wherein:
 the third yarns comprise at least 25% of the total number of yarns in the second direction, and   the fourth yarns comprise at least 25% of the total number of yarns in the second direction.   
   
   
       5 . The fiber network layer of  claim 1 , wherein the fiber network layer has an areal density of no more than 10 kg/m 2 . 
   
   
       6 . The fiber network layer of  claim 2 , wherein each of the first, second, third and fourth yarns have an elongation at break of at least 2% and a modulus of elasticity of at least 150 grams per dtex. 
   
   
       7 . The fiber network layer of  claim 1 , wherein the second yarns are made of a second polymer which is different than the first polymer. 
   
   
       8 . The fiber network layer of  claim 1 , wherein the first yarns have a different average linear density than the average linear density of the second yarns. 
   
   
       9 . The fiber network layer of  claim 1 , wherein the first and second yarns comprise multifilament yarns with filaments and the filaments of the first yarns have an average linear density different from the filaments in the second yarns. 
   
   
       10 . The fiber network layer of  claim 1 , wherein:
 the first and third yarns are made of the first polymer, have the same average linear density, and the filaments of the first and third yarns have the same average linear density, and   the second and fourth yarns are made of the second polymer, have the same average linear density, and the filaments of the second and fourth yarns have the same average linear density.   
   
   
       11 . The fiber network layers of  claim 2 , wherein the filaments of the first, second, third and fourth yarns have a linear density of 0.1 to 10 decitex. 
   
   
       12 . The fiber network layer of  claim 1 , wherein the first and second yarns arranged in an alternating sequence. 
   
   
       13 . The fiber network layer of  claim 2 , wherein the third and fourth yarns arranged in an alternating sequence. 
   
   
       14 . The fiber network layer of  claim 1 , wherein the first and second polymers are selected from the group consisting of polyamide, polyolefin, polybenzoxazole, polybenzothiazole, poly{2,6-diimidazo[4,5-b4′,5′-e]pyridinylene-1,4(2,5-dihydroxy)phenylene}, polyareneazoles, polypyridazoles, polypyridobisimidazoles and mixtures thereof. 
   
   
       15 . A flexible penetration resistant article comprising a plurality of fiber network layers of  claim 1 . 
   
   
       16 . The flexible penetration resistant article of  claim 15 , wherein the article has an areal density of 2 to 12 kg/m 2 . 
   
   
       17 . A flexible ballistic resistant article, comprising a plurality of layers of fabric having two different types of yarns arranged in an alternating sequence in both warp and fill directions of the fabric. 
   
   
       18 . The flexible ballistic resistant article of  claim 17  wherein at least one layer of said fabric layers being impregnated with a polymeric matrix comprising a thermoset resin, a thermoplastic resin, or mixtures thereof. 
   
   
       19 . A method of forming a fiber network comprising:
 weaving a first plurality of yarns and a second plurality of yarns, each of the first and second yarns arranged in a first direction parallel or substantially parallel to the other first and second yarns; with   a third plurality of yarns, each of the third yarns arranged in a second direction parallel or substantially parallel to the other third yarns, the second direction transverse to the first direction, the third yarns and either the first yarns or the second yarns made of a first polymer; and   each of the first, second and third yarns having a tenacity of at least 15 g/dtex;   wherein (i) the second yarns are made of a second polymer which is different than the first polymer, or (ii) the first yarns have a different average linear density than the average linear density of the second yarns, or (iii) the first and second yarns comprise multifilament yarns with filaments and the filaments of the first yarns have an average linear density different from the filaments in the second yarns, or (iv) combinations thereof.   
   
   
       20 . The method of  claim 19  further comprising:
 weaving a fourth plurality of yarns, each of the fourth yarns arranged in the second direction parallel or substantially parallel to the third yarns,   wherein (i) the fourth yarns are made of the second polymer or a third polymer, or (ii) the third yarns have a different average linear density than the average linear density of the fourth yarns, or (iii) the third and fourth yarns comprise multifilament yarns with filaments and the filaments of the third yarns have an average linear density different from the filaments in the fourth yarns, or (iv) combinations thereof.