Ballistic-resistant laminate assemblies and panels

Abstract

A sheet of ballistic-resistant fiber strands includes a bi-directional array of bonding fibers interwoven with the ballistic-resistant fibers to form a fiber panel. In one embodiment, a sheet of laminated ballistic-resistant fibers is joined to the first sheet of laminated ballistic-resistant fibers with the ballistic-resistant fibers running in a second direction as compared to the first fibers. In yet another embodiment, individual laminated sheets of ballistic-resistant fibers are stitched together to form packets of sheets that may be used singularly or bundled together.

1 - 63 . (canceled) 
     
     
         64 . A method of forming a ballistic-resistant laminate assembly, the method comprising:
 providing a first layer comprising a plurality of ballistic-resistant fiber strands positioned adjacent to each other,   coating at least one of a plurality of first bonding strips and a plurality of second bonding strips with an adhesive material;   connecting the plurality of first bonding strips with the plurality of ballistic-resistant fiber strands with the first bonding strips being arranged at a first angle relative to the fiber strands in positions spaced apart from each other by a selected distance;   connecting the plurality of second bonding strips with the plurality of ballistic-resistant fiber strands with the second bonding strips being arranged at a second angle relative to the fiber strands and being spaced apart from each other by a selected distance, and further comprising cross-plying the plurality of second bonding strips with the first bonding strips;   positioning a first laminate film on one side of the fiber strands and bonding the first laminate film to the first layer with the first or second bonding strips; and   positioning a second laminate film adjacent to a side of the fiber strands opposite the first laminate film.   
     
     
         65 . The method of  claim 64 , wherein the connecting one of the plurality of first bonding strips and the plurality of second bonding strips with the plurality of ballistic-resistant fiber strands further comprises arranging the plurality of bonding strips in a woven arrangement with the fiber strands. 
     
     
         66 . The method of  claim 64  wherein the first bonding strips are ballistic-resistant bonding fibers coated with an adhesive material. 
     
     
         67 . The method of  claim 66  wherein the first bonding strips further comprise aramid fibers coated with the adhesive material. 
     
     
         68 . The method of  claim 64  wherein the adhesive material further comprises a pressure sensitive adhesive material. 
     
     
         69 . The assembly of  claim 64 , further comprising bonding the second laminate film to the first layer for forming a first laminated ballistic-resistant sheet;
 forming a second ballistic-resistant sheet; and   coupling together the first and second ballistic-resistant sheets.   
     
     
         70 . The assembly of  claim 69 , wherein coupling together the first and second ballistic-resistant sheets further comprises one of adhesively coupling together the first and second ballistic-resistant sheets, and stitching together the first and second ballistic-resistant sheets. 
     
     
         71 . A method of forming a ballistic-resistant laminate assembly, the method comprising:
 interconnecting first and second bonding fibers with a plurality of ballistic-resistant fiber strands in a manner that forms a bi-directional array of the first and second bonding fibers for holding a plurality of ballistic-resistant fiber strands in a substantially parallel orientation, with at least one of the first and second bonding fibers being ballistic-resistant fibers coated with a pressure sensitive adhesive material, and further comprising:
 orienting the first bonding fibers at a predetermined angle relative to the plurality of ballistic-resistant fiber strands with the first bonding fibers being spaced apart from each other, and 
 orienting the second bonding fibers at a predetermined angle relative to the first bonding fibers with the second bonding fibers being spaced apart from each other; 
   positioning a first laminate film adjacent to a first side of the plurality of ballistic-resistant fiber strands; and   bonding the first laminate film to at least one of the first or second bonding fibers.   
     
     
         72 . The method of  claim 71 , further comprising arranging at least one of the first and second bonding fibers in a substantially woven pattern with the plurality of ballistic-resistant fiber strands. 
     
     
         73 . The assembly of  claim 71 , wherein the first and second bonding fibers further comprise aramid fibers. 
     
     
         74 . The assembly of  claim 71 , further comprising positioning a second laminate film adjacent to a second side of the plurality of ballistic-resistant fiber strands opposite from the first laminate film; and
 laminating and substantially sealing the plurality of ballistic-resistant fiber strands and the first and second bonding fibers between the first and second films with interstitial air pockets therebetween for forming a laminated ballistic-resistant assembly having positive buoyancy.   
     
     
         75 . The assembly of  claim 71 , wherein bonding the first laminate film to at least one of the first or second bonding fibers forms a first laminated ballistic-resistant sheet;
 forming a second ballistic-resistant sheet; and   coupling together the first and second ballistic-resistant sheets.   
     
     
         76 . The assembly of  claim 75 , wherein coupling together the first and second ballistic-resistant sheets further comprises one of: adhesively coupling together the first and second ballistic-resistant sheets, and stitching together the first and second ballistic-resistant sheets. 
     
     
         77 . The assembly of  claim 71 , further comprising positioning a second laminate film adjacent to a second side of the plurality of ballistic-resistant fiber strands opposite from the first laminate film;
 laminating and substantially sealing the plurality of ballistic-resistant fiber strands and the first and second bonding fibers between the first and second films for forming a first laminated ballistic-resistant sheet;   forming a second laminated ballistic-resistant sheet; and   coupling together the first and second laminated ballistic-resistant sheets.   
     
     
         78 . The assembly of  claim 77 , wherein coupling together the first and second laminated ballistic-resistant sheets further comprises one of: adhesively coupling together the first and second laminated ballistic-resistant sheets, and stitching together the first and second laminated ballistic-resistant sheets. 
     
     
         79 . A method of forming a ballistic-resistant laminate assembly, the method comprising:
 forming a first layer comprising a first plurality of unidirectional ballistic-resistant first fiber strands positioned adjacent to each other;   interconnecting a plurality of substantially continuous bonding strips to the first plurality of unidirectional ballistic-resistant fiber strands, with the bonding strips being oriented at a predetermined angle relative to the first plurality of unidirectional ballistic-resistant fiber strands and the bonding strips being spaced apart from each other, and the bonding strips further comprising a pressure sensitive adhesive material; and   adhering a first laminate film to the first layer with the first plurality of unidirectional ballistic-resistant fiber strands in a substantially parallel orientation, the first layer and the first laminate film forming a first laminated ballistic-resistant sheet;   forming a second layer comprising a second plurality of unidirectional ballistic-resistant second fiber strands positioned adjacent to each other;   adhering a second laminate film to the second layer with the second plurality of unidirectional ballistic-resistant fiber strands in a substantially parallel orientation, the second layer and the second laminate film forming a second laminated ballistic-resistant sheet; and   connecting the second laminated ballistic-resistant sheet to the first laminated ballistic-resistant sheet.   
     
     
         80 . The method of  claim 79 , wherein the bonding strips are oriented substantially perpendicular to the first plurality of unidirectional ballistic-resistant fiber strands of the first layer. 
     
     
         81 . The method of  claim 79 , wherein adhering a second laminate film to the second layer further comprises adhering the second laminate film between the first plurality of unidirectional ballistic-resistant fiber strands and the second plurality of unidirectional ballistic-resistant fiber strands. 
     
     
         82 . The method of  claim 81 , wherein adhering a second laminate film to the second layer further comprises substantially sealing interstitial air spaces between the first and second laminate films, and imparting a positive buoyancy to the ballistic-resistant laminate assembly formed thereby. 
     
     
         83 . The method of  claim 79 , wherein the first plurality of unidirectional ballistic-resistant first fiber strands further comprise aramid fibers. 
     
     
         84 . The method of  claim 79 , wherein the plurality of bonding strips further comprise bonding fibers; and
 further comprising coating the bonding fibers with an adhesive material.   
     
     
         85 . The method of  claim 84 , wherein coating the bonding fibers with an adhesive material further comprise coating the bonding fibers with a pressure sensitive adhesive material. 
     
     
         86 . The method of  claim 85 , further comprising forming the bonding fibers of ballistic-resistant bonding fibers. 
     
     
         87 . The method of  claim 79 , wherein the plurality of bonding strips further comprises a first plurality of bonding strips being oriented at a first predetermined angle relative to the first plurality of unidirectional ballistic-resistant fiber strands; and
 further comprising cross-plying a second plurality of substantially continuous bonding strips with the first plurality of substantially continuous bonding strips for forming an array of bi-directional bonding strips, the second plurality of bonding strips being spaced apart from each other and oriented at a second predetermined angle relative to the first plurality of unidirectional ballistic-resistant fiber strands, the second plurality of bonding strips further comprising a pressure sensitive adhesive material.   
     
     
         88 . The method of  claim 87 , wherein the first plurality of bonding strips further comprises a first plurality of bonding fibers; and
 further comprising coating the first plurality of bonding fibers with an adhesive material;   wherein the second plurality of bonding strips further comprises a second plurality of bonding fibers;   further comprising coating the second plurality of bonding fibers with an adhesive material; and   further comprising cross-plying the second plurality of bonding fibers with the first plurality of bonding fibers for forming an array of bi-directional bonding fibers.   
     
     
         89 . The method of  claim 79 , wherein connecting the second laminated ballistic-resistant sheet to the first laminated ballistic-resistant sheet further comprises
 one of: adhesively connecting the second laminated ballistic-resistant sheet to the first laminated ballistic-resistant sheet, and stitching the second laminated ballistic-resistant sheet to the first laminated ballistic-resistant sheet.