Fiber - resin composites and ballistic resistant armor articles containing the fiber - resin composites

Abstract

A fiber-resin composite useful in a ballistic resistant armor article comprises a first nonwoven layer comprising a first plurality of yarns arranged parallel with each other and a second nonwoven layer comprising a second plurality of yarns arranged parallel with each other. The first plurality of yarns have an orientation in a direction that is different from the orientation of the second plurality of yarns, The composite further comprises a binding resin partially coating portions of internal surfaces of the yarns and partially filling some space between the filaments of the yarns so as to leave discrete areas of yarn surfaces that are free from binder resin coating, A viscoelastic resin coats at least portions of external surfaces of the yarns and fills in some space between the filaments of the yarns. A binding yarn is interlaced transversely within the first and second nonwoven layers.

What is claimed is: 
     
         1 . A fiber-resin fiber-resin composite useful in a ballistic resistant soft armor article, comprising:
 (a) from 75.0 to 94.0 weight percent of
 a first nonwoven layer comprising a first plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the first plurality of yarns arranged parallel with each other, 
 a second nonwoven layer comprising a second plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the second plurality of yarns arranged parallel with each other, 
 wherein the first plurality of yarns of the first nonwoven layer have an orientation in a direction that is different from the orientation of the second plurality of yarns in the second nonwoven layer, 
   (b) from 1.0 to 10.0 weight percent of a thermoset or thermoplastic binding resin partially coating portions of internal surfaces of the first plurality and the second plurality of yarns and partially filling some space between the filaments in the first plurality and the second plurality of yarns in the region of the interface between the two nonwoven layers so as to leave discrete areas of yarn surfaces that are free from binder resin coating,   (c) from 0.1 to 10.0 weight percent of a viscoelastic resin coating at least portions of external surfaces of the first plurality and the second plurality of yarns and filling some space between the filaments in the first plurality and the second plurality of yarns, and   (d) a transverse binding yarn interlaced transversely within the first and second nonwoven layers.   wherein the weight percentages are expressed relative to the total weight of the fiber-resin composite.   
     
     
         2 . The fiber-resin composite of  claim 1 , wherein the yarns of the first and second pluralities of yarns have a yarn linear density of 50 to 4500 dtex and a yarn modulus of 100 to 3500 g/dtex. 
     
     
         3 . The fiber-resin composite of  claim 1 , wherein the yarns of the first and second pluralities of yarns have a yarn tenacity of 20 to 35 grams per dtex. 
     
     
         4 . The fiber-resin composite of  claim 1 , wherein the yarns of the first and second pluralities of yarns have an yarn elongation at break of 3.8 to 4.5 percent. 
     
     
         5 . The fiber-resin composite of  claim 1 , wherein the second plurality of yarns in the second nonwoven layer are oriented orthogonally to the first plurality of yarns in the first nonwoven layer. 
     
     
         6 . The fiber-resin composite of  claim 1 , wherein the first and the second pluralities of yarns are present in the first and the second nonwoven layers as substantially distinct yarns. 
     
     
         7 . The fiber-resin composite of  claim 1 , wherein the first and second nonwoven layers comprise yarns comprising filaments of para-aramid, polyolefin, polyazole or blends thereof. 
     
     
         8 . The fiber-resin composite of  claim 1 , wherein the viscoelastic resin is polyolefin, polyvinyl alcohol, polyisoprene, polybutadiene, polybutene, polyisobutylene, polyester, polyacrylate, polyamide, polysulfone, polysulfide; polyurethane, polycarbonate, polyfluorocarbon, silicone, glycol, liquid block copolymer, polyacrylic, epoxy, phenolic, liquid rubber, styrene copolymer or mixtures thereof. 
     
     
         9 . The fiber-resin composite of  claim 1 , wherein the thermoplastic binding resin is polyurethane, polyethylene or a blend of elastomeric block copolymer and polyethylene copolymer. 
     
     
         10 . The fiber-resin composite of  claim 1  wherein the area of yarn surface in the region of the interface between the nonwoven layers that is free from binding resin is from 40 to 95 percent of the total surface area of the yarn surfaces in the region of the interface between the nonwoven layers. 
     
     
         11 . The fiber-resin composite of  claim 1 , wherein the transverse yarn comprises a plurality of filaments wherein the filaments are polyester filaments, polyethylene filaments, polyamide filaments, aramid filaments, polyareneazole filaments, polypyridazole filaments, polybenzazole filaments, or mixtures thereof. 
     
     
         12 . The fiber-resin composite of  claim 8 , wherein the viscoelastic resin is polybutene or polyisobutylene. 
     
     
         13 . A fiber-resin fiber-resin composite useful in a ballistic resistant soft armor article, comprising:
 (a) from 75.0 to 94.0 weight percent of
 a first nonwoven layer comprising a first plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the first plurality of yarns arranged parallel with each other, 
 a second nonwoven layer comprising a second plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the second plurality of yarns arranged parallel with each other, 
 a third nonwoven layer comprising a third plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the third plurality of yarns arranged parallel with each other, 
 a fourth nonwoven layer comprising a fourth plurality of yarns having a yarn tenacity of from 10 to 65 grams per dtex, a modulus of from 100 to 3500 grams per dtex and an elongation at break of 3.8 to 5.0 percent, the fourth plurality of yarns arranged parallel with each other, 
 wherein the second plurality of yarns of the second nonwoven layer have an orientation in a direction that is different from the orientation of the first plurality of yarns in the first nonwoven layer and the third plurality of yarns in the third nonwoven layer, and 
 the fourth plurality of yarns of the fourth nonwoven layer have an orientation in a direction that is different from the orientation of the third plurality of yarns in the third nonwoven layer, 
   (b) from 1.0 to 10.0 weight percent of a thermoset or thermoplastic binding resin partially coating portions of internal surfaces of the first, second, third and fourth pluralities of yarns and partially filling some space between the filaments of the first, second, third and fourth pluralities of yarns in the region of the interfaces between the nonwoven yarn layers so as to leave discrete areas of yarn surfaces that are free from binder resin coating, and   (c) from 0.1 to 10.0 weight percent of a viscoelastic resin coating at least portions of external surfaces of the first plurality and the fourth plurality of yarns and filling some space between the filaments in the first plurality and the fourth plurality of yarns, and   (d)) a transverse binding yarn interlaced transversely within the first and fourth nonwoven layers.   wherein the weight percentages are expressed relative to the total weight of the fiber-resin composite.   
     
     
         14 . A ballistic resistant armor article comprising a plurality of the fiber-resin fiber-resin composites of  claim 1 . 
     
     
         15 . A ballistic resistant armor article comprising a plurality of the fiber-resin fiber-resin composites of  claim 13 . 
     
     
         16 . A ballistic resistant armor article of  claim 14  comprising a plurality of the fiber-resin fiber-resin composites of  claim 1  as a strike face. 
     
     
         17 . A ballistic resistant armor article of  claim 15 , comprising a plurality of the fiber-resin fiber-resin composites of  claim 13  as a strike face.