Woven multi-layer fabrics for use with non-ballistic threats

Abstract

A multi-layer woven fabric, including an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together to form the upper woven layer. The cover factor of at least one of the layers is selected so as to inhibit penetration by non-ballistic threats

1 . A multi-layer woven fabric, comprising:
 a. an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together to form the upper woven layer;   b. a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together to form the lower woven layer; and   c. a plurality of securing yarns, each securing yarn interwoven with at least some of the upper yarns and some of the lower yarns so as to secure the upper and lower woven layers together;   d. wherein the multi-layer ballistic woven fabric is formed by interweaving the securing yarns with the warp yarns and weft yarns as the upper woven layer and lower woven layer are made; and   e. wherein the cover factor of at least one of the layers is selected so as to inhibit penetration by non-ballistic threats.   
     
     
         2 . The fabric of  claim 1 , wherein at least one of the layers has a cover factor of between 70% and 130%. 
     
     
         3 . The fabric of  claim 1  or  claim 2 , wherein both of the layers have a cover factor of between 70% and 130%. 
     
     
         4 . The fabric of any preceding claim, wherein at least one of the layers has a cover factor of between 80% and 120%. 
     
     
         5 . The fabric of any preceding claim, wherein both of the layers have a cover factor of between 80% and 120%. 
     
     
         6 . The fabric of any preceding claim, wherein at least one of the layers has a cover factor of between 90% and 110%. 
     
     
         7 . The fabric of any preceding claim, wherein both of the layers have a cover factor of between 90% and 110%. 
     
     
         8 . The fabric of any preceding claim, wherein at least one of the layers has a cover factor of around 100%. 
     
     
         9 . The fabric of any preceding claim, wherein both of the layers have a cover factor of around 100%. 
     
     
         10 . The fabric of any preceding claim wherein at least some of the securing yarns are made of non-ballistic yarns. 
     
     
         11 . The fabric of any preceding claim wherein at least some of the securing yarns are made of ballistic yarns. 
     
     
         12 . The fabric of any preceding claim wherein at least some of the warp yarns and weft yarns are made of ballistic yarns. 
     
     
         13 . The fabric of any preceding claim wherein at least some of the warp yarns and weft yarns are made of non-ballistic yarns. 
     
     
         14 . The fabric of any preceding claim, wherein the spacing and arrangement of weaving patterns of the fabric are selected to provide for at least some protection against non-ballistic threats. 
     
     
         15 . The fabric of any preceding claim, wherein after the fabric has been woven, the fabric is subjected to a treatment process that encourages the securing yarns to shrink, drawing the warp yarns and weft yarns towards each other. 
     
     
         16 . The fabric of  claim 15 , wherein the securing yarns are encouraged to shrink by up to 1%. 
     
     
         17 . The fabric of  claim 15 , wherein the securing yarns are encouraged to shrink by up to 3%. 
     
     
         18 . The fabric of  claim 15 , wherein the securing yarns are encouraged to shrink by up more than 3%. 
     
     
         19 . The fabric of  claim 15 , wherein the securing yarns are encouraged to shrink by up to 10%. 
     
     
         20 . The fabric of any preceding claim, wherein at least some of the upper weft yarns and lower weft yarns are offset from each other so as to overlap by between 30% and 70%. 
     
     
         21 . The fabric of any preceding claim, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by between 10% and 95%. 
     
     
         22 . The fabric of any preceding claim, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by more than 95%. 
     
     
         23 . The fabric of any preceding claim, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by more than 98%. 
     
     
         24 . The fabric of any preceding claim, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by more than 99%. 
     
     
         25 . The fabric of any preceding claim, wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by about 100%. 
     
     
         26 . The fabric of any preceding claim, wherein the upper weft yarns and lower weft yarns are offset from each other so as to overlap by about 50%. 
     
     
         27 . The fabric of any preceding claim, wherein the securing yarns are of significantly smaller denier than the warp yarns and weft yarns and have significantly lower tenacities and tensile moduli than the warp yarns and weft yarns. 
     
     
         28 . The fabric of any preceding claim wherein at least some of the securing yarns are aligned with the warp yarns and perpendicular to the weft yarns. 
     
     
         29 . The fabric of any preceding claim wherein at least some of the securing yarns are aligned with the weft yarns and perpendicular to the warp yarns. 
     
     
         30 . The fabric of any preceding claim wherein the securing yarns include first securing yarns oriented in a first direction and second securing yarns oriented in a second direction. 
     
     
         31 . The fabric of  claim 30 , wherein the first securing yarns are separated by a first spacing, and the second securing yarns are separated by a second spacing. 
     
     
         32 . The fabric of  claim 31 , wherein the first spacing is between one inch and three inches, and the second spacing is between one inch and three inches. 
     
     
         33 . The fabric of any preceding claim, wherein the securing yarns are aligned with either the warp yarns or the weft yarns, and are separated by a spacing of less than three inches. 
     
     
         34 . The fabric of any preceding claim, wherein the warp yarns and weft yarns have a tenacity of at least about 15 grams per denier and a tensile modulus of at least about 400 grams per denier. 
     
     
         35 . The fabric of any preceding claim, wherein the securing yarns are made from a high elongation, low strength, and low modulus yarn. 
     
     
         36 . The fabric of any preceding claim, wherein the securing yarns are made from a high strength yarn. 
     
     
         37 . The fabric of any preceding claim, wherein at least one of the warp yarns or weft yarns is used as a securing yarn. 
     
     
         38 . The fabric of any preceding claim, wherein at least one of the securing yarns is woven underneath a first lower weft yarn, then above a second upper weft yarn adjacent the first lower weft yarn, then underneath a third lower weft yarn adjacent the second upper weft yarn and then above a fourth upper weft yarn adjacent the third lower weft yarn. 
     
     
         39 . The fabric of any preceding claim, wherein at least one of the securing yarns is woven underneath at least one lower weft yarn, and then above at least one upper weft yarn adjacent the at least one lower weft yarn.