Materials gradient within armor for balancing the ballistic performance

Abstract

Hybrid, multi-panel ballistic resistant articles useful for the fabrication of body armor. The articles include at least three different fabric sections that are arranged into a gradient wherein the outermost, strike-face section of the article is formed from fibers having the highest tenacity of the article.

What is claimed is: 
     
         1 . A ballistic resistant composite comprising:
 a first fibrous material comprising one or more first fibrous plies, each of the first fibrous plies comprising fibers that have a tenacity of greater than 27 g/denier;   a second fibrous material attached to the first fibrous material, said second fibrous material comprising one or more second fibrous plies, each of the second fibrous plies comprising fibers that have a tenacity lower than the tenacity of the fibers of the first fibrous material; and   a third fibrous material attached to the second fibrous material, said third fibrous material comprising one or more third fibrous plies, each of the third fibrous plies comprising fibers that have a tenacity lower than the tenacity of the fibers of the second fibrous material;   wherein the first fibrous material, second fibrous material and third fibrous material are bonded together and form a consolidated, unitary composite article.   
     
     
         2 . The ballistic resistant composite of  claim 1  wherein each of the fibers of the first fibrous material has a tenacity of 40 g/denier or more. 
     
     
         3 . The ballistic resistant composite of  claim 1  wherein each of the fibers of the first fibrous material has a tenacity of 45 g/denier or more. 
     
     
         4 . The ballistic resistant composite of  claim 1  wherein each of the fibers of the second fibrous material has a tenacity of at least 25% less than the tenacity of each of the fibers of the first fibrous material. 
     
     
         5 . The ballistic resistant composite of  claim 1  wherein each of the fibers of the second fibrous material has a tenacity of 21 g/denier or less. 
     
     
         6 . The ballistic resistant composite of  claim 1  wherein each of the fibers of the third fibrous material has a tenacity of at least 25% less than the tenacity of each of the fibers of the second fibrous material. 
     
     
         7 . The ballistic resistant composite of  claim 1  wherein the third fibrous material comprises nylon fibers, polyester fibers, polypropylene fibers, polyolefin fibers or a combination thereof. 
     
     
         8 . The ballistic resistant composite of  claim 1  wherein the first fibrous material comprises ultra-high molecular weight polyethylene fibers, the second fibrous material comprises either ultra-high molecular weight polyethylene fibers or aramid fibers or a combination thereof, and the third fibrous material comprises nylon fibers. 
     
     
         9 . The ballistic resistant composite of  claim 1  wherein the first fibrous material comprises a woven aramid fabric, the second fibrous material comprises a non-woven aramid fabric, and the third fibrous material comprises nylon fibers. 
     
     
         10 . The ballistic resistant composite of  claim 1  wherein the first fibrous material is a non-woven fabric comprising a plurality of unidirectionally oriented fibers, the second fibrous material is a non-woven fabric comprising a plurality of unidirectionally oriented fibers, and the third fibrous material is either a non-woven fabric comprising a plurality of unidirectionally oriented fibers, a woven fabric, a knitted fabric or a felt. 
     
     
         11 . The ballistic resistant composite of  claim 1  wherein the first fibrous material is a woven fabric, the second fibrous material is a woven fabric, and the third fibrous material is either a non-woven fabric comprising a plurality of unidirectionally oriented fibers, a woven fabric, a knitted fabric or a felt. 
     
     
         12 . The ballistic resistant composite of  claim 1  further comprising a non-fibrous isotropic polymer layer attached to the third fibrous material, wherein the first fibrous material, second fibrous material, third fibrous material and the non-fibrous isotropic polymer layer are bonded together and form a consolidated, unitary composite article. 
     
     
         13 . The ballistic resistant composite of  claim 1  wherein the fibers of the first fibrous material and the fibers of the second fibrous material are substantially coated with a polymeric binder. 
     
     
         14 . A ballistic resistant composite comprising:
 a first fibrous material comprising one or more first fibrous plies, each of the first fibrous plies comprising fibers;   a second fibrous material attached to the first fibrous material, said second fibrous material comprising one or more second fibrous plies, each of the second fibrous plies comprising fibers that have a tenacity lower than the tenacity of the fibers of the first fibrous material; and   a non-fibrous sheet material attached to the second fibrous material;   wherein the first fibrous material, second fibrous material and third fibrous material are bonded together and form a consolidated, unitary composite article.   
     
     
         15 . The ballistic resistant composite of  claim 14  wherein the non-fibrous sheet material comprises a non-fibrous isotropic polymer layer. 
     
     
         16 . The ballistic resistant composite of  claim 14  wherein each of the fibers of the first fibrous material has a tenacity of 40 g/denier or more and wherein each of the fibers of the second fibrous material has a tenacity of at least 25% less than the tenacity of each of the fibers of the first fibrous material. 
     
     
         17 . The ballistic resistant composite of  claim 14  wherein the first fibrous material is a non-woven fabric comprising a plurality of unidirectionally oriented fibers and the second fibrous material is a non-woven fabric comprising a plurality of unidirectionally oriented fibers. 
     
     
         18 . The ballistic resistant composite of  claim 14  wherein the first fibrous material is a woven aramid fabric and the second fibrous material is a non-woven aramid fabric. 
     
     
         19 . A ballistic resistant composite comprising:
 a first fibrous material comprising one or more first fibrous plies, each of the first fibrous plies comprising fibers, wherein each of said fibers has a tenacity of greater than 27 g/denier;   a second fibrous material attached to the first fibrous material, said second fibrous material comprising one or more second fibrous plies, each of the second fibrous plies comprising fibers, wherein each of said fibers has a tenacity of at least 50% less than the tenacity of the fibers of the first fibrous material; and   a third fibrous material attached to the second fibrous material, said third fibrous material comprising one or more third fibrous plies, each of the third fibrous plies comprising fibers, wherein each of said fibers has a tenacity of at least 50% less than the tenacity of the fibers of the second fibrous material;   wherein the first fibrous material, second fibrous material and third fibrous material are bonded together and form a consolidated, unitary composite article.   
     
     
         20 . The ballistic resistant composite of  claim 19  wherein the consolidated, unitary composite article has a total areal density of from about 0.75 lb/ft 2  to about 1.5 lb/ft 2 .