Woven multi-layer fabrics and methods of fabricating same

Abstract

A multi-layer ballistic 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 multi-layer ballistic woven fabric also includes a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together, and 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. 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. 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.

1 - 26 . (canceled) 
     
     
         27 . A multi-layer ballistic woven fabric, comprising:
 a. an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together;   b. a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together; 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/or weft yarns as the upper woven layer and lower woven layer are made.   
     
     
         28 . The multi-layer ballistic woven fabric of  claim 27 , wherein at least some of the upper and lower yarns are offset from each other such that the upper yarns and/or lower yarns of one layer cover openings in an adjacent layer. 
     
     
         29 . The multi-layer ballistic woven fabric of  claim 27 , wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by more than 10%. 
     
     
         30 . The multi-layer ballistic woven fabric of  claim 27 , 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%. 
     
     
         31 . The multi-layer ballistic woven fabric of  claim 27 , wherein at least some of the upper yarns and lower yarns are offset from each other so as to overlap by between 30% and 70%. 
     
     
         32 . The multi-layer ballistic woven fabric of  claim 27 , wherein at least some of the upper yarns and lower yarns are completely offset from each other so as to not overlap. 
     
     
         33 . The multi-layer ballistic woven fabric of  claim 27 , wherein the warp yarns and weft yarns are ballistic yarns. 
     
     
         34 . The multi-layer ballistic woven fabric of  claim 27 , wherein one or more of the warp yarns and/or weft yarns are used in place of one or more of the securing yarns for holding the two or more layers together. 
     
     
         35 . The multi-layer ballistic woven fabric of  claim 27 , wherein the securing yarns include one or more of the upper warp yarns, the lower warp yarns, the upper weft yarns and the lower weft yarns. 
     
     
         36 . The multi-layer ballistic woven fabric of  claim 27 , wherein the securing yarns include one or more of the upper warp yarns and the upper weft yarns. 
     
     
         37 . The multi-layer ballistic woven fabric of  claim 27 , wherein the securing yarns include one or more of the lower warp yarns and the lower weft yarns. 
     
     
         38 . The multi-layer ballistic woven fabric of  claim 27 , wherein the securing yarns include one or more of the upper warp yarns and the lower warp yarns. 
     
     
         39 . The multi-layer ballistic woven fabric of  claim 27 , wherein the securing yarns include one or more of the upper weft yarns and the lower weft yarns.