Fabric laminates having superior resistance to penetration of fragments, such as shrapnel. The fabrics are formed of high-strength fibers consolidated with from about 7% to about 15% by weight of an elastomeric matrix composition, and in combination with protective layers of a polymer film on each surface of the fabric. The fabrics achieve a significant improvement in fragment resistance compared to fabrics of the prior art, while also maintaining excellent ballistic resistant properties.
1. A fragment resistant material comprising:
a) at least one consolidated network of fibers, said consolidated network of fibers comprising a plurality of cross-plied, non-woven fiber layers, each fiber layer comprising a plurality of fibers arranged in a substantially parallel array; said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; said fibers having an elastomeric matrix composition thereon, said elastomeric matrix composition substantially coating each of the individual fibers and comprising from about 7% to about 15% by weight of said consolidated network of fibers; the plurality of cross-plied, non-woven fiber layers being consolidated with said matrix composition to form said consolidated network of fibers; said consolidated network of fibers having anterior and posterior surfaces; wherein if said fibers comprise aramid fibers or poly (p-phenylenebenzobisoxazole) fibers, said matrix composition comprises at least about 11% by weight of said consolidated network of fibers; and
b) at least one layer of a polymer film attached to each of said anterior and posterior surfaces of said consolidated network of fibers, wherein said polymer film layers comprise from about 2% to about 25% percent by weight of the overall material.
2. The fragment resistant material of claim 1 wherein said fibers comprise a material selected from the group consisting of extended chain polyolefin fibers, aramid fibers, polybenzazole fibers, polyvinyl alcohol fibers, polyamide fibers, polyethylene terephthalate fibers, polyethylene naphthalate fibers, polyacrylonitrile fibers, liquid crystal copolyester fibers, glass fibers and carbon fibers.
3. The fragment resistant material of claim 1 wherein said fibers comprise polyethylene fibers.
4. The fragment resistant material of claim 1 wherein the matrix composition comprises a material selected from the group consisting of polybutadiene, polyisoprene, natural rubber, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, polysulfide polymers, polyurethane elastomers, chiorosulfonated polyethylene, polychloroprene, plasticized polyvinylchloride, butadiene acrylonitrile elastomers, poly(isobutylene-co-isoprene), polyacrylates, polyesters, polyethers, fluoroelastomers, silicone elastomers, copolymers of ethylene, and combinations thereof.
5. The fragment resistant material of claim 1 wherein the matrix composition comprises polystyrene-polyisoprene-polystrene-block copolymer.
6. The fragment resistant material of claim 1 wherein said matrix composition comprises from about 7% to about 14% by weight of the consolidated network of fibers.
7. The fragment resistant material of claim 1 wherein said matrix composition comprises from about 7% to about 13% by weight of the consolidated network of fibers.
8. The fragment resistant material of claim 1 wherein said matrix composition comprises from about 7% to about 12% by weight of the consolidated network of fibers.
9. The fragment resistant material of claim 1 wherein said matrix composition consists essentially of from about 7% to about 11% by weight of the consolidated network of fibers.
10. The fragment resistant material of claim 1 wherein said matrix composition consists essentially of from about 11% to about 15% by weight of the consolidated network of fibers.
11. The fragment resistant material of claim I wherein said fibers comprise aramid fibers or poly(p-phenylenebenzobisoxazole) fibers, and said matrix composition comprises from about 11% to about 15% by weight of the consolidated network of fibers.
12. The fragment resistant material of claim 1 wherein said polymer film layers comprise a material selected from the group consisting of selected from the group consisting of polyolefins, polyamides, polyesters, polyurethanes, vinyl polymers, fluoropolymers and copolymers and combinations thereof.
13. The fragment resistant material of claim 1 wherein said polymer film layers comprise a linear low density polyethylene having a thickness of about 9 μm.
14. The fragment resistant material of claim 1 wherein each of said fiber layers are cross-plied at a 90° angle relative to the longitudinal fiber direction of each adjacent fiber layer.
15. A fragment resistant article incorporating a fragment resistant material, which fragment resistant material comprises:
a) at least one consolidated network of fibers, said consolidated network of fibers comprising a plurality of cross-plied, non-woven fiber layers, each fiber layer comprising a plurality of fibers arranged in a substantially parallel array; said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; said fibers having an elastomeric matrix composition thereon, said elastomeric matrix composition substantially coating each of the individual fibers and comprising from about 7% to about 15% by weight of said consolidated network of fibers; the plurality of cross-plied, non-woven fiber layers being consolidated with said matrix composition to form said consolidated network of fibers; said consolidated network of fibers having anterior and posterior surfaces; wherein if said fibers comprise aramid fibers or poly (p-phenylenebenzobisoxazole) fibers, said matrix composition comprises at least about 11% by weight of said consolidated network of fibers; and
b) at least one layer of a polymer film attached to each of said anterior and posterior surfaces of said consolidated network of fibers, wherein said polymer film layers comprise from about 2% to about 25% percent by weight of the overall material.
16. The fragment resistant article of claim 15 which comprises a plurality of consolidated networks of fibers assembled in a bonded array.
17. The fragment resistant article of claim 15 which comprises a plurality of consolidated networks of fibers assembled in a non-bonded array.
18. The fragment resistant article of claim 15 which comprises a garment having a plurality of consolidated networks of fibers adjoined thereto.
19. The fragment resistant article of claim 18 wherein said garment comprises a vest having said plurality of consolidated networks of fibers adjoined thereto.
20. The fragment resistant article of claim 15 wherein said matrix composition consists essentially of from about 7% to about 11% by weight of the consolidated network of fibers.
21. The fragment resistant article of claim 15 wherein said matrix composition consists essentially of from about 11% to about 15% by weight of the consolidated network of fibers.
22. The fragment resistant article of claim 15 wherein said fibers comprise aramid fibers or poly(p-phenylenebenzobisoxazole) fibers, and said matrix composition comprises from about 11% to about 15% by weight of the consolidated network of fibers.
23. A method of producing a fragment resistant material comprising:
a) forming at least two fiber layers, each fiber layer being formed by arranging a plurality of fibers into a substantially parallel, unidirectional array; said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; said fibers having an elastomeric matrix composition applied thereon;
b) arranging said fiber layers wherein the unidirectional array of fibers of each layer are cross-plied at a non-parallel angle relative to the longitudinal fiber direction of each adjacent layer;
c) bonding said cross-plied layers under conditions sufficient to form a consolidated network of fibers, the consolidated network of fibers having anterior and posterior surfaces; wherein said matrix composition substantially coats each of the individual fibers and comprises from about 7% to about 15% by weight of said consolidated network of fibers, and wherein if said fibers comprise aramid fibers or poly (p-phenylenebenzobisoxazole) fibers, said matrix composition comprises at least about 11% by weight of said consolidated network of fibers; and
d) attaching at least one layer of a polymer film to each of said anterior and posterior surfaces of said consolidated network of fibers, wherein said polymer film layers comprise from about 2% to about 25% percent by weight of the overall material.
24. The method of claim 23 wherein said matrix composition consists essentially of from about 7% to about 11% by weight of the consolidated network of fibers.
25. The method of claim 23 wherein said matrix composition consists essentially of from about 11% to about 15% by weight of the consolidated network of fibers.
26. The method of claim 23 wherein said fibers comprise aramid fibers or poly(p-phenylenebenzobisoxazole) fibers, and said matrix composition comprises from about 11% to about 15% by weight of the consolidated network of fibers.
27. The method of claim 23 wherein each of said fiber layers are cross-plied at a 90° angle relative to the longitudinal fiber direction of each adjacent fiber layer.
28. A fragment resistant material comprising:
a) at least one consolidated network of fibers, said consolidated network of fibers comprising a plurality of cross-plied fiber layers, each fiber layer comprising a plurality of fibers arranged in an array; said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; said fibers having an elastomeric matrix composition thereon, said elastomeric matrix composition substantially coating each of the individual fibers and comprising from about 7% to about 15% by weight of said consolidated network of fibers; the plurality of cross-plied fiber layers being consolidated with said matrix composition to form said consolidated network of fibers; said consolidated network of fibers having anterior and posterior surfaces; and
b) at least one layer of a polymer film attached to each of said anterior and posterior surfaces of said consolidated network of fibers, wherein said polymer film layers comprise from about 2% to about 25% percent by weight of the overall material.
29. An article comprising the fragment resistant material of claim 28 .
30. The fragment resistant material of claim 1 which has a peel strength of at least about 0.17 lb/ft 2 .
31. The fragment resistant material of claim 10 which has a peel strength of at least about 0.206 lb/ft 2 .