Lightweight Fabrics for Resistance from High-Velocity Projectiles

Abstract

A ripstop fabric made with ribs consisting of one or more continuous multi-filament yarns of made of para-aramid or UHMWPE is designed to protect from blast debris in buried blast events is described. The ribs or other supports can be made, for example, from a single multi-filament yarn or a pair of continuous filament yarns. The ribs may be woven and spaced at regular intervals with intervening staple body yarns in a woven ripstop fabric. The ripstop fabric may include an array of continuous filament yarns and staple yarns. The ripstop fabric may be used alone or may be integrated with one or more layers of backing fabric to form a garment that is lightweight, flexible, unbulky, and cost-effective and able to resist tearing and/or other damage from blast debris.

Claims

1. A reinforced flame-resistant ripstop fabric comprising: staple body yarns; and reinforcing ribs comprising continuous multi-filament yarns, wherein the reinforcing ribs are spaced at regular intervals along weft and warp directions of the reinforced flame-resistant fabric.

2. The reinforced flame-resistant ripstop fabric of claim 1, wherein the continuous multi-filament yarns comprise para-aramid or ultra-high molecular weight polyethylene.

3. The reinforced flame-resistant ripstop fabric of claim 2, wherein the continuous multi-filament yarns comprise para-aramid or ultra-high molecular weight polyethylene in the range of two hundred to eight hundred Denier yarns, most preferably in the range of about four hundred to six hundred Denier yarns.

4. The reinforced flame-resistant ripstop fabric of claim 1, wherein each reinforcing rib comprises one continuous multi-filament yarn.

5. The reinforced flame-resistant ripstop fabric of claim 1, wherein each reinforcing rib comprises a pair of adjacent continuous multi-filament yarns.

6. The reinforced flame-resistant ripstop fabric of claim 1, wherein the staple yarns are configured as body yarns between the reinforcing ribs of the reinforced flame-resistant ripstop fabric.

7. The reinforced flame-resistant ripstop fabric of claim 6, comprising nineteen staple yarns between each reinforcing rib in the warp direction and ten staple yarns between each reinforcing rib in the weft direction.

8. The reinforced flame-resistant ripstop fabric of claim 6, comprising ten staple yarns between each reinforcing rib in the warp direction and five staple yarns between each reinforcing rib in the weft direction.

9. A clothing item comprising: a flame-resistant ripstop fabric comprising: staple yarns; and reinforcing ripstop ribs comprising continuous multi-filament yarns, wherein the reinforcing ripstop ribs are spaced at regular intervals along weft and warp directions of the reinforced flame-resistant fabric.

10. The clothing item claim 9, wherein the continuous multi-filament yarn comprises para-aramid or ultra-high molecular weight polyethylene.

11. The clothing item of claim 9, wherein each of the reinforcing ribs comprises one continuous multi-filament yarn.

12. The clothing item of claim 9, wherein each of the reinforcing ribs comprises a pair of adjacent continuous multi-filament yarns.

13. The clothing item of claim 9, wherein the staple yarns are configured as body yarns between the reinforcing ribs of the reinforced flame-resistant ripstop fabric.

14. The clothing item of claim 13, wherein the first plurality of staple yarns comprises nineteen staple yarns and the second plurality of staple yarns comprises ten staple yarns.

15. The clothing item of claim 13, wherein the first plurality of staple yarns comprises ten staple yarns and the second plurality of staple yarns comprises five staple yarns.

16. A clothing item comprising: a reinforced flame-resistant ripstop fabric comprising: staple yarns; reinforcing ribs comprising continuous multi-filament yarns, wherein the reinforcing ribs are spaced at regular intervals along weft and warp directions of the reinforced flame-resistant fabric; and a backing layer of fabric attached to the reinforced flame-resistant fabric.

17. The clothing item of claim 16, wherein the backing layer of fabric is a woven, knit, or non-woven fabric.

18. The clothing item of claim 16, wherein the backing layer of fabric comprises para-aramid or ultra-high molecular weight polyethylene (UHMWPE).

19. The clothing item of claim 16, wherein the ripstop fabric and secondary layer of fabric are attached together via sewing or stitching.

20. The clothing item claim 16, wherein the continuous multi-filament yarn comprises para-aramid or ultra-high molecular weight polyethylene.

21. The clothing item of claim 16, wherein each of the reinforcing ribs comprises one continuous multi-filament yarn.

22. The clothing item of claim 16, wherein each of the reinforcing ribs comprises a pair of adjacent continuous multi-filament yarns.

23. The clothing item of claim 16, wherein the first plurality of staple yarns comprises nineteen staple yarns and the second plurality of staple yarns comprises ten staple yarns.

24. The clothing item of claim 16, wherein the first plurality of staple yarns comprises ten staple yarns and the second plurality of staple yarns comprises five staple yarns.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The novel features of the disclosure are set forth in the appended claims. However, for purpose of explanation, several embodiments are illustrated in the following drawings.

[0013] FIG. 1 illustrates a magnified view of a section of ripstop fabric of one or more embodiments described herein;

[0014] FIG. 2 illustrates an enlarged magnified view of a section of ripstop fabric of one or more embodiments described herein; and

[0015] FIG. 3 illustrates an example magnified front view of one or more embodiments described herein, in which a garment including a ripstop fabric or a garment including a ripstop fabric with an attached backing layer or layers of fabrics integrated in some areas of the garment.

DETAILED DESCRIPTION OF THE INVENTION

[0016] The following detailed description describes currently contemplated modes of carrying out exemplary embodiments. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of some embodiments, as the scope of the disclosure is best defined by the appended claims.

[0017] The textiles used in current military uniforms and gear are designed to provide wearers with durable protection from the natural environment (e.g., waterproofing, thermal regulation, and microbial and insect protection), protection from exceptional hazards and threats (e.g., camouflage, flame resistance, stain repellant), and measurable levels of comfort (e.g., breathability, moisture vapor transmission, moisture-wicking), while also allowing for maximum agility, range-of-motion, and mobility in complex terrains and landscapes in extreme conditions. Various industrial fiber and fabric processing technologies, including the use of functional coatings and finishes and other textile technologies, are implemented to construct fabrics and uniforms that meet these requirements. For example, to provide camouflage and prevent detection in operational environments or by night-vision devices, uniforms have to be printed/dyed in specific color shades that do not readily fade or run from environmental exposure or laundering. Similarly, to provide flame resistant (FR) properties, uniform fabrics are made from a fiber blend that includes para-aramid.

[0018] Para-aramids and UHMWPE have been implemented in textiles for uniform fabrics and gear to provide lightweight solutions to address specific threats or challenge for firefighters, law enforcement, and the military (vest, body armor, face masks, and helmets). Para-aramids and UHMWPE are synthetic polymers that are converted into high-strength fibers with exceptional properties. Para-aramid fibers show exceptional tensile strength (particularly tensile strength-to-weight ratio), Young's modulus, and stability toward thermal or mechanical degradation. The use of UHMWPE fibers have become widespread in the fields of composite reinforcements and soft armor.

[0019] To meet the challenges of serious burns occurring as a result of buried blast events, uniform fabrics were developed using para-aramid fibers that are inherently FR. These FR uniforms achieved the goal of reducing the incidence of serious burn injuries in these instances. To address the challenges of buried blast events relating to the release of high-velocity fragments and debris, protective undergarments (PUGs) were developed as a separate garment that is worn under the uniform to protect lower extremities and soft tissues from serious injuries. PUGs are designed to include knit and woven para-aramid fabrics and to be breathable and moisture-wicking. Additionally, a protective outer-garment (POG) and Blast Pelvic Protector (BPP) have been developed to be worn over the uniform and protect the wearer's pelvic area.

[0020] One factor to consider in addressing the threats from blast debris is the type of soil and its composition, in which the buried blast event takes place. For example, in desert environments, the debris field will consist largely of sand, gravel, and rock fragments. In tropical locations, wet soil masses and small rocks will likely make up the blast debris. In urban and subterranean settings, the debris will likely consist of different sizes of irregular-shaped fragments and chards of manmade construction materials, such as concrete, glass, pavement, masonry, and other stonework, as well as soil, dirt, and rocks. Protection is needed from the different types of high velocity projectiles and composition of blast debris, that may occur in diverse operational environments, damage protective gear through different mechanisms, and cause a spectrum of injuries (abrasion, infection, penetrations, blunt trauma), particularly in the lower extremities and pelvic area.

[0021] There is a need for lightweight, flexible, high strength, tear resistant fabrics that can be made into combat uniform garments, and there is a need for lightweight, flexible, tear resistant fabrics that can be integrated with a backing layer or layers to make unbulky combat uniform garments, that help reduce the risk of injury, particularly to the groin area and lower extremities, that may result from the large number of high-velocity metallic and non-metallic fragments and secondary debris that are ejected over a prolonged but finite duration in buried blasts and blast-related events.

[0022] The present disclosure includes reinforced ripstop fabrics with ribs or support elements that include continuous multi-filament yarns made of para-aramid or UHMWPE. Garments may be constructed with this ripstop fabric, such that the garment provides enhanced resistance to blast debris, as observed in outdoor buried blast tests with a detonable charge, without compromising the myriad textile and multi-functional properties of the uniform, comfort, and wearability for the movement, agility, and mobility of the wearer.

[0023] The present disclosure includes fabric constructs that include one layer of ripstop fabric with ribs that include continuous multi-filament yarns made of para-aramid or UHMWPE that are reinforced by attachment to one or more backing layers of woven, knit, or non-woven fabric made of para-aramid or UHMWPE, such that the resultant fabric construct provides enhanced resistance to blast debris, as observed in outdoor buried blast tests with a detonable charge, without compromising the myriad textile and multi-functional properties of the uniform, comfort, and wearability for the movement, agility, and mobility of the wearer.

[0024] The present disclosure includes a protective garment that includes one layer of ripstop fabric with ribs that include continuous multi-filament yarns made of para-aramid or UHMWPE, to provide enhanced resistance to blast debris to protect the lower extremities and pelvic area without compromising the myriad textile and multi-functional properties of the uniform, comfort, and wearability for the movement, agility, and mobility of the wearer.

[0025] The present disclosure includes a protective garment that includes one layer of ripstop fabric made with continuous multi-filament para-aramid or UHMWPE yarns as ribs and integrated with areas that include one or more backing layers of woven, knit, or non-woven fabric made of para-aramid or UHMWPE, such that the protective garment includes ripstop fabrics and fabric constructs strategically integrated to provide enhanced resistance to blast debris to protect the lower extremities and pelvic area without compromising the myriad textile and multi-functional properties of the uniform, comfort, and wearability for the movement, agility, and mobility of the wearer.

[0026] Various features are described below that can each be used independently of one another or in combination with other features. Broadly, some embodiments generally provide ripstop fabrics that may include continuous multi-filament yarns of the high-strength materials para-aramid or UHMWPE. The continuous multi-filament yarns may form ribs or reinforcing structural support elements that may be distributed throughout a fabric with other continuous filament yarns and/or staple yarns. Some embodiments generally provide ripstop fabrics that may include continuous multi-filament yarns as ribs, and that also may include one or more backing layers of woven, knit, or non-woven fabrics made of high-strength materials as a fabric construct or strategically integrated into a garment for protection of particularly sensitive areas.

[0027] FIG. 1 illustrates a magnified view of a section of ripstop fabric 100 of one or more embodiments described herein. The section of reinforced fabric 100 exemplifies a plain weave construct with the white solid lines representing staple yarns 110 and the shaded solid lines representing continuous multi-filament yarns 120. Each vertical and horizontal rib 130 of the ripstop fabric structure may include multiple continuous multi-filament yarns 120 as shown. In this example, each rib 130 includes two adjacent continuous multi-filament yarns 120, with ribs 130 spaced at regular intervals throughout the cloth or fabric. The section of ripstop fabric 100 may be associated with a fabric area of about one square centimeter in some embodiments.

[0028] The section of ripstop fabric 100 may include a repeating pattern of ribs 130 with respect to a weft axis 140 and a warp axis 150. In this example, there are nineteen staple yarns 110 between every rib 130 along the weft axis 140, and there are ten staple yarns 110 between every rib 130 along the warp axis 150. This pattern of ribs 130 in the ripstop fabric may be referred to as a nineteen-by-ten (1910) array. Other example arrays include twenty-by-ten (2010), ten-by-five (105), six-by-three (63), and six-by-two (62).

[0029] Different embodiments of the ripstop fabric may include different reinforced structures arranged in various different patterns. For instance, ribs 130 may be spaced closer together than a nineteen-by-ten array or a twenty-by-ten array, such as a ten-by-five array, six-by-three array, or six-by-two array, in order to increase stability for protection, or spaced farther apart to increase comfort or flexibility.

[0030] FIG. 2 illustrates a front elevation view of a section of ripstop fabric 200 of one or more embodiments described herein. The section of ripstop fabric 200 may be a sub-section of the section of ripstop fabric 100. The section of ripstop fabric 200 may include a ripstop structure reinforcing a plain weave pattern, where the weft and warp are interlaced as shown. Each rib 130 in this example includes two adjacent continuous multi-filament yarns 120, as shown, that include continuous multi-filament yarns of para-aramid or UHMWPE. Different embodiments of the ribs 130 in the ripstop fabric may include, for example, a single continuous multi-filament yarn 120, a pair of adjacent continuous multi-filament yarns 120, three adjacent continuous multi-filament yarns 120, etc.

[0031] The continuous multi-filament yarns 120 of the ripstop reinforcing structure may be separated by staple yarns 110 woven into the cloth. The ribs 130 may include continuous multi-filament yarns 120 that may be repeated at regularly spaced intervals (e.g., a nineteen-by-ten, twenty-by-ten, ten-by-five, or seven-by-three array). Continuous multi-filament yarns 120 may be four hundred, five hundred denier, six hundred denier, or eight hundred denier para-aramid or UHMWPE. Ribs 130 may include, for example, one or two four hundred denier continuous multi-filament yarns 120 space throughout a reinforcing ripstop structure. The ribs 130 may be spaced at regular intervals with staple yarns 110 intervening between the ribs 130, for example, as a nineteen-by-ten, twenty-by-ten, ten-by-five, or seven-by-three array.

[0032] FIG. 3 illustrates an example overview of one or more embodiments described herein, with a front view of a trouser garment 300. The trouser garment 300 includes a ripstop fabric 310 (designated with square pattern), such as ripstop fabric 100, throughout the entire trouser garment 300. Other embodiments may include the trouser garment 300 that includes the ripstop fabric 310 with sections that are reinforced with one or more backing layers of fabric, where such reinforced sections of ripstop fabric 320 are designated with diamond fill pattern.

[0033] As shown, trouser garment 300 may include reinforced sections of ripstop fabric 320 in some association with sensitive areas, such as the lower extremities and pelvic region, and/or areas of expected high usage or wear-and-tear, such as knee pads. The layer of ripstop fabric 310 and/or the reinforcing layers associated with reinforced sections of ripstop fabric 320 may include a woven fabric that includes staple yarns 110 interwoven with a ripstop structure that includes continuous multi-filament yarns 120 that may form a set of ribs 130 as structural support. The woven ripstop fabric 310 may include ribs 130 including continuous filament yarns 120 spaced at regular intervals, as shown. Each multi-filament yarn 120 may include materials such as para-aramid, UHMWPE, and/or other appropriate materials. Each continuous multi-filament yarn may be in the range of two hundred Denier to eight hundred Denier yarns, most preferably in the range of about four hundred Denier to six hundred Denier yarns.

[0034] Each staple yarn 110 may include various appropriate types of natural fibers (e.g., wool, cotton, silk, etc.) and/or types of synthetic fibers (rayon, spandex, polyester, nylon, para-aramid, UHMWPE, etc.). The staple yarns 110 may include FR fiber blends, such as those used in an FR Army Combat Uniform (FRACU).

[0035] Trouser garment 300 may include sections with one or more layers of reinforcing backing fabric 320 in some embodiments. For example, the trouser garment 300 may include sections of ripstop fabric 310 integrated with one or more additional layers of reinforcing fabric 320 in sensitive areas (e.g., pelvic region, lower extremities, etc.). In some embodiments, trouser garment 300 may include ripstop fabric integrated with sections of reinforcement with one or more backing layers of fabric 320 including woven or knit para-aramid or UHMWPE fabrics. Trouser garment 300 may include any number of other elements, such as fasteners (e.g., buttons, snaps, zippers, etc.) and/or other appropriate elements (e.g., those associated with a combat uniform).

[0036] Buried blast events and/or fragmenting munitions or other similar blast-related occurrences may eject high velocity small metallic and non-metallic fragments, natural materials such as soils, gravel, and rocks, and manmade construction materials such as broken concrete, rock, or masonry shards, metal, glass, pavement, etc. The trouser garment 300 including the ripstop fabric 310 may include sections with one or more backing layers of fabric 320 for reinforcement and may be better able to resist various types of damage (e.g., tears, penetrations) from high velocity projectiles and blast debris and/or otherwise maintain the structural integrity of the trouser garment 300 and/or otherwise minimize the effects of such damage that may cause injuries in buried blast or blast-related events.

[0037] No element, act, or instruction used in the present application should be construed as critical or essential unless explicitly described as such. An instance of the use of the term and, as used herein, does not necessarily preclude the interpretation that the phrase and/or was intended in that instance. Similarly, an instance of the use of the term or, as used herein, does not necessarily preclude the interpretation that the phrase and/or was intended in that instance. Also, as used herein, the article a is intended to include one or more items and may be used interchangeably with the phrase one or more. Where only one item is intended, the terms one, single, only, or similar language is used. Further, the phrase based on is intended to mean based, at least in part, on unless explicitly stated otherwise.

[0038] The foregoing relates to illustrative details of exemplary embodiments and modifications may be made without departing from the scope of the disclosure. Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the possible implementations of the disclosure. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. For instance, although each dependent claim listed below may directly depend on only one other claim, the disclosure of the possible implementations includes each dependent claim in combination with every other claim in the claim set.