CA2491717C

CA2491717C - Ballistic laminate structure in sheet form

Info

Publication number: CA2491717C
Application number: CA 2491717
Authority: CA
Inventors: Andrew D. Park; Dave Park; Alexander J. Park
Original assignee: PTI Materials LLC
Current assignee: PTI Materials LLC
Priority date: 2004-03-08
Filing date: 2005-01-07
Publication date: 2010-03-23
Anticipated expiration: 2025-01-07
Also published as: EP1574811A1; CA2491717A1; US20050197020A1; US7148162B2

Abstract

A ballistic laminate structure includes a first high-performance unifabric composite. The unifabric composite incorporates an array of unidirectionally oriented fiber bundles carried on a fiber-stabilizing scrim and having a tensile strength greater than 7 grams per denier. A second high-performance unifabric composite includes an array of high performance, unidirectionally-oriented fiber bundles. The fiber bundles of the second composite are carried on a fiber-stabilizing scrim and have a tensile strength greater than 7 grams per denier. The first and second unifabric composites are cross-plied at an angle and banded together to form the ballistic laminate structure.

Description

BALLISTIC LAMINATE STRUCTURE IN SHEET FORM

Technical Field and Backqfound of the Invention rooo11 This application relates to a ballistic laminate structure in sheet form, a ballistic panel constructed of a plurality of the sheets, a ballistic garment constructed of one or more of the baflistic panels, and a method of fabricating a ballistic laminate structure, and a baliistic resistant composite for fiard-armor appiication.

[oonzi Numerous ballistic laminates are known in the art including those described in Applicants own United States Patent Nos. 5,437,905; 5,443,883;
5,547,536; 5,535,288; 5,935,678; and 5,952,078.

toooaI A baiiisdc non-woven iaminate referred to commerciai'ly as SPECTRA
SHIELD is manufactured by Honeywell, Inc. The laminate structure is used in soft body armor to protect the wearer agalnst high-veiocity bullets and fragments.
SPECTRA
SHIELD Is made by first forming a non-woven unidirectional tape, composed of unidirectional polyethylene fibers and an elastic resin material that holds the fibers together. The resin penetrates to the fllament level, impregnating the entire structure with the resin produc#. Two layers, or arrays, of the unidirectional tape are then laminated together (cross-plied) at right angles to form a panel. Then, the panel is covered on both sides with a thin film of polyethylene on the order of 0.001 inches thick.
The film prevents adjacent panels from sticking together when the panels are layered together in the soft body armor.

[oo" Appt9canYs pr9or patents listed above describe a substantial improvement of ttris technology. Specifically, Applicant determined that baifistic iaminates can be - -122121 Aroe 1. -constructed of high performance fibers 'w4thout using resins to hold the fibers together.
This substantially reduces the weight of the structure without compromising the anti-bailistic characteristics of the structure. By omitting the resin, the cross-plied arrays of fibers directiy contact each other, instead of being encapsulated and therefore separatr:d from each other by the resin. An uitra-thin fiim Is used both to cover the crass-piied arrays and to hold the arrays to each other. The prior art teaches that a critical limit of 80% fiber must be maintained in the laminate In order to maintain product integrity. If the percentage of resin, covers, and the like exceeds 20%, the anti-ballistic qualities of the laminate begin to degrade.

iooos] As a further improvement, Applicant recentiy dlscovered unexpected advantages In using a scrim to hold and stabilize the high performance fibers prior to tamination. The resutting laminate atructure offers substantially enhanced baliistic performance. The scrim adds little weight to the final product, provides durable bonding and anti-fray performance, and is dry-olean resistant Summary of the In}ro ion Therefore, it is an object of the Invention to provide an improved ballistic laminate structure comprising unidirectionaliy-oriented high performance fibers stabilized using one or more nonwoven, adhesive scrims.

Iooon It is another object of the Invention to provide an improved ballistic laminate structure which utilizes one or more fber-stabiilzing layers which little weight to the final product.

Ioo" It is another object of the invention to provide an improved ballistic laminate stn,cture which utPiizes one or more fiber-stabilizing layers which provide durable bonding and anti-fray performance.

[ca" It is another object of the invention to provide an Improved bailistic laminate structure which utilizes one or more fiber-stabilizing layers Including adhesives that are dry-ciean resistant.

rau,ct tt Is another object of the invention to provide an improved ballistic laminate structure which utilizes one or more fiber-stabilizing scrims comprising muJtifdarnent yams of polyester, nylon, glass, rayon and pofypropyiene.

[ooirl It Is another object of the Invention to provide an improved baliistic laminate structure which utiiizas one or more fiber-stabilizing scrims which are heat activated, [oo121 It Is another object of the inventlon to provide an improved ballistic laminate structure which utilizes one or more fiber-stabiilzing scrims having low basis weights.

tuoi33 It Is another object of the invention to provide an improved bailistic laminate structure which utilizes one or more fiber-stabilizing scrims that provided enhanced weight to pen`ormance ratios, porosity, and bond strength to breathabdity ratios.

tooa41 It is another object of the invendon to provide an improved ballistic laminate structure which utilizes one or more fiber-stabiiizing scrims having low weight to bond strength ratios.

ims] lt is another object of the invention to provide an improved high-performance unifabric composite.

too141 It Is another object of the inventfon to provide an Improved protective garmeint.

[00171 These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a ballistic laminate structure In sheet form. The laminate strucCture indudes a first high-perfomnanoe unifabric compostte. The unifabric composite comprises an array of unidirectionally-oriented fiber bundles carried on a fiber-stabilizing sc-im and having a tensile strength greater than 7 grams per denier. A second high-perforrnance unifabric composite Includes an array vf high performance, unidirectionaiiy-oriented fiber bundles. The fiber bundles of the secortd composite are carried on a f1ber-stabilizing sscrim and have a tensile strength greater than 7 grams per denier. The first and second unifabric composifes are cross-plied at an angle and bonded together to form the ballistic laminate structure.
too,e] The term "scrim" Is used broadly herein to refer to any loosely woven or normroveri, open structure having a yam density (yams per inch in one direction) in the range of 5-20 per Inch. The "high-performartce unifabric composite" refers to a composite comprising fibers having a tensife strength greater than 7 grams per denier.
[ooiv] Preferably, the scrim is a nonwoven adhesive web.

too2M According to another preferred embodiment of the invention, a polymeric film resides betvveen the first and second cross-plied unifabric composites to adhere the composites together without substantiai penetration of the film into the fiber bundies.
roozra Aecording to another preferred embodiment of the invention, the polymeric flYm Is polyethylene film having a thickness of about 0.35 mils.

[oorn According to another preferred embodiment of the invention, the first unifabric cornposite is cross-plied at an angle of 90 degrees to the second unifabric - -122l21 Pag+e 4- -composite.

too231 According to another preferred embodiment of the invention, the percentage by weight of the higli performance fibers tn the ballistic laminate structure is at least 80 percent of the total weight of the ballistic laminate structure.

(oo24) According to another preferred embodiment of the invention, the fiber bundles of the first and second unifabric oomposftes comprise fibers chosen frorn the group consisting of aramid fiber, polyolefin, vinylon, and liquid crystal polymer-based fiber.

roozaj Ac.cvrding to another preferred embodiment of the fnventfon, the fiber bundles of the first and second unifabria composites comprise frbers chosen from the group corislsting of extended chain ultra-high molecular weight polyethylene (UHMWPE), poly (p-phenylene-2, 6-benzob(soxazote) (PBO), and poly (dumidazo pyridinylene (dihydroxy) phenylene) (M5).

1002Q According to another preferred embodiment of the invention, the first unitabric oomposite has a second fiber-stabilWng scrim located on an opposita side of the fiber bund(es, toorn ACCOrding to another preferred embodiment of the lnvention, the second unifabric ct-mposite has a second itber-gtabilizinQ scrim located on an opposite side of the fiber bundles.

too291 In another embodiment, the inventron is a batiistic laminate structure In sheet form including a first high-perfarmanoe unifabric composite. The first composite includes an array of unidirectionally-oriented fiber bundles sandwiched between first and second fiber-stabilizJng scrirns. 'The fibers have a tensile strength greater than 7 - -=izznY Page S. -grams per denier. A second high-performance unifabric composite includes an array of high performance, unidirectionaliy-0tiented fiber bundles sandwiched between first and second fiber-stabiliztng scrims. The fibers of this compasite also have a tensile strength greater than 7 grams per denier. The first and second unifabric composites are cross-plied at an angle and bonded together to form the bailistic laminate structure.

LooM In yet another embodiment, the invention is a high-performance unifabric compos'rte adapted for lncorporation in a she$t-foml ba0istic laminate structure. The unifabric composite includes an array of unidireationally-oriented fiber bundles carried on a fiber-stabttizing scrim. The fibers of each bundle have a tensile strength greater than 7 grams per denier.

13nef jZescript'~0 of the DaWngs ro03M Some of the objects of the invention have been set forth above. Other objects and advantages of the invention witi appear as the invention proceeds when taken in conjunction with the followtng drawings. In which:

(oosll Figure 1 is an armored body garment according to a preferred embodiment of the invention;

tcorp Figure 2 Is a perspective view of a bailistic panel insert incorporating a stacked arrangement of the present laminate structure;

Ioo331 Figure 3 illustrates formation of the ballistic laminate structure from twa identical, cmss-plied laminate composites;

too34 Figure 4 illustrates formation of the laminate composite incorporated In the ballistic laminate structure;

P03M Figure 5 is an enlarged, diagrammatic representatlon of the interaction of - -122l21 Page 6- -the thin covering fdms and the unidirectional fiber arnays of the laminate structure;

PM Figure 6 is an enlarged view of a single fiber bundle according to the prior art, showing complete Impregnation of the resin into the structure of the fiber bundie;
mca71 Figure 71s a enlarged view of a singla fber bundle according to an embodirnent of the Invention showing lack of impregnation of the resin into the structure of the fiber bundle; and iowe) Figure 8 iliustrates fomnation of a laminate composite according to a further preferred embodiment of the invention.

De~riplign the Preferred Embodiment and Best Mode tooa~ Referring now speclfrcaliy to the drawings, a body-armor product according to the present Invention Is lilusfrated In Figure 1 and shown generally at reference numeral 10. Afthou9h a baliistic vest 10 is shown, the principle of the invention is broadly applicable to any soft or hard armar product Including other protective garments, panel inserts, helmets, vvindshieids, vessels, tanks and other land vehicles, aircraft, and the !'ke. The vest 10 Is especlally adapted for use by military personnel to protect the wearer against fragments and artillery frre.

rom The vest 10 Incorporates a number of strategically arranged hard or soft-arrnor panel inserts 11, shown in Figure 2. The inserts, referred to as "smaii arms protection inserts" (or SAPJ's) comprise a rigid facing 12 and ballistic fabric backing 14 encased in an outer cover 15. The cover 15 may be formed of a single knit material, such as nylon fabric, or may be a rubberized coating formed by dipping, or may be a combination of fabric, rigid plastic, and foam or honeycomb structure that protects the plate from wear-and-tear, and which contains any fragmentation upon impact as - -7122t2I Page 7- -appropriate.

ioo417 The fabric backing 14 is constructed of mukipie stacked layers of the ballistic laminate structure 20 iliustrated ir? Figures 3 and 5, and described in further detail below. The stacked layers are laminated under heat and pressure to create a dense, rigid, unitary backing ranging In thickness from 0.1304nches to 0.350-inches.
Lamination occurs via autaclave, press molding, a resin transfer mold, and/or an oven with vacuum pressure.

8aitistic Raminate Structure 20 taoexa Referring to Figures 3, 4, and 5, the ballistic laminate structure 20 comprises multiple, high-performance, unifabric corrmposites 21 and 22 stacked together in precise registration and coated on the outside with polyethylene film 24 and 25. A
single cornposite 21 is best illustrated In Figure 4. The composite 21 includes bundles 23A of untwisted, oontinuous-filament fibers iandwiched between respective fiber-stabiiizing scrims 26A,, 26B. The fibers are para)feiized and formed into a unidirectionally-oriented array having a predetermined uniform number of bundles 23A
per inch of width. The bundled fibers comprise any one or a combination of aramid, extended chain uffra-hiQh molecuiar= weight polyethylena (UHMWPE), poly {p-phenylene-2, 6-benzobisoxazole) (PBO), and poly {diimidazo pytidinytene (dlhydroxy) phenyiene) (MS). Each of these ffbars has a tensiie strength greater than 7 grams per denier. Suitable commercial ffbers include: TwaronO micro-denier fiber, Spectra ShieidO PCR fiber, DyneemaB- Ua (unidirectionai) fiber, PBO Zyfon(D fiber, and aramid Keviai fiber. The fibers are preferabty HM (high modulus) grade with low moisture content. The preferred embodiment utilizes high-performance fibers having less than - -122R1 Fage $- -5.4 dpf (deneier per filament), and more preferably, less than 2.0 dpf, and most preferably, less than 1.5 dpf. The unifabric composite 22 is identical to the composite 21 described above and shown In Figure 4.

roasi Each scrim 26A, 26B and 27A, 27B is forrned of a heat-activated, nonwoven, adhesive web, such as that manufactured and sold commercially by Spunfab of Cuyahoga Falls, Ohio. The adhesive web is based upon one or a canbination of potyamlde, polyester, eiastomeric, urethane, and olefin poiymers, and may be supplied in tape, sheet or roll form as a pre-measured, ready to use product.
The web is cut to match the predse width and length of the fiber bundles 23A, 238, and is loosely arranged over each opposing surface prior to activation of the adhesive.
Once activated, the scrim 26A, 268 and 27A, 27B bonds to and further stabipzes the paralielized fiber bundles 23A, 23B. Thermal bonding may also be achieved through both heat activatable binder systems, such as Dow "Primacore", and thermoplastic bicomponent yams. Heat is used to hold the scrim together Initially, and to reactivate the scrim for bonding in subsequent lamination. Typical chemistries for the binders used to lock scrim yams in piace include polyvinyl alcohol, polyvinyl acetate, and butadlene styrene.

ioo~s~ Referring again to Figure 3, after application of the fiber-stabilizing scrims 26A, 268 and 27A, 278, the un'ifabric composites 21, 22 are stacked in a cross-plied, 0190-desree orientation such that the unidinectionally-oriented fiber bundies 23A of the first composite 21 extend substantialty perpendicular to the uriidirectionaDy-oriented fiber bundles 23B of the second composite 22. Other cross-ply angles are possible, such as 45 degrees. The stacked composites 21, 22 together with the outer films 24.

_ _122/21 P'oe 0. .

{
{ 25 are then saminated under heat and pressure to create the ballistic laminate structure 20. The outer ffms 24, 25 may be applted to the composites 21, 22 either individualty prior to lamination, or simuttaneousiy during taminatton.

[e"st The poiyethylene films 24, 25 are extremely thin, on the order of about 0.25-1.0 mit and most preferably about 0.35 mil, so that the films witl slightly coat the exterior surfaces of the individual fiber bundles 23A, 238 in each composite 21, 22, but will not penetrate into the fiber bundles 23A, 23B so as to coat and encapsulate the individuai fibers and filarnents. As indir.ated In Figure 5, sufficient ptasticized film materiat flows between the adjacent cross-plied arrays of fiber bundles 23A, 23B to bond the two cornposftes 21, 22 together without use of additional adhesives or other bonding agents.

toael The percent ratia by weight of hlgh performance fibers to film in the ballistic laminate structure 20 ts preferably equal to or greater than 80:20.
When the fiber weight drops below 80% of the overall weight oÃthe laminate structure 20, the antt-baHistic qualities of the laminate structure 20 begin to degrade.

tooa?] As best shown in Figure 5, the fiber bundles 23A, 23B of each of the compositm 21, 22 are at right angles to each other. Respective outer surfaces of the composites 21, 22 are coated with the films 24, 25. As is illustrated, the film 24, 25 has meited and flowed into the (nterstices between the fiber bundles 23A, 23B of each of the composites 21, 22. Sufficient matted polyethylene from both of the films 24, 25 have intermingled with each other and coated the outer surface of the fiber bundles 23A. 23B of the other composite to create a surÃace bond to hold the two composites 21, 22 together to form the batttstic laminate stnicture 20.

- -I22f2I Pagc 10- -1004ej This Is illustrated more ciearly In Figuraes 6 and 7. Figure 6 shows a prior art ootistn,ction such as a SPECTRA SHIELD product using both an elastic resin and a surface film. The Individual fiber bundles 20 the individual fibers which make up the bundle are substantially completely encapsuiated with the elastic resin (the black, surrounding materiai) as well as the outside of the fiber bundle. This adds to the weight of the product and creates the possibility of variation in quality if too much or too little resin is used, or if the resin is applied unevenly or inconsistently.

loNat In contrast, the fiber bundles 23A according to the present Invention are coated by the film 24 on the outside surface only, so that the integral stnicture of paraflel, cJosely bunched filaments and fibers remains intact, and intimate contact between the closely bunched filaments and fibers remains. The film may not even coat the entire outer surface of the fiber bundle, but only to a suifcient degree to properly bond the two composites 21, 22 together to form the laminate structure 20.
Film 25 coats the 15ber bundles 23B In an identical manner.

taoam Although the films 24, 25 of the laminate structure 20 are preferably formed of polyethylene, other polymeric materials such as thenrosetting plastics, thermoplastics, or elastomerics may be used. In the case of thermsetting plastics, the film is not fully cured prior to forfrration of the laminate structure. The amount of heat and pressura required during laminatlon is a function of the duration of the lamination process, and the thickness and other properties of the film being used.

Ioosll A second embodiment of a high-performance, unifabric composite 30 according to present invention is shown in Figure B. The unifabrtc composite comprises ari outer polyethylene film layer 31, a tiber-stabifizing scrim 32, and a unidirectionally-oriented array of high-tenacity fiber bundles 33, as described above.
The layers 31, 32, and 33 are stacked in precise registration and laminated under heat and pressure to form the unifabric composite 30. The film-coated composite 30 is then cross-plied with a like composite (not shown) and faminated to form a further ballistic laminate structure according to the present invention.

10064 in yet another embodiment, a film-coated unifabric composite may be cross-plied and faminated with a composite that does not include a film coating. In this case, the plasticized film flowing from the coated array of fiber bundles to the uncoated array of fiber bundies is sufficient to bond the two sheet composites together to form a modified ballistic laminate structure. Altematively, the laminate structure may be formed by sandwiching a film layer between two uncoated sheet composites of high-performance fibers, or between two coated composites of high performance fibers.

100531 One preferred embodiment of the ballistic laminate structure is given in the foflowing example:

Fiber-- aramid Fiber construction-- 840 denier, less than 1.5 den/fil (denier per filament) per tow.
Scrim-- 2 layers of polyethylene-based, nonwoven, adhesive web I unifabric Laminate Constnaction- nominal 20-21 ends/inch unidirectional untwisted tows Number of unifabric composites in laminate structure-- 2 plies Sheet orientafion of 1st and 2nd laminate structures-- 90 degrees Film--.35 mil polyethylene Laminate structure-intimately plied sheets with overlying, surface-applied polyethyiene film Percentage of fiber weight to film weight-- 80%

Iao541 For added fiber stability, one or more frff fibers may be woven or stitched - -122/21 Paae 12- -into the arrayed fiber bundles prior to forming the banistic laminate structure in order to maintain the unidinectional orientation and structurai integrity of the fibers during handling and lamination. The fiA fibers may be any commerciaiiy available fiber which may or may not be a high perforntance fiber. The fill fibers may be monofiiament, muit+-fiiament;, bi-component filament, ribbon, or strips_ Eaitistics Testinct tooset in the bailistics industry, perfonnance is generaliy deterrnined basad on V50 ballistic test Umits for impacts on an 18" x 18" test cloth. The test cloth is formed of multiple overiying plies of batiistic fabric. The V50 baiNstic test iimit is the average of 10 fair impat:t velocities consistin$ of the five lowest comptete penetration veioc~sies and five highest partial penetration veiracitbs provided that the spread for the 10 veiocities is not greatEr than an allowable range of 150 feet per second (fps). if the 14-round average cannot be attained wPthin the allowable range, the ballistic cloth is retested.
The V50 ballistic iimit is determined for a given-size steel fragment by averaging thO
V50 test retsuits for three test cloths.

ioos~ A cloth sample of the present batiiBtic laminate structure (Sample A) was tested and compared against a sintiiar laminate structure (Sampie B). "Sampie A" was constructed, as described above, using scrims on each side of thQ
unidirectionaiiy-oriented fiber bundles. "Sampie B" was constructed in an Identical manner using the same fibers, but without the use of scarims to further stabiiize the fiber bundles. Each sample was nominal 1$x1 8 inches, and Included 30 overlying plies of the parkicuiar (aminate structurre.

toosn Testing was conducted in acaordance with the V50 provisions of NIJ-STD-0101.Q4, using caliber 9mm Luger, 124 yratn, FMJ ammunition. The test samples were mounted on an Indoor range 15.4 feet from the rnuzaie of a test barrel to produoe zero degree obliquity impacts. Photoelectric lumiline screens were positioned at 6.5 feet and 11.5 feet which, In con)unetion with elapsed time counters (chronographs), were used to determine projectile velocities 9.0 feet from the muzzle. Table 1 is a summary of the attached data records.

TABLE 1: SUMMARY OF RESULTS

Test Sample Ballistic Threat Ballistic Limit (fps) Number Weight Caliber TeGai V50 High Law ob) ShotsN5o BL(P) ParHal Complete Sample A 2.41 ` 9mm 12110 1821 1818 1805 Sample B 1.93= 8mm 11/10 1668 1695 1841 Dry fabric weight for each of tiampie A and B was equal.

toosa~ As shown above, the. "Sample A" test cloth incorporating the present baAistic laminate structure offered superior ballistic performance, ss compared to "Sample Et" which omitted the scrirns.

toossi A high-performance unffabrfc aomposite, ballistic laminate structure incorporat+ng cross-plied unifabriC cxmposftes, bailistic panel Insert incorporating multiple ballistic laminate structures, and a garment including one or more baiiistic panel inserts are described above. Various details of the invention may be changed without departing from its scope. Furthenrrore, the foregoing description of the preferred ernbodiment of the invenllon and the best mode for practicing the invention are provided for the purpose of iilusttation only and not for the purpose of fimitation-the invention being defined by the claims.

- -122l21 Page 14 -

Claims

1. A ballistic laminate structure in sheet form, comprising:
(a) a first high-performance unifabric composite including an array of unidirectionally-oriented fiber bundles carried on a fiber-stabilizing scrim and having a tensile strength greater than 7 grams per denier, (b) a second high-performance unifabric composite including an array of high performance, unidirectionally-oriented fiber bundles carried on a fiber-stabilizing scrim and having a tensile strength greater than 7 grams per denier, and (c) said first and second unifabric composites being cross-plied at an angle and bonded together to form said ballistic laminate structure.

2. A ballistic laminate structure according to claim 1, wherein said scrim comprises a nonwoven adhesive web.

3. A ballistic laminate structure according to claim 1, and comprising a polymeric film residing between said first and second cross-plied unifabric composites to adhere said composites together without substantial penetration of said film into said fiber bundles.

4. A ballistic laminate structure according to claim 1, wherein said polymeric film comprises polyethylene film having a thickness of about 0.35 mils.

5. A ballistic laminate structure according to claim 1, wherein said first unifabric composite is cross-plied at an angle of 90 degrees to said second unifabric composite.

6. A ballistic laminate structure according to claim 1, wherein the percentage by weight of the high performance fibers in the ballistic laminate structure is at least 80 percent of the total weight of the ballistic laminate structure.

7. A ballistic laminate structure according to claim 1, wherein the fiber bundles of said first and second unifabric composites comprise fibers chosen from the group consisting of aramid fiber, polyolefin, vinylon, and liquid crystal polymer-based fiber.

8. A ballistic laminate structure according to claim 1, wherein the fiber bundles of said first and second unifabric composites comprise fibers chosen from the group consisting of extended chain ultra-high molecular weight polyethylene (UHMWPE), poly {p-phenylene-2, 6-benzobisoxazole} (PBO), and poly {diimidazo pyridinylene (dihydroxy) phenylene} (M5).

9. A ballistic laminate structure according to claim 1, wherein said first unifabric composite comprises a second scrim located on an opposite side of said fiber bundles.

10. A ballistic laminate structure according to claim 1, wherein said second unifabric composite comprises a second scrim located on an opposite side of said fiber bundles.

11. A ballistic laminate structure in sheet form, comprising:
(a) a first high-perfomance unifabric composite including an array of unidirectionally-oriented fiber bundles sandwiched between first and second fiber-stabilizing scrims, and having a tensile strength greater than 7 grams per denier;
(b) a second high-performance unifabric composite including an array of high performance, unidirectionally-oriented fiber bundles sandwiched between first and second scrims, and having a tensile strength greater than 7 grams per denier;
and (c) said first and second unifabric composites being cross-plied at an angle and bonded together to form said ballistic laminate structure.

12. A high-performance unifabric composite adapted for incorporation in a sheet-form ballistic laminate structure, said unifabric composite comprising an array of unidirectionally-oriented fiber bundles carried an a fiber stabilizing scrim and having a tensile strength greater than 7 grams per denier.

13. A high-performance unifabric composite according to claim 12, and comprising a second fiber-stabilizing scrim located on an opposite side of said unidirectionally-oriented fiber bundles.

14. A high-performance unifabric composite according to claim 12, wherein said unidirectionally-oriented fiber bandies comprise fibers chosen from the group consisting of aramid fiber, polyolefin, vinylon, and liquid crystal polymer-based fiber.

15. A high-performance unifabric composite according to claim 12, wherein said unidirectionally-oriented fiber bundles comprise fibers chosen from the group consisting of extended chain ultra-high molecular weight polyethylene (UHMWPE), poly {p-phenylene-2,6-benzobisoxazole} (PBO}, and poly {diimidazo pyridinylene (dihydroxy) phenylene} (M5).

-~~~~-Page 18-

16. A high-performance unifabric composite according to claim 12, said scrim comprlsea a nonwoven adhesive web.

17. A high-performance unifabric composite according to claim 12, and comprising a polymeric film residing between said scrim and said unidirectionally-oriented fiber bundles to adhere said composite together without substantial penetration of said film into said fiber bundles.

18. A high-performance unifabric composite according to claim 12, wherein said polymeric film comprises polyethylene film haying a thickness of about 0.35 mils.