EP0479902A1 - Article composite antiballistique - Google Patents

Article composite antiballistique

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Publication number
EP0479902A1
EP0479902A1 EP19900911148 EP90911148A EP0479902A1 EP 0479902 A1 EP0479902 A1 EP 0479902A1 EP 19900911148 EP19900911148 EP 19900911148 EP 90911148 A EP90911148 A EP 90911148A EP 0479902 A1 EP0479902 A1 EP 0479902A1
Authority
EP
European Patent Office
Prior art keywords
filaments
layer
article
filament
composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP19900911148
Other languages
German (de)
English (en)
Inventor
Dusan Ciril Prevorsek
Young Doo Kwon
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honeywell International Inc
Original Assignee
AlliedSignal Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AlliedSignal Inc filed Critical AlliedSignal Inc
Publication of EP0479902A1 publication Critical patent/EP0479902A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0414—Layered armour containing ceramic material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0414—Layered armour containing ceramic material
    • F41H5/0428—Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
    • F41H5/0435—Ceramic layers in combination with additional layers made of fibres, fabrics or plastics the additional layers being only fibre- or fabric-reinforced layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0442—Layered armour containing metal
    • F41H5/0457—Metal layers in combination with additional layers made of fibres, fabrics or plastics
    • F41H5/0464—Metal layers in combination with additional layers made of fibres, fabrics or plastics the additional layers being only fibre- or fabric-reinforced layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0485—Layered armour containing fibre- or fabric-reinforced layers all the layers being only fibre- or fabric-reinforced layers

Definitions

  • This invention relates to ballistic resistant composite articles. More particularly, this invention relates to such articles having improved ballistic protection.
  • Fibers conventionally used include aramid fibers such as poly(phenylenediamine terephthala ide) , graphite fibers, nylon fibers, ceramic fibers, glass fibers and the like.
  • aramid fibers such as poly(phenylenediamine terephthala ide)
  • graphite fibers such as poly(phenylenediamine terephthala ide)
  • nylon fibers such as poly(phenylenediamine terephthala ide)
  • the fibers are used in a woven or knitted fabric.
  • the fibers are encapsulated or embedded in a composite material.
  • a fourth requirement is that the textile material have a high degree of heat resistance; for example, a polya ide material with a melting point of 255 C appears to possess better impact properties ballistically than does a polyolefin fiber with equivalent tensile properties but a lower melting point.
  • AD-A018 958 “New Materials in Construction for Improved Helmets", A. L. Alesi et al., a multilayer highly oriented polypropylene film material (without matrix), referred to as "XP" was evaluated against an aramid fiber (with a phenolic/pol vinyl butyral resin matrix).
  • U.S. Patent Nos. 4,457,985, and 4,403,012 disclose ballistic-resistant composite articles comprised of networks of high molecular weight polyethylene or polypropylene fibers, and matrices composed of olefin polymers and copolymers, unsaturated polyester resins, epoxy resins, and other resins curable below the melting point of the fiber.
  • U.S. Patent Nos.4,623,574 and 4,748,064 disclose a simple composite structure comprising high strength fibers embedded in an elastomeric matrix.
  • the simple composite structure exhibits outstanding ballistic protection as compared to simple composites utilizing rigid matrices, the results of which are disclosed in the patents.
  • Particularly effective are simple composites employing ultra-high molecular weight poly ethylene and poly propylene such as disclosed in U.S. Patent No. 4,413,110.
  • U.S. Patent No. 4,737,402 and 4,613,535 disclose complex rigid composite articles having improved impact resistance which comprises a network of high strength fibers such as the ultra-high molecular weight polyethylene and polypropylene disclosed in U.S. Patent No.
  • the present invention is directed to a complex ballistic resistant composite article of manufacture having improved impact resistance, said article comprised of two or more layers, at least one of said layers is a fibrous layer comprising a network of high strength filaments having a tenacity of at least about 7 grams/denier, a tensile modulus of at least about 160 grams/denier and an energy-to-break of at least about 8 joules/gram in a matrix material and at least one of said layers is a hard, rigid layer comprising at least one hard rigid material which is harder than said fibrous layer, wherein the relative weight percents of said layers and the relative positioning of said layers are such that said composite exhibits a mass efficiency (E ) equal to or greater than about 2.5.
  • E mass efficiency
  • Em defeat a threat
  • AD is the areal density of the armor or material in
  • the mass efficiency is determined by determining the AD required to defeat a threat of a designated projectile at a designated impact velocity with (1) armor grade steel and (2) the material under consideration, and computing Em by the above equation.
  • the composite article of the present invention can advantageously provide a selected level of ballistic protection while employing a reduced weight of protective material.
  • the article of the present invention can provide increased ballistic protection as compared to conventionally constructed composite armor of equal or substantially equal weight.
  • Figures 1 to 8 are depictions of cross-sectional views of various embodiments of this invention showing various representative structural configurations.
  • Composites of this invention include at least two essential components.
  • One component is a fibrous layer comprised of a fiber network in a matrix material and the other component is a hard rigid layer composed of one or more hard rigid materials.
  • the particular structure of the composite may vary widely.
  • the two layers may abut or may be separated by a void space.
  • the composite may be in the form of a multiple composite which includes two or more fibrous layers and two or more hard layers,or may include more that one fibrous layer and only one hard, rigid layer or, alternatively may include more than one hard rigid layer and only one fibrous layer, either abutting or separated by void spaces.
  • Various illustrative configurations of this invention are set forth in the figures.
  • Figure 1 shows one embodiment having three layers, a hard ceramic layer 1, a hard metal layer 2 and a fibrous composite layer 3.
  • ceramic layer 1 which is the layer first exposed to the threat functions to shatter or distorted the projectile.
  • Ceramic layer 1 abuts metal layer 2 and the abutting layers 1 and 2 are separated from fibrous layer 3 by void space 4.
  • Figure 2 is depicted an embodiment of this invention which consists of hard ceramic layer 1 having a metal or fibrous backing layer 5 which is separated from fibrous layer 3 by void space 4.
  • the hard ceramic layer 1 is the first layer exposed to the threat and functions to shatter or distort the projectile thereby increasing the effectiveness of fibrous layer 3.
  • Figure 3 depicts a representative embodiment of the invention in which metal layer 2 is the layer first exposed to the threat. Layer 2 is separated from ceramic layer 1 which abuts fibrous layer 3 by void space 4.
  • Figure 4 depicts a multilayer/multivoid space embodiment of this invention.
  • the embodiment of Figure 4 has a metal layer 2 initially exposed to the threat, separated from ceramic layer 1 which abuts backing layer 5 by void space 4.
  • the abutting ceramic layer 1 and backing layer 5 are separated from fibrous layer 3 by void space 4'.
  • Figure 5 is depicted an embodiment of the invention having multiple metal layer composed of layers 2 and 2' which are directly exposed the the thereat.
  • Layers 2 and 2* are fabricated of metals having differing hardness and are separated from fibrous layer 3 by void space 4.
  • Figure 6 depicts an embodiment which is composed of only two layers.
  • One layer is a ceramic layer 1 which is directly exposed to the threat and which abuts fibrous layer 3.
  • Figure 7 depicts an embodiment of the invention having a ceramic layer 1 with abutting backing layer 5 which is directly exposed to the threat.
  • Layer 1 is separated from metal layer 2 by void space 4 which, in turn, is separated from fibrous layer 3 by void space 4A
  • Figure 8 depicts an embodiment of the invention having three abutting layers. Ceramic layer 1, which is directly exposed to the threat abuts metal layer 2 which, in turn, abuts fibrous layer 3.
  • the composite comprises at least two hard rigid layers of varying hardness in addition to the essential fibrous layer.
  • the various layers are preferably arranged in order of decreasing hardness with respect to the ballistic threat, such as ceramic layer exposed to the threat followed by a metal layer and a fibrous layer.
  • the ballistic threat such as ceramic layer exposed to the threat followed by a metal layer and a fibrous layer.
  • the size and shape of the space may vary widely depending on various factors such as limitation to armor thickness, limitations in the construction of the armor, the perceived threat and the like.
  • Space width usually will vary from about 0.5 cm to about 30 cm, preferably from about 1 cm to about 20 cm, more preferably from about 1.5 cm to about 10 cm and most preferably from about 2.5 cm to about 7.5 cm.
  • the relative weight percents of fibrous layer(s) and rigid hard layer(s) in the composite may vary widely.
  • the amount of either fibrous layer(s) or hard rigid layer(s) may vary from about 20% to about 80% by weight of the composite.
  • the amount of fibrous layer(s) may vary from about 20 to about 80% by weight of the composite, and the amount of hard rigid layer(s) may vary from about 80 to about 20% by weight of the composite; and in the particularly preferred embodiments of the invention the amount of fibrous layer(s) may vary from about 20 to about 60% by weight of the composite and the amount of hard rigid layer(s) is from about 60 to about 40 based on the weight of the composite.
  • most preferred are those embodiments in which the amount of fibrous layer is from about 25 to about 50% by weight of the composite, and the amount of the hard rigid layer(s) is from about 75 to about 50% be weight of the composite.
  • the structure of fibrous layer(s) may vary widely.
  • the filaments in fibrous layer(s) may be arranged in networks having various configurations. For example, a plurality of filaments can be grouped together to form a twisted or untwisted yarn bundles in various alignment.
  • the filaments in each layer are aligned substantially parallel and unidirectionally in which the matrix material substantially coats the individual filaments of the filaments.
  • the filaments or yarn may be formed as a felt, knitted or woven (plain, basket, satin and cro feet weaves, ets.) into a network, fabricated into non-woven fabric, arranged in parallel array, layered, or formed into a fabric by any of a variety of conventional techniques.
  • filaments used in the fabrication of the fibrous layer(sO of the article of this invention may vary widely and can be metallic filaments, semi-metallic filaments, inorganic filaments and/or organic filaments.
  • Preferred filaments for use in the practice of this invention are those having a tenacity equal to or greater than about 10 g/d, a tensile modulus equal to or greater than about 150 g/d and an energy-in-break equal to or greater than about 8 joules/grams.
  • Particularly preferred filaments are those having a tenacity equal to or greater than about 20 g/d, a tensile modulus equal to or greater than about 500 g/d and energy-to-break equal to or greater than about 30 joules/grams.
  • filaments of choice have a tenacity equal to or greater than about 30 g/d, the tensile modulus is equal to or greater than about 1300 g/d and the energy-to-break is equal to or greater than about 40 joules/grams.
  • Filaments for use in fibrous layer(s) may be metallic, semi-metallic, inorganic and/or organic.
  • useful inorganic filaments are those formal from S-glass, silicon carbide, asbestos, basalt, E-glass, alumina, alumina-silicate, quartz, zirconia-silica, ceramic filaments, boron filaments, carbon filaments, and the like.
  • useful metallic or semi-metallic filaments are those composed of boron, aluminum, steel and titanium.
  • useful organic filaments are those composed of aramids (aromatic polya idesO, poly(m-xylylene adipamide) , poly(p-xylylene sebacamide), poly(2,2,2- trimethylbexamethylene terephthalamide) , poly(piperazine sebacamide), poly(metaphenylene isophthalamide) (Nomex) and ⁇ oly( ⁇ -phenylene terephthalamide) (Kevlar) and aliphatic and cycloaliphatic polyamides, such as the copolyamide of 30% hexamethylene diammonium isophthalate and 70% hexamethylene diammonium adipate, the copolyamide of up to 30% bis-(-amidoclyclohexyl) methylene, terephthalic acid and caprolactam, polyhexamethylene adipamide (nylon 66), poly(butyrolactam) (nylon 4), poly(9-aminonoanoic acid
  • R., and R- are the same or different and are hydrogen, hydroxy, halogen, alkylcarbonyl, carboxy, alkoxycarbonyl, heterocycle or alkyl or arly either unsubstituted or substituted with one or more substituents selected from the group consisting of alkoxy, cyano, hydroxy, alkyl and aryl.
  • polymers of ⁇ & -unsaturated monomers are polymers including polystyrene, polyethylene, polypropylene, polyd- octadecene) , polyisobutylene, poly(l-pentene) , poly(2- methylstyrene) , poly(4-methylstyrene), poly(l-hexene) , poly(l-pentene), ⁇ oly(4- methoxystyrene) , poly(5- methyl-1-hexene), poly(4-methylpentene), poly(1-butene) , poly(3-methyl-l-butene) , poly(3-phenyl-l-propene) , polyvinyl chloride, polybutylene, polyacrylonitrile, pol (methyl pentene-1), poly(vinyl alcohol), poly(vinylacetate) , poly ⁇ vinyl butyral), poly(vinyl chloride),
  • all or a portion of the fibrous layer(s) include a filament network, which may include a high molecular weight polyethylene filament, a high molecular weight polypropylene filament, an aramid filament, a high molecular weight polyvinyl alcohol filament, a high molecular weight polyacrylonitrile filament or mixtures thereof.
  • a filament network which may include a high molecular weight polyethylene filament, a high molecular weight polypropylene filament, an aramid filament, a high molecular weight polyvinyl alcohol filament, a high molecular weight polyacrylonitrile filament or mixtures thereof.
  • USP 4,457,985 generally discusses such high molecular weight polyethylene and polypropylene filaments, and the disclosure of this patent is hereby incorporated by reference to the extent that it is not inconsistent herewith.
  • suitable filaments are those of molecular weight of at least 150,00, preferably at least one million and more preferably between two million and five million.
  • Such extended chain polyethylene (ECPE) filaments may be grown in solution as described in U.S. Patent No. 4,137,394 to Meihuzen et al., or U.S. Patent No. 4,356,138 of Kavesh et al., issued October 26, 1982, or a filament spun from a solution to form a gel structure, as described in German Off. 3,004,699 and GB 2051667, and especially as described in Application Serial No. 572,607 of Kavesh et al. filed January 20, 1984 (see EPA 64,167, published Nov. 10,
  • polythylene shall mean a predominantly linear polyethylene material that may contain minor amounts of chain branching or monomers not exceeding 5 modifying units per 100 main chain carbon atoms, and that may also contain admixed therewith not more than about 50 wt% of one or more polymeric additives such as alkene-1-polymers, in particular low density polyethylene, polypropylene or polybutylene, copolymers containing mono-olefins as primary monomers, oxidized polyolefins, graft polyolefin copolymers and polyoxy ethylenes, or low molecular weight additives such as anti-oxidants, lubricants, ultra-violet screening agents, colorants and the like which are commonly incorporated by reference.
  • polymeric additives such as alkene-1-polymers, in particular low density polyethylene, polypropylene or polybutylene, copolymers containing mono-olefins as primary monomers, oxidized polyolefins, graft polyolef
  • the tenacity of the filaments should be at least 15 grams/denier, preferably at least 20 grams/denier, more preferably at least 25 grams/denier and most preferably at least 30 grams/denier.
  • the tensile modulus of the filaments is at least 300 grams/denier, preferably at least 500 grams/denier and more preferably at least 1,000 grams/denier and more preferably at least 1,200 grams/denier.
  • polypropylene filaments of molecular weight at least 200,000, preferably at least one million and more preferably at least two million may be used.
  • Such high molecular weight polypropylene may be formed into reasonably well oriented filaments by the techniques prescribed in the various references referred to above, and especially by the technique of U.S. Serial No. 572,607, filed January 20, 1984, of Kavesh et al. and commonly assigned. Since polypropylene is a much less crystalline material than polyethylene and contains pendant methyl groups, tenacity values achievable with polypropylene are generally substantially lower than the corresponding values for polyethylene.
  • a suitable tenacity is at least 8 grams/denier, with a preferred tenacity being at least 11 grams/denier.
  • the tensile modulus for polypropylene is at least 160 grams/denier, preferably at least 200 grams/denier.
  • PV-OH filaments having high tensile modulus are described in USP 4,440,711 to Y. Kwon, et al., which is hereby incorporated by reference to the extent it is not inconsistent herewith.
  • PV-OH filament of molecular weight of at least about 200,000.
  • Particularly useful PV-OH filament should have a modulus of at least about 300 g/denier, a tenacity of at least about 7 g/denier (preferably at least about 10 g/denier, more preferably at about 14 g/denier, and most preferably at least about 17 g/denier), and an energy to break of at least about 8 joules/g.
  • PV-OH filaments having a weight average molecular weight of at least about 200,000, a tenacity of at least about 10 g/denier, a modulus of at least about 300 g/denier, and an energy to break of about 8 joules/g are more useful in producing a ballistic resistant article.
  • PV-OH filament having such properties can be produced, for example, by the process disclosed in U.S. Patent No. 4,599,267.
  • PAN filament of molecular weight of at least about 400,000.
  • Particularly useful PAN filament should have a tenacity of at least about 10 g/denier and an energy to break of at least about 8 joule/g.
  • PAN filament having a molecular weight of at least about 400,000, a tenacity of at least about 15 to about 20 g/denier and an energy to break of at least about 8 joule/g is most useful in producing ballistic resistant articles; and such filaments are disclosed, for example, in USP No. 4,535,027.
  • aramid filaments suitable aramide filaments formed principally from aromatic polyamide are described in US. Patent No. 3,671,542, which is hereby incorporated by reference.
  • Preferred aramid filament will have a tenacity of at least about g/d, a tensile modulus of at least about 400 g/d and an energy-to-break at least about 8 joules/gram, and particularly preferred aramid filaments will have a tenacity of at least about 20 g/d, a modulus of at least about 480 g/d and an energy-to-break of at least about 20 joules/gram.
  • aramid filaments will have a tenacity of at least about 20 g/denier, a modulus of at least about 900 g/denier and an energy-to-break of at least about 30 joules/gram.
  • poly(phenylenediamine terephalamide) filaments produced commercially by Dupont Corporation under the trade mane of Kevlar R 29 and 49 and having moderately high moduli and tenacity values are particularly useful in forming ballistic resistant composites.
  • Kevlar 29 has 500 g/denier and 22 g/denier
  • Kevlar 49 has 1000 g/denier and 22 g/denier as values of modulus and tenacity, respectively
  • poly(metaphenylene isophthalamide) filaments produced commercially by Dupont under the tradename Nomex .
  • the filaments are arranged in a network which can have various configurations.
  • a plurality of filaments can be grouped together to form a twisted or untwisted yarn.
  • the filaments or yarn may be formed as a felt, knitted or woven (plain, basket, sating and crow feet weaves, etc.) into a network. or formed into a network by any of a variety of conventional techniques.
  • the filaments are untwisted mono- ilament yarn wherein the filaments are parallel, unidirectionally aligned.
  • the filaments may also be formed into nonwoven cloth layers be conventional techniques.
  • the filaments are most preferably dispersed in a continuous phase of a matrix material which preferably substantially coats each filament contained in the bundle of filament.
  • the manner in which the filaments are dispersed may vary widely.
  • the filaments may be aligned in a substantially parallel, unidirectional fashion, or filaments may be aligned in a multidirectional fashion with filaments may be aligned in a multidirectional fashion with filaments at varying angles with each other.
  • filaments in each layer are aligned in a substantially parallel, unidirectional fashion such as in a prepare, pultruded sheet and the like.
  • the matrix material employed may vary widely and may be a metallic, semi-metallic material, an organic material and/or an inorganic material.
  • the matrix material may be flexible (low modulus) or rigid (high modulus).
  • useful high modulus or rigid matrix materials are thermoplastic resins such as polycarbonates, polyether, ether ketones, polyarylenesulfides, polyarylene oxides, polyestercarbonates, polyesterimides, and polyimides, thermosetting resins such as epoxy resins, phenolic resins, modified phenolic resins, allylic resins, alkyd resins, unsaturated polyesters, aromatic vinylesters as for example the condensation produced of bisphenol A and methacrylic acid diluted in a vinyl aromatic monomer (e.g.
  • the matrix material is a low modulus elastomeric material.
  • elastomeric materials and formulations may be utilized in the preferred embodiments of this invention.
  • Suitable elastomeric materials for use in the formation of the matrix are those which have their structures, properties, and formulations together with crosslinking procedures summarized in the Encyclopedia of Polymer Science, Volume 5 in the section Elastomers-Synthetic (John Wiley & Sons Inc., 1964).
  • any of the following elastomeric materials may be employed: polybutadiene, polyisoprene, natural rubber, ethylene-propylene copolymers, ethylene-propylene-diene, terpolymers, polysulfide polymers, polyurethane elastomers, chlorosulfonated polyethylene, polychloroprene, plasticized polyvinylchloride using dioctyl phthate or other plasticers well known in the art, butadiene acrylonitrile elastomers, poly(isobutylene-co-iso ⁇ rene) , polyacrylates, polyesters, polyethers, fluoroelastomers, silicone elastomers, thermoplastic elastomers, copolymers of ethylene.
  • Particularly useful elastomer are block copolymers of conjugated dienes and vinyl aromatic monomers. Butadiene and isoprene are preferred conjugated dien elastomers. Styrene, vinyl toluene and t-butyl styrene are preferred conjugated aromatic monomers. Block copolymers incorporating polyisoprene may be hydrogenated to produce thermoplastic elastomers having saturated hydrocarbon elastomer segments.
  • A is a block from a polyvinyl aromatic monomer
  • B is a block from a conjugated dien elastomer.
  • Many of these polymers are produced commercially by the Shell Chemical Co. and described in the bulletin "Kraton Thermoplastic Rubber", SC-68-81.
  • the elastomeric matrix material consists essentially of at least one of the aobve-mentioned elastomers.
  • the low modulus elastomeric matrices may also include fillers such as carbon black, silica, glass microballons, and the like up to an amount preferably not to exceed about 50% by volume of the elastomeric material, preferably not to exceed about 40% by weight, and may be extended with oils, may include fire retardants such as halogenated parafins, and vulcanized by sulfur, peroxide, metal oxide, or radiation cure systems using methods well known to rubber technologists.
  • Blends of different elastomeric materials may be used together or one or more elastomer materials may be blended with one or more thermoplastics.
  • High density, low density, and linear low density polethylene may be cross-linked to obtain a matrix material of appropriate properties, either alone or as blends.
  • the modulus of the elastomeric matrix material should not exceed about 6,000 psi (41,300 kPa) , preferably is less than about 5,000 psi (34,500 kPa) , more preferably is less than 1000 psi (6900 kPa) and most preferably is less than 500 psi (3450 kPa) .
  • the matrix material is a low modulus, elastomeric material.
  • the low modulus elastomeric material has a tensile modulus, measured at about 23°C, of less than about 6,000 psi (41,300 kPa) .
  • the tensile modulus of the elastomeric material is less than about 5,000 psi (34,500 kPa), more preferably, is less than 1,000 psi (6900 kPa) and most preferably is less than about 500 psi (3,450 kPa) to provide even more improved performance.
  • the glass transition temperature (Tg) of the elastomeric material (as evidenced by a sudden drop in the ductility and elasticity of the material is less than about 0°C.
  • Tg of the elastomeric material is less than about -40°C, and more preferably is less than about -50°C.
  • the elastomeric material also has an elongation to break of at least about 50%.
  • the elongation to break of the elastomeric material is at least about 100%, and more preferably is at least about 300%.
  • the proportions of matrix to filament in the fibrous layer(s) is not critical and may vary widely depending on a number of factors including, whether the matrix material has any ballistic-resistant properties of its own (which is generally not the case) and upon the rigidity, shape, heat resistance, wear resistance, flammability resistance and other properties desired for the composite article.
  • the proportion of matrix to filament in the composite may vary from relatively small amounts where the amount of matrix is about 10% by volume of the filaments to relatively large amounts where the amount of matrix is up to about 90% by volume of the filaments.
  • matrix amounts of from about 15 to about 80% by volume are employed. All volume percents are based on the total volume of the composite.
  • ballistic-resistant articles of the present invention contain a relatively minor proportion of the matrix (e.g., about 10 to about 30% by volume of composite), since the ballistic-resistant properties are almost entirely attributable to the filament, and in the particularly preferred embodiments of the invention, the proportion of the matrix in the composite is from about 10 to about 30% by weight of filaments.
  • the fibrous layer(s) can be fabricated using a number of procedures.
  • the layers are formed by molding the combination of the matrix material and filaments in the desired configurations and amounts by subjecting them to heat and pressure.
  • the filaments may be premolded by subjecting them to heat and pressure.
  • molding temperatures range from about 20 to about 150°C, preferably from about 80 to about 145°C, more preferably from about 100 to about 135°C, and more preferably from about 110 to about 130 °C.
  • the pressure may range from about 10 psi (69 kpa) to about 10,000 psi (69,000 kpa) .
  • 100°C for a period of time less than about 1.0 min. may be used simply to cause adjacent filaments to stick together.
  • Pressures from about 100 psi (6900 kpa) to about 10,000 psi (69,000 kpa), when coupled with temperatures in the range of about 100 to about 155°c for a time of between about 1 to about 5 min. may cause the filaments to deform and to compress together (generally in a film-like shape).
  • Pressures from about 100 psi (690 kpa) to aboutl0,000 psi (69,000 kPa) when coupled with temperatures in the range of about 150 to about 155°C for a time of between 1 to about 5 min., may cause the film to become translucent or transparent.
  • the upper limitation of the temperature range would be about 10 to about 20°C higher than for ECPE filament.
  • the filaments are precoated with the desired matrix material prior to being arranged in a network and mold as described above.
  • the coating may be applied to the filaments in a variety of ways and any method known to those of skill in the art for coating filaments may be used
  • one method is to apply the matrix material to the stretched high modulus filaments either as a liquid, a sticky solid or particles in suspension, or as a fluidized bed.
  • the matrix material may be applied as a solution or emulsion in a suitable solvent which does not adversely affect the properties of the filament at the temperature of application.
  • any liquid capable of dissolving or dispersing the matrix material may be used.
  • preferred groups of solvents include water, paraffin oils, ketones, alcoholic, aromatic solvents or hydrocarbon solvents or mixtures thereof, with illustrative specific solvents including paraffin oil. xylene, toluene and octane.
  • the techniques used to dissolve or disperse the matrix in the solvents will be those conventionally used for the coating of similar elastomeric materials on a variety of substrates.
  • Other techniques for applying the coating to the filaments may be used, including coating of the high modulus precursor (gel filament) before the high temperature stretching operation, either before or after removal of the solvent from the filament. The filament may then be stretched at elevated temperatures to produce the coated filaments.
  • the gel filament may be passed through a solution of the appropriate matrix material, as for example an elastomeric material dissolved in paraffin oil, or an aromatic or aliphatic solvent, under conditions to attain the desired coating. Crystallization of the polymer in the gel filament may or may not have taken place before the filament passes into the cooling solution. Alternatively, the filament may be extruded into a fluidized bed of the appropriate matrix material in powder form.
  • the appropriate matrix material as for example an elastomeric material dissolved in paraffin oil, or an aromatic or aliphatic solvent
  • the proportion of coating on the coated filaments or fabrics may vary from relatively small amount (e.g. 1% by weight of filaments) to relative large amounts (e.g. 150% by weight of filaments), depending upon whether the coating material has any impact or ballistic-resistant properties of its own (which is generally not the case) and upon the rigidity, shape, heat resistance, wear resistance, flam ability resistance and other properties desired for the complex composite article.
  • ballistic-resistant articles of the present invention containing coated filaments should have a relatively minor proportion of coating (e.g., about 10 to a bout 30 percent by volume of filaments) , since the ballistic-resistant properties are almost entirely attributable to the filament. Nevertheless, coated filaments with higher coating contents may be employed. Generally, however, when the coating constitutes greater than about 60% (by volume of filament), the coated filament is consolidated with similar coated filaments to form a simple composite without the use of additional matrix material.
  • the coating may be applied to a precursor material of the final filament.
  • the desired and preferred tenacity, modulus and other properties of the filament should be judged by continuing the manipulative process on the filament precursor in a manner corresponding to that employed on the coated filament precursor.
  • the coating is applied to the xerogel filament described in U.S. Application Serial No.
  • each filament be substantially coated with the matrix material for the production of the fibrous layer(s) having improved impact protection and/or having maximum ballistic resistance.
  • a filament is substantially coated by using any of the coating processes described above or can be substantially coated by employing any other process capable of producing a filament coated essentially to the same degree as a filament coated by the processes described heretofore (e.g., by employing known high pressure molding techniques) .
  • the filaments and networks produced therefrom are formed into the fibrous layer(s) which is a "simple composites".
  • the term, "simple composite”, as used herein is intended to mean composites made up of one or more layers, each of the layers containing filaments as described above with a single major matrix material, which material may include minor proportions of other materials such as fillers, lubricants or the like as noted heretofore.
  • the proportion of elastomeric matrix material to filament is variable for the simple composites, with matrix material amounts of form about 5% to about 150
  • Vol % by volume of the filament, representing the broad general range.
  • composites having a relatively high filament content such as composites having only about 10 to about 50 Vol % matrix material, by volume of the composite, and more preferably from about 10 to about 30 Vol % matrix material by volume of the composite.
  • the filament network occupies different proportions of the total volume of the simple composite.
  • the filament network comprises at least about 30 volume percent of the simple composite.
  • the filament network comprises at least about 50 volume percent, more preferably about 70 volume percent, and most preferably at least about 75 volume percent, with the matrix occupying the remaining volume.
  • a particularly effective technique for preparing the fibrous layer(s) for use in a preferred composite of this invention comprised of substantially parallel, unidirectionally aligned filaments includes the steps of pulling a filament or bundles of filaments through a bath containing a solution of a matrix material preferable an elastomeric matrix material, and circumferentially winding this filament into a single sheet-like layer around and along a bundly of filaments the length of a suitable form, such as a cylinder. The solvent is then evaporated leaving a sheet-like layer of filaments embedded in a matrix that can be removed from he cylindrical form.
  • a plurality of filaments or bundles of filaments can be simultaneously pulled through the bath containing a solution or dispersion of a matrix material and laid down in closely positioned, substantially parallel relation to one another on a suitable surface. Evaporation of the solvent leaves a sheet-like layer comprised of filaments which are coated with the matrix material and which are substantially parallel and aligned along a common filament direction.
  • the sheet is suitable for subsequent processing such as laminating to another sheet to form composites containing more than one layer.
  • a yarn-type simple composite can be produced by pulling a group of filament bundles through a dispersion or solution of the matrix material to substantially coat each of the individual filaments, and then evaporating the solvent to form the coated yarn.
  • the yarn can then, for example, be employed to form fabrics, which in turn, can be used to form more complex composite structures.
  • the coated yarn can also be processed into a simple composite by employing conventional filament winding techniques; for example, the simple composite can have coated yarn formed into overlapping filament layers.
  • the number of layers included in the fibrous layer(s) of may vary widely depending on the uses of this composite.
  • the number of layers would depend on a number of factors including the degree of ballistic protection desired and other factors known to those of skill in the ballistic protection art. In general for this application, the greater the degree of protection desired, the greater the number of layers included in the fibrous layer(s) for a given weight of the article. Conversely, the lessor the degree of ballistic protection required, the lessor the number of layers required for a given weight of the article. It is convenient to characterize the geometries of the fibrous layer(s) by the geometries of the filaments and then to indicate that the matrix material may occupy part or all of- the void space left by the network of filaments.
  • One such suitable arrangement is a plurality of layers or laminates in which the coated filaments are arranged in a sheet-like array and aligned parallel to one another along a common filament direction. Successive layers of such coated. undirectional filaments can be rotated with respect to the previous layer.
  • An example of such laminate structures are composites with the second, third, fourth and fifth layers rotated +45°, -45°, 90° and 0°, with respect to the first layer, but not necessarily in that order.
  • Other examples include fibrous layer(s) composed of layers of coated, undirectional filaments in which adjacent layers are oriented 0 /90 with respect to their common filament direction.
  • One technique for forming fibrous layer(s) having more than one layer includes the steps of arranging coated filaments into a desired network structure, and then consolidating and heat setting the overall structure to cause the coating material to flow and occupy the remaining void spaces, thus producing a continuous matrice.
  • Another technique is to arrange layers or other structures of coated or uncoated filament adjacent to and between various forms, e.g. films, of the matrix material and then to consolidate and heat set the overall structure.
  • the matrix can be caused to stick or flow without completely melting. In general, if the matrix material is caused to melt, relatively little pressure is required to form the composite; while if the matrix material is only hated to a sticking point, generally more pressure is required.
  • the complex composite of the invention includes at least one rigid layer which is preferably comprised of an impact resistant material.
  • an impact resistant material is steel plates, composite armor plates, ceramic reinforced metallic composites, ceramic plates, concrete, and high strength filament composites
  • the rigid impact resistant layer is one which is ballistically effective, such as ceramic plates or ceramic reinforced metal composites.
  • a desirable embodiment of our invention is the use of a rigid impact resistant layer which will at least partially deform the initial impact surface of the projectile or cause the projectile to shatter such as a layer formed of a ceramic as for example aluminum oxide, boron carbide, silicon carbide, titanium borides, beryllium oxide and the like and/or a layer formed from a metal as for example stainless steel, copper, aluminum, titanium, and the like (see Laible, supra. Chapters 5-7 for additional useful rigid layers) .
  • the complex composites include at least one rigid layer comprised of a ceramic material such as aluminum oxide, silicon carbide, boron carbide and titanium diboride.
  • the various ceramic materials can be made into different grades having varying physical properties as desired such as purity, density, hardness, strength, modulus and the like by manipulation of raw materials and manufacturing processes.
  • the shape of the ceramic material can vary widely.
  • the ceramic layer is formed from flat ceramic tiles of various sizes.
  • Ceramic materials for use in this invention can be made by various processes know to those of skill in the ceramic art.
  • a ceramic powder is prepared from the raw material by milling and screening.
  • the resulting powder is processed further to achieve better processibility in the subsequent processes by specific treatments and addition of blending additives know in the art.
  • the resulting, processed powder is then cold-formed into the desired shape by pressing or molding, afterwhich the shaped powder is densified by sintering or hot pressing at elevated temperature. In some cases, the densified product is finished by machining with diamond or other means.
  • the composite will comprise at least three layers, one of which is composed of a fibrous layer such as high molecular weight polyethylene in a polymer matrix, and a ceramic layer or a glass or glass reinforced layer.
  • these composites also include a metal layer, such as a layer composed of steel.
  • the metal layer is perforated. The perforations cause the projectile to tilt, rotate and preferably break up into smaller pieces which can be stopped by the fibrous layer more effectively. Tilting or rotating the projectile helps improve ballistic performance because the projectile will hit the fibrous layer on its side rather than by its nose enabling the composite to receive the impact over a greater area.
  • the degree of perforation may vary widely, and is preferably is at least about 20 Vol% based on the total volume of the metal layer is more preferably from about 20 Vol% to about 70 vol% on the aforementioned basis and is most preferably from about 30 to about 60 Vol%.
  • the spacing and size of the perforation in the metal layer may vary widely. The larger the size of threat projectile, the larger the spacing and size of perforation in the metal layer is suitable for greater impact on the mass efficiency of the composite.
  • An example of a perforated steel plate is shown in Fig. 9.
  • the size of the perforation may vary widely. In general, the size depends on the particular ballistic threat being countered, and is usually of such a size as to allow tilting and/or rotation of the projectile.
  • the shape of the perforations may also vary widely. Such perforation may be circular, oblong, square, rectangular and the like. In the preferred embodiments of this invention, the perforations are oblong.
  • the composites of this invention are useful for the fabrication of ballistic resistant article such as landing craft hull and other type of armor, and helmets.
  • the protective power of a structure may be expressed in term of its mass efficiency (E ).
  • the mass efficiency of the composite of this invention exhibits superior mass efficiency of at least about 2.5.
  • the mass efficiency is at least about 3 and in the particularly preferred embodiments is at least about 3.5.
  • most preferred are those embodiments in which the mass efficiency is at least about 4.0.
  • a composite armor has the geometrical shape of a shell or plate.
  • the specific weight of the shells and plates can be expressed in terms of the areal density (AD).
  • the areal density corresponds to the weight per unit area of the structure.
  • the filament areal density of composites is another useful weight characteristic. This term corresponds to the weight of the filament reinforcement per unit area of the composite (AD).
  • a ballistic panel was prepared by molding a plurality of sheets comprised of Spectra R -900 uni-directional high strength extended chain polyethylene (ECPE) yarn impregnated with a Kraton D1107 thermoplastic elastomer matrix (a polystyrene-polyisoprene-polystrene-block co- polymer having 14 wt% styrene and a product of Shell Chemical).
  • the yarn had a tenacity of 30 g/denier, a modulus of 1,200 g/denier and energy-to-break of 55 joules/g.
  • the elongation to break of the yarn was 4%, denier was 1,200 and individual filament denier was 10, or 118 filaments per yarn end. Each filament has a diameter of 0.0014" (0.0036 cm).
  • a total of 360 layers were used, and were stacked or laminated together with a 0°/90° yarn orientation with each layer having filament length perpendicular to the filament length of the adjacent layers
  • the laminated composite panel was then molded between two parallel plates of 24" (61 cm) X 24" (61 cm) square at a temperature of 124°C and a pressure of 420 psi (2900 k Pa) for a period of 40 minutes. After molding, the panel was allowed to cool to room temperature over a 30 minute period. The molded panel measured 24" (61 cm) X 24" (61 cm) X 0.93" (2.36 cm), and had an areal density of 24 kg/m .
  • a complex ballistic panel was fabricated using titanium diboride tile [4" (10.1 cm) X 4" (10.1 cm)] x 0.858" (2.18 cm) having areal density of 97 kg/m 2 (Ceralloy 225, Ceradyne, Inc.), and the fibrous panel containing the Spectra R polyethylene fiber.
  • the titanium diboride tile abutted the fibrous panel.
  • Total areal density for the complex ballistic article was 121 Kg/m 2 .
  • the complex ballistic article was tested with a designated projectile which required approximately 400 kq/m of roll-hardened armor plate (RHA) to defeat.
  • the impact velocity of the projectile was 3,069 ft/sec (935 m/sec) .
  • the projectile penetrated the titanium diboride tile but only partially penetrated the fibrous composite formed from the S ⁇ ectra R fiber, and 12 kg/m 2 of the Spectra R composite remained unpenetrated.
  • the Em of the article was approximately 3.3.
  • Example I Using the procedure of Example I, a complex ballistic article having the structural features set forth in Table I was fabricated. The features are listed in the order in which they are exposed to the projectile during testing.
  • Total areal density of the article was 113 Kq/m .
  • Example II Using the procedure of Example I, the complex article was struck by the projectile at an impact velocity of 3,125 ft/s_e_c_ (953 m/sec) . The projectile penetrated the aluminum oxide and steel layers but
  • Example II Using the procedure of Example I, a complex ballistic article having the structural features set forth in Table II was fabricated. The features are listed in the order in which they are exposed to the projectile during testing.
  • Total areal density of the composite was 122 Kq/m .
  • Example II Using the procedure of Example I, the complex ballistic article was struck by the projectile at an impact velocity of 3,058 ft/secconnect (932 m/s ⁇ ec). The projectile penetrated the aluminum oxide tile and glass
  • Spectra composite was unpenetrated.
  • the E of the complex composite was approximately 3.3.
  • Example III Using the procedure of Example I, a complex ballistic article having the structural features set forth in Table III was fabricated. The features are listed the in order in which they are exposed to the projectile during testing. TABLE III
  • Example II Using the procedure of Example I, the complex article was struck by the projectile at an impact velocity of
  • Example IV Using the procedure of Example I, a complex ballistic artidle having the structural features set forth in the following Table IV was fabricated. The features are listed in the order in which they are exposed to the projectile during testing. TABLE IV
  • the total areal density of the complex composite was 123 Kq/m 2 .
  • Example II Using the procedure of Example I, the complex article was struck by the projectile at an impact velocity of

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)

Abstract

Article composite antiballistique constitué d'au moins une couche rigide et dure (1, 2) et au moins une couche fibreuse (3) et une couche vide (4) entre ladite couche rigide et la couche fibreuse, les pourcentages du poids relatif de ladite couche dure et rigide, et ladite couche fibreuse, et le positionnement desdites couches étant tels que ledit article démontre une efficacité de masse égale ou supérieure à environ 2,5.
EP19900911148 1989-06-30 1990-06-13 Article composite antiballistique Withdrawn EP0479902A1 (fr)

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WO1991000490A1 (fr) 1991-01-10
JPH04506325A (ja) 1992-11-05
CA2059271A1 (fr) 1990-12-31

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