GB2355469A - Non woven impact resistant material - Google Patents

Non woven impact resistant material Download PDF

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Publication number
GB2355469A
GB2355469A GB0025760A GB0025760A GB2355469A GB 2355469 A GB2355469 A GB 2355469A GB 0025760 A GB0025760 A GB 0025760A GB 0025760 A GB0025760 A GB 0025760A GB 2355469 A GB2355469 A GB 2355469A
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GB
United Kingdom
Prior art keywords
needlefelt
impact resistant
resistant material
resin
material according
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Withdrawn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
GB0025760A
Other versions
GB0025760D0 (en
Inventor
Clive Chirwa
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.)
ANDREW TEXTILE IND Ltd
BOLTON INST HIGHER EDUCATION
Original Assignee
ANDREW TEXTILE IND Ltd
BOLTON INST HIGHER EDUCATION
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 ANDREW TEXTILE IND Ltd, BOLTON INST HIGHER EDUCATION filed Critical ANDREW TEXTILE IND Ltd
Publication of GB0025760D0 publication Critical patent/GB0025760D0/en
Publication of GB2355469A publication Critical patent/GB2355469A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness

Abstract

A nonwoven impact resistant material 10 (e.g. for use as armour, building applications, piping, furniture, vehicles) comprises resin impregnated needle felt comprised of at least one layer of batt 11, 12. The material may further comprise a layer of scrim 13 between two layers of batt 11, 12 needled together through the scrim 13 to produce a three dimensional needle felt. The fibres of the needle felt and scrim may be chosen from para-aramid, PEEK, p-phenylene 2, PBO glass, carbon fibres. The resulting needle felt is fully or partially encapsulated in a synthetic resin 15, 16 (e.g. Araldite (RTM) or Valiton (RTM)). The material may further be laminated with other materials.

Description

2355469 IMPACT RESISTANT MATERIAL This invention relates to impact
resistant materials.
Impact resistant materials have numerous potential uses in stationary and mobile structures, in load bearing applications and in providing 6 protective claddings and body shell structures, including personal and vehicle armour for military use.
Materials used in impact resistant, materials include metals, which include laminates and specially hardened steels, seeking to resist an impact by presenting an initial extremely hard surface to the initial impact, or absorbing the impact by sheer hardness of material, as was the case with early naval and tank armour. Other materials used may generally be classified as composites involving one or more synthetic materials, in combination with other materials such as ceramics used in armour, or a mass of rounded pebbles in a polyurethane matrix forming a panel for absorption of high velocity projectiles.
Prior reinforced plastics composites using glass, or carbon fibres or the like collapse catastrophically in a shatter mode after an impact has exceeded their yield strength. Many impact resistant materials, including metals give rise to "spalling", that is the shedding of particles or slivers of material from the face of the material opposite the impact site. This again provides a significant hazard, and in military technology, gives rise to crew casualties in armoured vehicles even when the projectile has not penetrated the armour.
Catastrophic collapse of reinforced plastics components may, apart from the injury hazard represented by the shards themselves, cause the release of health damaging fibres or powders into the environment following 6 an impact, due to collision for example and these may represent a hazard not only to accident victims but to rescue and salvage personnel.
Accordingly, it is an object of the invention to provide an impact resistant material which has improved shatter and energy absorbing properties when their yield strength is exceeded, and which are relatively economical to manufacture.
According to the invention an impact resistant material comprises a needlefelt non-woven fabric partially or preferably fully impregnated with a synthetic resin.
Preferably the resin fully impregnates and encapsulates the needlefelt and preferably forms a coherent layer covering each face surface of the needlefelt.
In a preferred embodiment, the needlefelt comprises one or more layers of non woven fibrous batt optionally with a non woven scrim. Batt layers may be assembled on either side of the scrim and then needled to produce a three dimensional needlefelt composed of synthetic fibres.
The fibres of the needlefelt, and possibly of the scrim can be any desired natural or synthetic fibre. For example polyamide (nylon), para- aramid (KEVLAR), meta-aramid--(NOMEX) polyester, PEEK, PBO (p (IZTM) phyeneylene-2, 6-benzobisoxazole) (eg ZYLO N,),, glass, carbon or bicomponent fibres may be used in the batts and/or- the scrim.
The resin used in the manufacture of the composite may be any resin, eg a thermoplastic resin or a thermosetting resin such as an epoxy resin.
ARALDITE (Trade Mark) or VALITON (Trade Mark) resins may be used.
The method of manufacture may comprise the steps of forming a three-dimensional needlefelt by placing two non-woven batt layers on opposite sides of a scrim, needling the batts to produce a needlefelt, and fully or partially impregnating the needlefelt with a plastic resin.
The impregnation of the needlefelt may be similar to the process of "potting" where a fibrous body is fully contained within a cast resin body, with a shell of resin encapsulating the body.
A preferred embodiment of impact resistant material will now be described with reference to the accompanying drawing, which is a cross-section of a sample of a material according to the invention.
An impact resistant-material according to the invention comprises a needlefelt 10 formed as a three dimension needlefelt synthetic fibre, by providing two batts 11, 12 of non-woven e.g. polyester fibre separated by a woven or non-woven scrim 13 of the same or different material. The needlefeft 10 is fully impregnated and encapsulated by a synthetic resin 14 which fully penetrates into the voids of the needlefelt 10 and by being provided slightly in excess forms an- encapsulating layer 15, 16 on each face of the needlefelt 10 which is substantially without fibrous inclusions. The resin used is IARALDITE LY 6082 (Trade Mark) in conjunction with a hardener.
For tests carried out according to BS EN 150 178:1997, nine samples were prepared, based on three different thicknesses of needlefelts and three different resins:
NF1 thickness = 3.6mm NF2 thickness = 4.6mm NF3 thickness = 8.6mm A sample of each needlefelt was impregnated with one of three resin systems:
System A resin = ARALDITE LY 5082, hardener HY 5083 System B resin = ARALDITE LY 5082, hardener HY 5084 System D resin = ARALDITE LY 556, hardener = HY 2962 The samples were impacted at a test speed of 3-7mps using a gauge length of 60mm., and a load v stroke graph with appropriate values of extension was obtained.
A total of 240 tests were conducted and typical average results are given in the table below.
MATERIAL STRESS AT YIELD STRES5 AT MAX LQA-D- NF1, Resin A 76.34 82.73 NF1, Resin B 85.83 88.29 NF1, Resin D 61.48 54.52 NF2, Resin A 51.82 66.70 NF2, Resin B 70.85 76.15 NF2, Resin D 68.50 70.53 NF3, Resin A 75.90 81.93 NF3, Resin B 46.98 47.34 NF3, Resin D 60.94 61.07 6 Each value is the mean of measured results obtained in four different directional axes.
The fibres of the needlefelt and of the scrim may be selected from polyamide, polyester, meta-aramid (NOMEZ or CONEX (Tms)), para-aramid (KEVLAR or TECHNORA) (Tms), polyester-etherketone (PEEK), poly (p phenylene 2, 6-Benzobisoxazole (PBO) glass, carbon or biocomponent fibres (sheath core or twisted). In an embodiment where the needle felt is only partially impregnated the outer reaches of the batt-may be impregnated leaving the inner layers and any scrim un-impregnated.
It has been found that the material according to the invention has improved characteristics, including many properties and yielding properties which are more similar to those of metals than of known plastics reinforced components. The material plastically deforms after its yield strength has been exceeded and thereafter the material strain hardens at a rate similar to metal. The material remains intact as cracks propagate, and does not fragment or shatter into small pieces as other components incorporating glass or carbon. This is particularly desirable where powdered or fibrous material in particular present a health hazard.
The material further posses a high impact energy absorption capability which is augmented by its ability to deform plastically, and it has a specific energy many times higher than that of metallic materials.
In some cases, the needlefelt and resin composite is used as a core material with other materials laminated as laminate skins on either or both faces of the impact resistant material. The further materials may include any one or more of:- polyamide; polyester; meta-aramid; (NOMEX or CONEX) para-aramid (KEVLAR or TECHNORA); polyetheretherketone (PEEK); poly (p-phenylene-2, 6-benzobisoxazole) (PBO); glass, carbon or bicomponent fibres, which laminate skins may be impregnated fully or partially as required.
The material is capable of being formed in any geometrical shape without losing its properties, so that it can be moulded to the shape of any desired component, due to its high durability and formability.
The impact resistant material of the invention may be used in a range of applications including buildings, offshore platforms, piping, furniture and in mobile structures including body shells and other parts for motor vehicles, railway rolling stock, aircraft, spacecraft and in armour for personnel and vehicles in military and police service.
Tests have been carried out with penetrations of various shapes, to simulate projectiles or collision with fixed structural members, and it has been found that spalling is minimal and that penetration does not shatter the material or cause fragments to fly off as the penetrator emerges.
It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiment which are described by way of example only.

Claims (11)

Claims
1. An impact resistant material comprising a needle felt non-woven fabric fully or partially impregnated with a synthetic resin.
2. An impact resistant material according to claim 1 wherein the resin 6 fully or partially impregnates and encapsulates the needlefelt and forms a coherent layer covering each face surface of the needlefelt.
3. An impact resistant material according to claim 2, wherein the needlefelt comprises at least one layer of non woven fibrous batt.
4. An impact resistant material according to claim 3, wherein a non woven scrim is placed between at least one pair of layers of th e non- woven fibrous batt.
5. An impact resistant material according to claim 4, wherein the batt layers are assembled on either side of the scrim and then needled together through the scrim to produce a three dimensional needlefelt of synthetic f ibres.
6. An impact resistant material according to any preceeding claim wherein the fibres of the needlefelt, comprise one or more of the following:
polyamide, para-aramid or metaramid, polyester, PEEK, PBO, glass, carbon or bicomponent fibre, are used in the batts and/or the scrim.
7. An impact resistant material according to any preceding claim wherein the resin is any one of a thermoplastic resin, or a thermosetting resin.
8. An impact resistant material according to any preceeding claim, wherein one or more further layers are laminated to the impregnated needlefelt.
9. An impact resistant material according to any preceeding claim wherein the needlefelt non-woven fabric is used as a core between laminate skins, said layers each comprising one or more of the following materials:
polyamide; polyester; meta-aramid; para-aramid; polyetheretherketone; poly (p-phenylene-2, 6-benzobisoxazole); glass, carbon, or bicomponent fibres.
10. A method of making an impact resistant material comprising forming a three-dimensional needlefelt by placing two non woven batt layers on opposite sides of a scrim to produce a needlefelt, and fully or partially impregnating the needlefelt with a plastic resin.
11. A method of making an impact resistant material according to claim 9 wherein the three-dimensional needle felt is fully contained within a cast resin body with a shell of resin encapsulating the needlefelt.
GB0025760A 1999-10-21 2000-10-20 Non woven impact resistant material Withdrawn GB2355469A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB9924893.2A GB9924893D0 (en) 1999-10-21 1999-10-21 Impact resistant material

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GB0025760D0 GB0025760D0 (en) 2000-12-06
GB2355469A true GB2355469A (en) 2001-04-25

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GB0025760A Withdrawn GB2355469A (en) 1999-10-21 2000-10-20 Non woven impact resistant material

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WO2007015706A1 (en) * 2004-10-27 2007-02-08 The Boeing Company Method and preforms for forming composite members with interlayers formed of nonwoven continuous materials
US7695802B2 (en) * 2005-07-26 2010-04-13 Hunter Douglas Inc. Slat for covering for architectural openings
US8206633B2 (en) 2005-07-26 2012-06-26 Hunter Douglas Inc. Method and apparatus for forming slats for fabric in coverings for architectural openings
CN103388240A (en) * 2012-05-08 2013-11-13 旭泰玻璃纤维股份有限公司 Production method for glass fiber texture
EP4201653A1 (en) * 2021-12-16 2023-06-28 Rolls-Royce plc Z-pin for increasing delamination resistance

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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8246882B2 (en) 2003-05-02 2012-08-21 The Boeing Company Methods and preforms for forming composite members with interlayers formed of nonwoven, continuous materials
US8852713B2 (en) 2003-05-02 2014-10-07 The Boeing Company Methods and preforms for forming composite members with interlayers formed of nonwoven, continuous materials
WO2007015706A1 (en) * 2004-10-27 2007-02-08 The Boeing Company Method and preforms for forming composite members with interlayers formed of nonwoven continuous materials
JP2008517812A (en) * 2004-10-27 2008-05-29 ザ・ボーイング・カンパニー Method and preform for forming a composite member having an intermediate layer formed of a nonwoven continuous material
US7695802B2 (en) * 2005-07-26 2010-04-13 Hunter Douglas Inc. Slat for covering for architectural openings
US8206633B2 (en) 2005-07-26 2012-06-26 Hunter Douglas Inc. Method and apparatus for forming slats for fabric in coverings for architectural openings
US8580178B2 (en) 2005-07-26 2013-11-12 Hunter Douglas Inc. Method and apparatus for forming slats for fabric in coverings for architectural openings
CN103388240A (en) * 2012-05-08 2013-11-13 旭泰玻璃纤维股份有限公司 Production method for glass fiber texture
EP4201653A1 (en) * 2021-12-16 2023-06-28 Rolls-Royce plc Z-pin for increasing delamination resistance
US11840613B2 (en) 2021-12-16 2023-12-12 Rolls-Royce Plc Z-pin for increasing delamination resistance

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