MXPA05012870A - Unique ballistic composition - Google Patents

Abstract

A ballistic composite comprises multiple layers of a fabric having unidirectional ballistic resistant yarns in at least two layers and a resin layer between each pair of such multiple layers adhered to the ballistic resistant yarns but not encapsulation the same and not penetrating the layer of fabric. The ballistic yarn layers are at 90°±5°with respect to each other and the ballistic resistant yarns are stabilized by being woven in a second fabric. The second fabric is formed of yarns having a substantially lower tenacity and tensile modulus than the ballistic resistant yarn. The ballistic resistant yarns have a tenacity of at least about 15 grams per denier and a modulus of at least about 40 grams per denier. The resin in the resin layer has a modulus of at least about 7000 psi.

Description

COMPOSITION ANTIBALAS U? ICA CROSS REFERENCE WITH RELATED REQUESTS This application claims priority in accordance with article 35, 119 (e) of the Code of Conduct.

USA (USC) of the provisional patent application No. 60 / 474,519, filed on May 29, 2003.

FIELD OF THE INVENTION The present invention relates to resistant bulletproof compounds.

BACKGROUND OF THE INVENTION The use of flexible resins with woven fabrics of high performance fibers to manufacture composite armored panels has been the subject of a large amount of research and many patents. The general consensus of this body of work is that the more flexible the resin system used in the manufacture of the compound, the better the bulletproof properties of the resulting panel.

In addition, the adhesion of the resin to bulletproof yarn should be so low that the delamination in the composite occurs during the ballistic event. This reguisite can be ignored if the resin in the composite breaks at such a low force that the energy dissipates.

P05 / 088-BI during the ballistic event. Considering this basic knowledge of the armored design, the design of an armored laminate then becomes a compensation for the bulletproof properties of the panel with respect to the structural regulations for the use of the panel. U.S. Pat. Do not . 3,000,772 from Lunn, 1961, is one of the first patents to describe the superior ballistic performance reguisite for a flexible resin system. This patent protects the use of a polyethylene film with a unidirectional fiberglass cloth. The fiberglass fabric has fiberglass yarns in the warp direction and secondary yarns in the weft direction to form the fabric. Then, the fabric is compressed into a laminate after orienting the subsequent fabric layers at 90 degrees with respect to the fabric layer above and below it. This is a general practice known as "cross-folding" the layers. U.S. Pat. ?or. 3,956,447 of Denommee, 1976, describes the manufacture of a bulletproof helmet for the United States Army with a thermoplastic or thermosetting resin. In this patent, the preferred resin system for the helmet is a PVB / phenolic system. Roy Liable, researcher at the US Army Research, Engineering and Development Center . { US Army 's Research, Engineering and Development Center), P0S / 088-BI Natick, Massachusetts, in his book "Ballistic Materials and Penetration Mechanics," Elsevier Scientific Publishing Company, 1980, p. 108, states that during development of the hull it was discovered that the phenolic resin itself was too rigid to produce good bulletproof results and that the polyvinyl butyrol component (PVB, Polyvinylbutyrol) of the system was added to give the resin some elongation and flexibility to improve the bulletproof properties while maintaining the necessary rigidity for a helmet. Several patents protect the use of films and thermoplastic resins in the compounds. U.S. Pat. Do not . 4,678,702 to Lancaster et al., 1987, shows the use of Surlyn as the resin wherein a Surlyn film forms currents in the fabric fabric by applying heat and pressure to encapsulate the yarn and form a flexible bulletproof composite. U.S. Pat. Do not . 4,574,105 by Donovan, 1986, shows the use of nylon and Keviar layers, where nylon adheres to the Keviar fabric by applying heat and pressure to form the composite, but nylon does not penetrate the fabric. A series of patents by Andrew Park (U.S. Patent Nos. 5,437,905, 5,443,882, 5,443,883, 5,547,536, 5,635,288 and 5,935,678) protect the use of films between layers of unidirectional yarns, wherein the film is used for P05 / 088-BI support layers of cross-folded yarns without penetrating the layers in an important way. U.S. Pat. No. 4,623,514 of Allied-Signal, protects the considerable encapsulation of high performance yarns in transversely folded layers of unidirectional yarns with a resin with a modulus less than 6000 psi.

SUMMARY OF THE INVENTION The object of this patent application is the use of thermoplastic resins with a single fabric to produce a superior bullet resistant composite. The resins have good adhesion to bullet resistant strands and a high voltage module. This combination of properties, when used with a conventional woven fabric or with a unidirectional cross-folded fabric, will not produce a superior bulletproof composite. The unique fabric of this invention is the subject of the US patent application. No. 10 / 135,573 filed May 1, 2002 (WO 02/090866), assigned to the assignee thereof, and whose description is considered incorporated herein by its sole reference. This fabric is an almost unidirectional fabric that has the bulletproof threads held in a unidirectional 0/90 orientation by means of a very elongated and low modulus thread, of relatively sticky diameter. This fabric is sold by Barrday Inc., transferee of P05 / 088-BI the same, with the brand name Sentinel fabrics. The fabric of bulletproof yarns in this fabric can be any high strength yarn with a tensile strength of at least about 15 grams per denier and a modulus of at least about 400 grams per denier. All commercially available bullet resistant threads have been woven into Sentinel fabrics. The resins available which perform suitably in this invention are any resin which adheres to the high performance yarns and has a modulus of at least about 7,000 psi. Previously, bullet resistant composites had not been constructed using resins with these modulus values, including those described in the above-mentioned patent application 10 / 135,573 (WO 02/090866). In one aspect of the present invention, there is provided a bullet-resistant composite comprising several layers of a fabric containing unidirectional bullet resistant strands in at least two layers, the strands of bullet-proof strands being at an angle of 90 ° ± 5 ° to each other; bullet-resistant threads are stabilized by being woven into a second fabric, the second fabric is formed by threads with a tensile modulus and tensile strength considerably inferior to bullet resistant thread, and the bulletproof resistant thread has a P05 / 088-BI tensile strength of at least about 15 grams per denier and a modulus of at least about 40 grams per denier,. and a resin layer between each pair of the multiple layers, adhered to the bullet-resistant strands, but without encapsulating them and without penetrating the fabric layer, the resin in the resin layer has a modulus of at least about JO00 psi.

DETAILED DESCRIPTION OF THE INVENTION The basic requirement that the threads are free to move and that the composite be defaced during the ballistic event has not been ignored in this invention. The freedom of movement of the yarn and the delaminating compound has been further provided by the low modulating encapsulant yarn of the Sentinel fabric by the resin system between the fabric layers. Two layers of very flexible bulletproof threads, strongly adhered to each other, produce a rigid but very thin compound. A stack of these thin rigid layers, even when the rigid layers are joined by a flexible thread, produces a rigid hard compound. In a Sentinel fabric layer composite, one of the yarn layers of this bound pair is the unidirectional top layer of a Sentinel fabric, and the other layer of strongly bonded yarn is the bottom layer of a second Sentinel fabric. In the present invention, the P05 / 088-BI Sentinel fabrics are arranged in layers with the same surface facing upwards and the fabrics are all oriented with the warp threads in the same direction. This arrangement results in a composite with adjacent unidirectional bullet yarn oriented at 0/90 degrees. The resin adheres together with the adjacent fabric layers forming rigid layers of layers laminated at 0/90. These layers laminated at 0/90 are connected by the module encapsulant wire, lower to the layer that is above and below it. The integrity and properties of the resulting compound are • determined by the resin, the amount of resin and the encapsulating threads. The flexible encapsulating yarn provides the necessary movement - and the delamination of the composite layers allows the use of adhesive resins with more dynamic adhesion than was previously observed in bulletproof compounds. The flexible encapsulating yarn also allows the use of resins and adhesives with a much higher tension modulus than that previously used. The strength of the delamination layer can be controlled by the encapsulating yarn, while the stiffness and hardness of the composite is determined by the type and amount of the thermoplastic resin and its adhesion to the fibers. The use of a high modulus resin of at least about 7,000 psi, preferably in the rangeP05 / 088-BI approximate 25,000 to 30,000 psi, with a dynamic bond to the thread, so that the resin does not penetrate the fabric or substantially encapsulate the bulletproof thread. If any of the latter were to occur, the freedom of the ballistic thread to move would be reduced and the ability of the wire to dissipate energy would be significantly affected. The placement of the resin between the layers of Sentinel fabric can be controlled by several means. One method is to restrict the amount of resin used, so that there is enough resin to wet only the surface of the fabrics. In general, the amount of resin used is less than about 20% by weight of the weight of the compound. To produce a rigid compound with such a small amount of resin, it is necessary that the resin adhere very, very well to the bulletproof thread. The stiffness in the composite is then provided by two layers of high modulus yarns strongly adhered to each other. A second method is to use a resin with high viscosity so that it does not flow at the temperature that is regulated for adhesion. Many resins in the form of film comply with this reguisite. Low density polyethylene is one of these films. Low density polyethylene softens and adheres to the fabric of Sentinel fabrics with high molecular weight polyethylene yarns, but does not penetrate the fabric considerably at the temperature necessary for adhesion. In this P05 / 088-BI case, polyethylene. Ultra-high molecular weight includes bullet-proof yarns of the type which will be described in more detail below and sold under the trade name Spectra and Dyneema '. Other films, including thermoplastic and ionomer and polyurethane nylon films, behave similarly. The ability to control the stiffness and hardness of the laminate while maintaining bulletproof performance has several advantages. When the threat of receiving an impact comes from a deformable projectile, for example from a 9 mm projectile, a hard laminate will deform the projectile rather than a soft laminate and the more deformed projectile is, in general, easier to stop. Similarly, a relatively non-deformable projectile, such as a Tokarev steel jacketed projectile, is easier to stop with a more flexible laminate where the projectile stops more gradually. The laminate can also be manufactured with layers of different hardness or stiffness. An example of this structure is a two-component laminate used as a backing for an armored ceramic plate. A layer of rigid and hard laminate is placed directly behind the ceramic plate, where it provides support to the ceramic during the ballistic event. The softer layers of the laminate form the backing of the composite and absorb energy by delamination, thus minimizing energy P05 / 088-BI transferred to the user of the shielded plate. The fabric layers used in the composite of the present invention have two yarn layers unidirectional at approximately 90 degrees to one another, stabilized by a second woven fabric, and are fully described in U.S. Patent Application Ser. No. 10 / 135,573 (WO 02/090866) mentioned above. The bullet-resistant yarns used in the present invention have a tensile strength of about 15 grams per denier and a tension modulus of at least about 400 grams per denier. Examples of bullet-resistant strands which can be used include: aramid fibers, extended chain polyethylene fibers, poly (p-phenylene-2,6-benzobisoxazole) (PBO) fibers and glass fibers. The aramid and aramid fibers of eopolymer are produced commercially by Du Pont, Twaron Products and Teijin, under the trade names Keviar®, Twaron® and Technora®, respectively. The extended chain polyethylene fibers are produced commercially by Synthetic Industries, and sold under the trade name Tensylon®. Toyobo produces PBO under the trade name Zylon®. Liquid crystal polymers are produced, under license, under the trade name Vectron®. Other bulletproof strands can be used.

P05 / 088-BI The stabilizing fibers, which are also known as encapsulating yarns, can be selected from a wide variety of fibers. These fibers include natural fibers, such as cotton, wool, heneguan, linen, jute and silk. The fibers also include filaments and artificial fibers, such as regenerated cellulose, rayon, polynomial rayon and cellulose esters. The fibers further include filaments and synthetic fibers, such as acrylic fibers, for example, polyacrylonitrile, modacrylics, such as acrylonitrile-vinyl chloride copolymers; polyamide, for example, polyhexamethylene adipamide (nylon 66), polycaproamide (nylon 6), polyundecanoamide (nylon 11), polyolefin, for example, polyethylene and polypropylene, polyester, for example, polyethylene terephthalate, rubber, synthetic rubber and saran. Glass fiber can also be used. The denier of the encapsulating yarn can vary between approximately 20 and 1000 deniers, depending on the size of the resistant bulletproof fibers. In general, the encapsulating yarn has an approximate diameter of up to 14% the diameter of the bulletproof yarn, preferably about 2.5%. The encapsulating yarn has, in general, a modulus of maximum tension of 1777 grams per tex (weight of 1 km of filament) and a maximum resistance "at 3% elongation, which is approximately 0.31% of the bulletproof thread.

P05 / 088-BI In the fabric, the count of bulletproof threads per inch is approximately 40% to 85%, preferably 50% +/- 1, of the maximum density that can be woven in a simple woven fabric composed entirely of bulletproof threads of the same size. In the preferred embodiment of this invention, the fiber used is a high modulus polyethylene (Spectra fiber) or polyaramide yarn (Keviar fabric) which has a tensile strength of at least about 15 grams per denier and a modulus of tension of at least about 400 grams per denier and the resin is a low density polyethylene film, preferably with a density between approximately 0.92 and 0.94 g / m3. The adhesion of low density polyethylene to the high modulus extended chain polyethylene fibers is very good and can not be explained as mere mechanical adhesion. The film seems to join or diffuse in the structure of the extended chain. The laminate constructed with Spectra fibers and low density polyethylene film shows marked improvements in performance with respect to prior art structures. The total thickness of the low density polyethylene film may be between about 0.35 and 1.75 mil, which may be provided by a single sheet or by several sheets.

P05 / 088-BI EXAMPLES Example 1 This Example is a comparative example. A simple woven Sentinel fabric, Barrday style number 4850, woven with 1200 denier Spectra® 900 yarn, was coated with a Kraton 1107D thermoplastic blog copolymer. The fabric had a pass count of 16 x 16 and a regional density of 184 g / m2. This resin is the most commonly used in Spectra shielded laminates and has a modulus of less than 6,000 psi. The Kraton coating was 18% by weight. A 16"x 16" laminate was manufactured using this coated fabric by consolidating 18 layers in a hot hydraulic press. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The value V-50 is the speed at which the probability of the projectile halting on the panel or crossing it was determined. The V-50 value is a common measure of the panel's resistance against bullets, and is known to those who are familiar with the armored design. It is the speed at which 50% of a certain type of projectile, when P05 / 088-BI hits the panel, it will completely penetrate the target. The V-50 of the panel was 1253 feet / second. Example 2 This Example illustrates one embodiment of the invention. 18 layers of the fabric used in Example 1 were laminated together with three layers of polyethylene film (PE, Polyethylene) of low density of 0.35 mil between each layer of fabric. The low density polyethylene film had a density of 0.92 g / m3 and a modulus of 25,000 a 29,000 psi. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 performance of the panel was determined. The determined V-50 of the panel was 1440 feet / second, notoriously higher than the V-50 of Example 1. Example 3 This Example illustrates a further embodiment of the invention. 18 layers of the fabric used in Example 1 were laminated together with a PE film layer of 0.35 mil between each layer of fabric. The PE film had the same P05 / 088-BI properties as specified in Example 2. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1516 feet / second. The V-50 of this panel was notoriously higher than the V-50 of Example 1. Example 4 This Example illustrates a further embodiment of the invention. 34 layers of a Sentinel fabric woven with Spectra 1000 650 denier yarn were laminated together with a PE film layer of 0.35 mil between each layer of fabric. The PE film had the same properties as specified in Example 2. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1699 feet / second.

P05 / 088-BI Example 5 This Example illustrates a further embodiment of the invention. 34 layers of the same Sentinel fabric used in Example 4, woven with Spectra 1000 650 denier yarn, were laminated together with three layers of 0.35 mil PE film between each fabric layer. The PE film had the same properties as specified in Example 2. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1440 feet / second. Example 6 This Example is a comparative example. A Spectra fabric, Barrday style number 4431, woven with 1200 denier Spectra 900 yarn, was laminated together with a PE film of 0.35 mil, which has the same properties as specified in Example 1. A laminate of 40.64 cm x 40.64 cm (16"x 16") was manufactured using this laminated fabric by consolidating 15 layers in a hot hydraulic press. The material was pressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel will P05 / 088-BI cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound weighed 0.74 pounds / ft2. The composite was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The V-50 of the panel was 1214 feet / second. The fabric of this Construction is one of the most common Spectra fabrics that are found in commerce. Example 7 This Example illustrates another additional embodiment of the invention. 28 layers of a Sentinel fabric woven with 1200 denier Spectra 900 yarn were laminated together with a 0.35 mil PE film layer between each layer of fabric. The Spectra yarn and the PE film are the same as in Comparative Example 6. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The finished compound weighed 0.68 pounds per foot2. The composite was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1509 feet / second. The V-50 of this panel was notoriously higher than the V-50 of Comparative Example 6.

P05 / 088-BI Example 8 This Example is a comparative example. 12 layers of a Barrday fabric, style 2182, were laminated together with a proprietary Barrday resin system, Black Thermo. The fabric is a simple woven fabric, woven with Keviar 29 thread of 3000 denier. The Black Thermo resin system has a module of approximately 1000 psi. The material was compressed at 150 psi during minutes at a temperature of 121 ° C (250 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The compressed panel had a regional fiber density of 1.20 pounds / ft2. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1211 feet / second. Example 9 This Example is a comparative example. 12 layers of a Barrday fabric, style 2183, were laminated together with a proprietary Barrday resin system, Black Thermo. The fabric is a simple woven fabric, woven with Twaron thread type 1000 of 3000 denier. The Black Thermo resin system has a module of approximately 1000 psi. The material was compressed at 150 psi for 30 minutes at a temperature of 121 ° C (250 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The panel P05 / 088-BI tablet had a regional fiber density of 1.20 pounds / ft2. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1188 feet / second. Example 10 This Example illustrates a further embodiment of the invention. 12 layers of a Barrday fabric, style 2858, were laminated together with a 1.75 mils PE film with a density of 0.92 g / m3. The fabric is a Sentinel 29 fabric woven with Keviar 29 thread of 3000 denier. The PE film has a voltage modulus in the range of 25,000 to 29,000. The material was compressed at 150 psi for 30 minutes at a temperature of 115 ° C (240 ° F). The panel was cooled to 82.2 ° C (180 ° F) before releasing the pressure. The compressed panel had a regional fiber density of 0.99 lb / ft2. The finished compound was mounted on a support and shot without backing material with a 9 mm projectile with a full metal jacket. The V-50 value of the panel was determined. The determined V-50 of the panel was 1440 feet / second. The V-50 of this panel was notoriously higher than that of the panels of Examples 8 and 9, while the regional density of the panel is notoriously lower.

P05 / 088-BI

Claims (1)

CLAIMS: 1. A bullet-resistant composite comprising: multiple layers of a fabric having unidirectional bullet resistant strands in at least two layers, the layers of bulletproof strands are at an angle of 90 ° ± 5o to each other, bullet-resistant yarns are stabilized by weaving on a second fabric, the second fabric is formed with yarns that have a tensile modulus and tensile strength considerably lower than those of the bulletproof resistant yarn, the yarn Bullet resistant has a tensile strength of at least 15 grams per denier and a modulus of at least 40 grams per denier, and a layer of resin between each pair of multiple layers adheres to bullet resistant strands, but does not encapsulate them nor does it penetrate the fabric layer, the resin of the resin layer has a modulus of at least 7000 psi. The compound according to claim 1, characterized in that the bullet resistant yarn is selected from the group consisting of aramid fibers, extended chain polyethylene fibers, poly (p-phenylene-2,6-benzobisoxazole) (PBO) fibers. and glass fibers. 3. The compound according to claim 1 or 2, characterized by the yarn of the P05 / 088-BI second fabric has a denier in the range of 20 to 1000. 4. The composite according to any of claims 1 to 3, characterized in that the yarns of the second fabric are selected from the group consisting of natural fibers, synthetic fibers and glass fibers. The compound according to claim 4, characterized in that the natural fiber is selected from the group consisting of cotton, wool, heneguan, linen, jute and silk, or the synthetic fiber is selected from the group consisting of regenerated cellulose rayon, rayon polynose, cellulose ester, acrylics, modacrylics, polyamides, polyolefins, polyester, rubber, synthetic rubber and saran, and is preferably selected from the group consisting of polyacrylonitrile, copolymers of acrylonitrile-vinyl chloride, polyhexaamephylene adipamide, polycaproamide, polyundecanoamide, Adipamide of polyethylene, polycaproamide, polyundecanoamide, polyethylene, polypropylene and polyethylene terephthalate. 6. The compound according to any of claims 1 to 5, characterized in that the yarns of the second fabric have a large elongation. 7. The compound according to any of claims 1 to 6, characterized in that the second yarn is broken before the bullet-resistant strands to the impact of a projectile on the composite. P05 / 088-BI 8. The compound according to any of claims 1 to 7, characterized in that the yarn of the second fabric has a diameter which is up to 14% the diameter of the bulletproof yarn, preferably 2.5% of the diameter of the yarn. Bulletproof thread. The compound according to any of claims 1 to 8, characterized in that the yarn of the second fabric has a maximum tension modulus of 1777 grams per tex and / or a maximum strength at 3% elongation, ie 0.31 % of the bulletproof thread. 10. The compound according to any of claims 1 to 9, characterized by the count of yarns of the bulletproof thread per inch is 40% to 85%, preferably 50% ± 1, of the maximum density that can be woven in a fabric. of simple fabric composed entirely of bulletproof threads of the same size. The compound according to any of claims 1 to 10, characterized in that the resin layer is formed with resin having a modulus of 25,000 to 30,000. 12. The compound according to any of claims 1 to 11, characterized in that the resin of the resin layer constitutes 20% by weight, or less, of the weight of the compound. 13. The compound in accordance with any P05 / 088-BI of claims 1 to 12, characterized in that the resin layer is formed with a film of the resin. 14. The compound according to any of claims 1 to 13, characterized in that the bullet resistant thread is formed with polyethylene, and the resin layer is formed with a low density polyethylene film. 15. The compound according to claim 14, characterized in that the low density polyethylene film has a thickness of 0.35 to

1.75 mil. P05 / 088-BI