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WO2010019697A1 - Système de moule et procédé pour fabriquer un casque - Google Patents

Système de moule et procédé pour fabriquer un casque Download PDF

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Publication number
WO2010019697A1
WO2010019697A1 PCT/US2009/053590 US2009053590W WO2010019697A1 WO 2010019697 A1 WO2010019697 A1 WO 2010019697A1 US 2009053590 W US2009053590 W US 2009053590W WO 2010019697 A1 WO2010019697 A1 WO 2010019697A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
flexible member
preg
cavity
rigid
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.)
Ceased
Application number
PCT/US2009/053590
Other languages
English (en)
Inventor
Lawrence J. Dickson
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.)
ArmorSource LLC
Original Assignee
ArmorSource LLC
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 ArmorSource LLC filed Critical ArmorSource LLC
Publication of WO2010019697A1 publication Critical patent/WO2010019697A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • F41H1/00—Personal protection gear
    • F41H1/04—Protection helmets
    • F41H1/08—Protection helmets of plastics; Plastic head-shields
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C2/00—Manufacturing helmets by processes not otherwise provided for
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4807—Headwear
    • B29L2031/4814—Hats
    • B29L2031/4821—Helmets

Definitions

  • the present invention relates to the field of articles of manufacture made from resin-fiber composites and methods for making such articles. More particularly, the invention relates to a ballistic helmet comprising an impact resistant composite shell, a mold for making the helmet, and a method for producing the helmet.
  • helmets having impact resistance and in particular ballistic resistance are known in the art. However, attempts are continually underway to improve the impact and ballistic resistance of such helmets.
  • a variety of helmets and methods for making helmets are described in publications such as US Patent Nos. 4,199,388; 4,953,234 and 5,112,667. These patents disclose using fiber-resin composite materials to create improved helmet shells.
  • US Patent No. 4,953,234 describes an improved helmet using polyethylene fibers in a polymer matrix.
  • the composite shell is made by assembling together pre-preg packets where each pre-preg packet containing a multitude of pre-preg layers.
  • Each pre-preg layer in turn has a multitude of unidirectional coplanar fibers embedded in a polymeric matrix, with adjacent fiber layers in the pre-preg packets situated at various angles relative to each other.
  • the ballistic resistant material described in these patents exemplifies known ballistic materials having penetration resistance.
  • a conventional helmet mold typically consists of a two-piece, matched-metal die. The rigid pieces of the die internest when closed and heat and pressure are applied to a resin-fiber pre-preg placed within. As a result, resin flows from the resin-fiber pre-preg into the gap between the internested rigid pieces.
  • Conventional helmet molding methods are not dynamic operations, however, that use molds designed to respond to resin flow by applying continuous pressure uniformly throughout the entire molding process. Rather, since the gap between the internested rigid pieces in a conventional mold is fixed, once sufficient flow of resin is achieved the pressure applied to the resin-fiber pre-preg is released. Consequently, conventional helmet molding methods are limited because high pressures are obtained only during initial stages of processing.
  • the present invention improves upon conventional helmet manufacturing by offering responsive molds and novel production methods that can be used with state of the art resin- fiber composite ballistic materials to optimize the ballistic performance of helmets produced.
  • the mold designs and methods described herein solve deficiencies associated with conventional helmet manufacturing techniques by allowing high pressure to be continuously and uniformly applied to a resin-fiber helmet pre-form during all stages of molding.
  • a method for forming a resin-fiber composite shell includes introducing a resin-fiber pre-preg packet between a rigid cavity and a rigid core.
  • a flexible member is introduced between the rigid cavity and the rigid core.
  • the flexible member has a first side and a second side that is opposite the first side.
  • the resin-fiber pre-preg packet is positioned on the first side of the flexible member.
  • a fluid is introduced between the flexible member and one of the cavity wall and the core wall for applying a substantially uniform pressure on the second side of the flexible member.
  • the first side of the flexible member applies the substantially uniform pressure to the resin- fiber pre-preg packet for forming the resin-fiber pre-preg packet into a shape of one of the cavity wall and the core wall.
  • FIGURE 1 illustrates a cross-section view of a mold that has a rigid cavity operatively connected to an expandable member, which contains an inward- forming reaction ring, in accordance with one embodiment of an apparatus illustrating principles of the present invention
  • FIGURE 2 illustrates a cross-section view of a mold that has a rigid cavity operatively connected to an expandable member, which contains an outward- forming reaction ring, in accordance with one embodiment of an apparatus illustrating principles of the present invention
  • FIGURE 3 illustrates an alternate embodiment of a cross-section view of a mold
  • FIGURE 4 illustrates another alternate embodiment of a cross-section view of a mold.
  • substantially void-free means at least 50% of the bulk structure of the molded composite, obtained after the molding operation is complete, does not contain any voids or have any gas or air pockets present.
  • optimal ballistic properties means that by design the ballistic performance of the molded composite structure is tailored to a particular use and meets the ballistic performance criteria that have been established for the particular use.
  • Methods described herein produce a resin-fiber composite shell that is substantially void-free and has optimized ballistic properties throughout.
  • the resin-fiber composite shell has a hemispherical shape and is produced by a method comprising expanding a flexible member within a hemispherical-shaped rigid cavity that contains one or more resin-fiber pre-preg packets.
  • the flexible member and the hemispherical-shaped rigid cavity are attached so that the flexible member expands into and fills the hemispherical-shaped rigid cavity.
  • the flexible member and the hemispherical-shaped rigid cavity comprise two parts of a mold suitable for carrying out the methods described herein.
  • a single resin-fiber pre-preg packet or a multitude of packets are placed in the rigid cavity.
  • the resin- fiber pre-preg packets are disposed between the surface of the flexible member and the concave surface of the substantially hemispherical-shaped rigid cavity.
  • the rigid cavity is heated to a temperature suitable for processing the resin-fiber pre-preg packets into a composite material.
  • a hydraulic medium is used to expand the flexible member, which can be pressurized to pressures of from about 14 psi to over 100,000 psi.
  • the flexible member Upon pressurization with the hydraulic medium, the flexible member expands and contacts the resin-fiber pre-preg packets.
  • the resin-fiber pre-preg packets are reacted and compressed between the surface of the flexible member and the surface of the substantially hemispherical-shaped rigid cavity.
  • resin from the resin-fiber pre-preg packets flows into the interfacial region between the flexible member and the substantially hemispherical-shaped rigid cavity to fill the space between these two surfaces. Both elevated temperatures and pressures are maintained throughout the entire molding process.
  • a conventional mold is a matched-metal die made from two rigid pieces. The pieces internest with a fixed gap existing between the two rigid surfaces. As a result of the fixed gap, when different thicknesses or different amounts of pre-preg materials are used in different regions of the mold, by design for example, the molding surfaces of conventional molds may pinch at the high points where the pre-preg materials are thickest. When this happens, the greatest molding pressures are applied only at the places where the mold pinches. Consequently, the bulk composite structure is exposed to non-uniform pressure during molding, which leads to non- uniformities in the composite structure and in ballistic performance.
  • Hydroforming is a specialized stamping process that uses high pressure hydraulic fluid at room temperature to press a continuous metal sheet or tube into a die. Hydroformation allows malleable metals to be manipulated to produce lightweight, structurally stiff, strong pieces with complex shapes that are otherwise difficult or impossible to make using standard solid stamping techniques.
  • hydroforming is done with metals at room temperature. Furthermore, the metals used in hydroforming operations do not undergo a phase change to form the structure.
  • the fiber-resin composites made using hydraulic pressure according to the present invention are molded at elevated temperatures.
  • the resin-fiber composite shell is formed, according to certain embodiments of the methods herein described, by using heat and constant pressure to compress together one or more resin-fiber pre-preg packets.
  • Any commercially available resin-fiber pre-preg packets can be used in conjunction with the methods herein described to produce suitable resin- fiber composite shells.
  • Resin-fiber pre-preg packets can be flat.
  • the pre-preg packets can be pre-formed, for example in a pre-molding step, into a pre-form that is partially hemispherical in shape.
  • the resin-fiber pre- preg packets can be pre-formed into a helmet-shaped pre-form in a pre-molding step.
  • Resin-fiber pre-preg packets are made from one or more continuous sheets that, optionally, have perforations, patterns, pre-cuts, pre-creases, or formed into pinwheel configurations in a pre-cutting step. This may aid with the pre-preg packets more easily adopting a three-dimensional shape upon molding without forming additional creases or folds or extraneous overlapping of material.
  • Resin-fiber sheets comprising the resin- fiber pre-preg packets contain ballistic fibers within a polymer matrix (e.g., Dyneema from DSM Corp., Spectra Shield from Honeywell International, etc).
  • Ballistic fibers suitable for fabrication of pre-preg packets vary widely and include organic or inorganic fibers having a tensile strength of at least about 5 grams/denier, a tensile modulus of at least about 30 grams/denier, and an energy-to-break of at least about 20 joules/gram.
  • the tensile properties may be measured by an Instron Tensile Testing Machine by pulling a 10 in. (25.4 cm) length of fiber clamped in barrel clamps at a rate of 10 in/min.
  • fibers that are suitable include those having 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-to-break equal to or greater than about 8 joules/gram.
  • Other fibers contemplated as suitable include 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 an energy-to-break equal to or greater than about 30 joules/grams.
  • thermoplastic resins contemplated maybe selected from various classes of thermoplastic polymers including but not limited to polyurethanes, polyethylenes, polyolefins, polypropylenes, polyesters and thermoplastic elastomers.
  • thermosetting resins contemplated may be selected from various classes of thermosetting polymers including but not limited to polyvinyl butyrols (PVB), polyesters, vinyl esters, PVB-phenolics, epoxies, and urethanes.
  • PVB polyvinyl butyrols
  • a resin-fiber pre-preg packet comprises a plurality of resin-fiber sheets.
  • each resin-fiber sheet may comprise one or more fiber layers embedded in a polymer matrix.
  • each of the fiber layers may be comprised of a unidirectional array of coplanar and substantially parallel fiber bundles.
  • the bulk direction of alignment of the substantially parallel fiber bundles making up each of the fiber layers in the polymer matrix is oriented in such a way, so that it is different from the bulk direction of alignment of any neighboring layer of coplanar fiber bundles.
  • the difference between the directions of orientation for any two neighboring layers may have an angle associated with them of from about 0 to about 180 degrees.
  • resin-fiber pre-preg packets comprise the resin-fiber composite shell
  • resin-fiber pre-preg packets comprise the resin-fiber composite shell
  • from about 5 to about 50 resin-fiber pre-preg packets comprise the resin- fiber composite shell.
  • from about 2 to about 20 resin-fiber sheets comprise each resin-fiber pre-preg packet
  • from about 5 to about 20 resin-fiber sheets comprise each resin-fiber pre- preg packet.
  • Mold systems (molds) described herein are useful for forming a resin-fiber composite shell.
  • the mold has a rigid cavity substantially hemispherical in shape, and a flexible member that is capable of expanding to fill the substantially hemispherical- shaped rigid cavity.
  • the flexible member and the rigid cavity are parts of the mold operatively connected together.
  • the flexible member and the rigid cavity are attached, positioned relative to one another, such that the flexible member expands into and fills the rigid cavity when it is pressurized with a hydraulic medium. Being connection in this way, the flexible member and the rigid cavity are two parts of a mold that is useful for carrying out the methods herein described.
  • An embodiment of the molds provided herein is a mold for forming a resin-fiber composite helmet.
  • the mold has a flexible member attached to a helmet-shaped rigid cavity, hi a similar manner to that described, the rigid cavity is heated and the flexible member is expanded within the helmet-shaped rigid cavity. Subsequently, one or more resin-fiber pre-preg packets, placed in the rigid cavity and disposed between the surface of the flexible member and the concave surface of the helmet-shaped rigid cavity, are compressed and are molded into a resin-fiber composite helmet that is substantially void-free and that has optimized ballistic properties suitable for specifically designed applications.
  • a conventional helmet mold is typically a matched-metal die that has two rigid pieces that internest and that have a void or air gap existing between the two rigid pieces when the mold is closed. Resin-fiber pre-preg material is place between the rigid pieces and it is held in place in the gap region when the mold is closed and pressure is applied.
  • a conventional mold may pinch at the high points and apply greatest pressures at areas where the pre-preg material is thickest or present in greatest amounts. Consequently, non-uniform pressures are applied to the bulk resin-fiber pre-preg material during the molding cycle leading to non-uniform ballistic performance in the resulting composite structure.
  • variable pressures may be applied during different stages of the molding process. For example, when pre-preg material used in a molding operation is initially thicker than the fixed gap width, the pre-preg material starts off being placed under very high pressure when the mold is closed. However, after sufficient heat is applied, the initial thickness of pre-preg material decreases as resin flows out of the pre-preg material into the surrounding regions of the mold. When this occurs, the thickness of the pre-preg material may end up being less than the width of the fixed gap. Because the rigid surfaces of the mold are as close as their rigid nature will allow them to be, the high pressure initially applied to the pre-preg material is released. Consequently, high molding pressures are applied to the pre-preg material only during the initial stages of molding.
  • the molds for making composite shells and helmets described herein utilize a flexible member pressurized with a hydraulic medium so that it expands within a hemispherical-shaped rigid cavity.
  • the flexible member expands and compresses pre-preg material against the surface of the rigid cavity wall.
  • the surface of the member adjusts throughout the molding operation to various changes that occur to the shape and thickness of the pre- preg material being molded as a result of resin flow. This keeps the surface of the flexible member in constant contact with the pre-preg material so that constant pressure is maintained on the pre-preg material throughout.
  • molds of the present invention apply very high pressures continuously throughout every stage of the molding process. This produces substantially void-free, hemispherical-shaped resin- fiber composite shells that exhibit optimal performance, and which can be used to make superior helmets with enhanced ballistic properties.
  • Another advantage to the molds described herein is the versatility that they provide.
  • the thickness of the gap and the design of the rigid molding surfaces are typically determined based on specifications associated with particular products that the mold will be used to produce. Therefore, when a conventional mold is used an operator is required to change out most or all of the components of the mold when a different product is desired.
  • This is unlike the molds of the present invention, where the space between the two molding surfaces (the rigid cavity surface and the flexible member) depends upon how much the flexible member is pressurized. As a result, one mold configuration may be used to mold several different types of products.
  • the rigid, concave cavity is hemispherical in shape.
  • the cavity provides a surface where the resin-fiber composite shell is made and acts as a template for forming the outside surface or exterior shape of the composite shell or helmet.
  • the rigid cavity is in the shape of a helmet and is used to produce helmet-shaped composite shells.
  • the rigid cavity is made from a material robust enough to withstand forces associated with being in contact with a flexible member that is pressurized with hydraulic medium, without undergoing deformation. Materials used to construct the rigid cavity are also capable of withstanding elevated temperatures for an extended period of time, since these are conditions typically used in the molding procedures. Furthermore, it is desirable to make the rigid cavity from a material that conducts heat, since this will facilitate effective transfer of heat to the resin-fiber pre-preg packets during molding. Heat can be applied during molding by using a separate heat source.
  • the rigid cavity contains or can be fitted with a heat source as part the construction.
  • the rigid cavity is made from, for example, a block of steel, aluminum, or brass.
  • a rigid core is also part of the mold construction, hi these embodiments, the rigid core attaches to both the flexible member and the rigid cavity.
  • the rigid core and the rigid cavity connect to each other, sandwiching the flexible member between their surfaces.
  • the surface of the rigid core that is in contact with the flexible member may be flat.
  • the surface of the rigid core that is in contact with the flexible member may protrude outward, either partially or wholly, and internest with the rigid cavity, hi this configuration, the mold in- part resembles a conventional two-piece matched-metal die.
  • the rigid core attaches to and forms a seal with the flexible member. However, the seal is only formed around the perimeter of the flexible member leaving the middle portion of the member free to expand when pressurized with hydraulic medium.
  • the rigid core may also be fitted with tubes, channels, and valves that are appropriate for controlling flow and pressurization of a hydraulic medium.
  • a pump and a reservoir for a hydraulic medium may also be provided as part of the rigid cavity, the rigid core, or as a completely separate component that is individually connected to the mold.
  • Materials used to construct the rigid core are also capable of withstanding elevated temperatures for an extended period of time, since these are the conditions typically used in the molding procedures.
  • heat can be applied during molding by using a separate heat source integrated with the rigid core, the rigid cavity, or both.
  • the rigid core, the rigid cavity, or both have or can be fitted with a heat source as part of its construction.
  • the rigid core is made from, for example, a block of steel, aluminum, or brass.
  • the flexible member is an elastic membrane, an elastic bag, an elastic balloon, an elastic bladder, etc., which is capable of expanding and can be pressurized with a suitable hydraulic fluid.
  • the flexible member is large enough so that upon expansion it can fill the substantially hemispherical shaped rigid cavity.
  • the flexible member provides a surface where the resin-fiber composite shell is made and acts as a template for forming the inside surface of the composite shell.
  • the flexible member is made from material robust enough to withstand being pressurized with hydraulic fluid without rupturing and is capable of withstanding elevated temperatures for an extended period of time, commensurate with conditions used during molding. Furthermore, the flexible member is chemically compatible with the type of hydraulic fluid used.
  • the flexible member is made, for example, from a thermally stable, resilient rubber which does not dissolve in hydraulic fluid.
  • suitable rubbers in this regard are elastomeric materials commercially available from the Mosites Rubber Company Inc., Fort Worth, Texas, which include Buna-N, Butyl, Chloroprene, Chlorinated Polyethylene, Chlorosulfonated Polyethylene, EPT or EPDM, Epichlorohydrin, Ethylene Acrylic, Ethylene Propylene/Silicone, Fluorocarbon Fluorosilicone, Natural, Polyacrylic, SBR, Silicone, and Urethane rubbers.
  • the flexible member is an impermeable, single layer, elastic membrane that stretches over the hemispherical-shaped rigid cavity when the mold is closed.
  • the flexible member forms a seal with and attaches around the perimeter of the cavity. In this closed configuration, the flexible member seals the rigid cavity shut and the mold resembles a drum.
  • the mold has an inside area and an outside area separated by the elastic membrane.
  • the pressure differential causes the flexible member to stretch towards the area of lower pressure. Because the flexible member is elastic, it expands into the rigid cavity.
  • Embodiments where the flexible member is partitioned into two or more sections that can be separately pressurized with hydraulic fluid are also contemplated.
  • the separate sections can be pressurized to either the same or different pressures.
  • the different member sections can be distinct chambers completely separate from one another that are individually attached to separate hydraulic systems and can then be pressurized to different pressures.
  • the flexible member can be comprised of a single, continuous membrane made with discrete sections that either have different thicknesses or are made from different materials that have different elastic properties.
  • a continuous member having such discrete sections can exhibit different levels of expansion relative to one another that, for example, may depend upon how thick the different sections are or on the types of material that they are made from.
  • a single hydraulic system can be used to pressurize a single membrane and produce the same results as if a single member with two distinct chambers attached to two separate hydraulic systems were used.
  • Embodiments having a flexible member partitioned into two or more distinct chambers or into two or more sections that can be separately pressurized with hydraulic fluid may be used, in accordance with methods herein described, to produce resin-fiber composite shells and helmets that have non-uniform thicknesses but uniform ballistic performance.
  • the non-uniformity of the thickness is a design feature of the helmet based on the proposed end use for the product.
  • One design feature for example, could be to produce lighter products with suitable or superior ballistic performance. Weight reduction can be achieved by selectively removing resin fiber composite only from helmet areas because it is known from field studies that ballistic events occur less frequently in this area. Therefore, a helmet designed to have less resin-fiber composite only in the crown region is desirable. Consequently, a mold for producing such helmets would allow helmets to be lightened without detrimentally impacting their overall utility.
  • a mold having a flexible member partitioned into two sections, where one section of the flexible member is used to form the crown of the helmet and another section of the flexible member is used to form the rest of the helmet.
  • the mold embodiment contemplated may be utilized so that the two distinct sections of the flexible member are pressurized to different pressures to produce a helmet with different amounts of resin-fiber composite material in the crown region versus the rest of the helmet.
  • a mold as described above, having a flexible member partitioned into two sections may be used in a method where the section of the flexible member associated with the crown of the helmet would be pressurized at a higher pressure than would be the section of the flexible member associated with the rest of the helmet.
  • Methods described and exemplified herein are for forming a resin-fiber composite shell, hi one embodiment, the method comprises expanding a flexible member within a hemispherical-shaped rigid cavity containing at least one and, optionally, more than one resin- fiber pre-preg packet.
  • the resin-fiber pre-preg packets are disposed between the flexible member and the surface of the hemispherical-shaped rigid cavity, hi this way, a hemispherical shaped resin-fiber composite shell is produced from the resin- fiber pre-preg packet.
  • the method for making a hemispherical shaped resin-fiber composite shell comprises the following steps: (1) providing a substantially hemispherical-shaped rigid cavity, operatively connected to a flexible member that is capable of expanding to fill the rigid cavity; (2) placing one or more resin- fiber pre-preg packets in the rigid cavity; (3) heating the rigid cavity; and (4) expanding the flexible member within the rigid cavity to compress the resin-fiber pre-preg packet against the surface of the substantially hemispherical-shaped rigid cavity. In this way a hemispherical-shaped resin-fiber composite shell is produced from the resin-fiber pre- preg packet.
  • Methods also described and exemplified herein involve forming a resin- fiber composite helmet and producing a high performance ballistic helmet, m one embodiment, the method for forming a resin-fiber composite helmet comprises expanding a flexible member within a helmet-shaped rigid cavity.
  • the rigid cavity contains at least one and, optionally, more than one resin-fiber pre-preg packet.
  • the resin-fiber pre-preg packets are disposed between the flexible member and the surface of the helmet-shaped rigid cavity. In this way, a resin-fiber composite helmet is produced from the resin-fiber pre-preg packet.
  • the helmet produced is substantially void-free and has optimized ballistic properties throughout.
  • a method for producing a high performance ballistic helmet involves using a mold comprised of a flexible member attached to a rigid cavity, the method comprising inducing uniform high pressure against a helmet pre-form by expanding the flexible member within the rigid cavity during a molding cycle to result in a high performance ballistic helmet molded at extremely high pressure in a very uniform process.
  • a method of forming a ballistic structure involves using a mold comprising a flexible member attached to a rigid template designed to form a surface of the ballistic structure, the method comprising inducing uniform high pressure against a ballistic pre-form by expanding the flexible member against the rigid template to compress the ballistic perform between the flexible member and the rigid template during a molding cycle to result in a high performance ballistic structure molded at extremely high pressure in a very uniform process.
  • the flexible member as described above which includes an elastic membrane or an elastic bag or balloon, is expanded by pressurization with a hydraulic medium.
  • the flexible member is pressurized to a pressure of from about 14 to about 100,000 psi.
  • the flexible member is pressurized to a pressure of about 14 to about 30,000 psi.
  • the hydraulic medium is a fluid having a low compressibility such that force is transferred through the fluid with minimal loss.
  • Suitable hydraulic mediums for use with the methods herein described include, for example, synthetic compounds, mineral oil, water, petroleum-based hydraulic oils, and water-based hydraulic mixtures.
  • suitable hydraulic mediums are robust enough to withstand extended periods of time at the elevated pressures and elevated temperatures associated with the conditions used in the molding procedures.
  • the hydraulic medium is chosen to be compatible with the type of material used to make the flexible member so that the flexible member does not dissolve, swell, or breakdown structurally when exposed to the hydraulic medium.
  • embodiments of the method are contemplated having the flexible member partitioned into two or more sections that can be pressurized separately.
  • the separate sections are pressurized to either the same or different pressures.
  • different sections of the flexible member are pressurized to different pressures and where the different sections of the flexible member are attached to separate hydraulic systems to carry out pressurization to different pressures.
  • separate sections of the flexible member are attached to separate hydraulic systems, where the separate hydraulic systems contain different hydraulic mediums having different compressibility. Consequently, the different hydraulic mediums may respond differently and may transfer different amounts of compressive force, by way of the partitioned flexible member, to the different areas of the mold and associated resin-fiber pre-preg packets.
  • resin-fiber composite shells and helmets having non-uniform thicknesses can be formed, which have distinctly defined areas of predetermined thicknesses by design.
  • the non-uniform thick resin-fiber composite shells and helmets can designed based on an end use planned for the product and one of ordinary skill will understand what locations and variations in thickness for the non-uniformities are acceptable for resin- fiber composites that are suitable for various ballistic purposes.
  • steps of the methods involve heating the mold, for example the rigid cavity in embodiments where the mold is constructed from a block of steel, and, optionally, maintaining the rigid cavity at a predetermined temperature.
  • Applying heat during molding facilitates the processing of pre-preg material into resin- fiber composite shells and helmets by enabling resin to flow from the resin-fiber pre-preg packets into the interface between the flexible member and the hemispherical shaped rigid cavity.
  • the temperature that the rigid cavity is heated to and, optionally, maintained at depends upon several factors, including the nature of the resin material present in the resin-fiber pre-preg packets and the design requirements associated with achieving a particular optimized ballistic performance for a particular product.
  • temperatures which are employed in various molding methods can be adjusted based on these factors.
  • resin flow is initiated by reaching the glass transition temperature of the polymer present in the resin material.
  • some resin formulations may need to reach higher temperatures.
  • the resin melt temperature may need to be reached for suitable resin flow to occur during molding.
  • Resin flow is related to the resin viscosity, which depends on both the heat and pressure applied. Therefore, in certain cases where low pressures are preferred for forming resin-fiber composite shells and helmets, it may be advantageous to heat the mold, for example the rigid cavity in embodiments where the mold is constructed from a block of steel, to higher temperatures. Conversely, in cases where resin decomposition or resin reaction is likely and high temperatures are undesirable, pressures used in the molding operation may be increased to have suitable resin flow during molding.
  • the mold for example the rigid cavity in embodiments where the mold is constructed from a block of steel, is heated to temperatures of from about 180° F to about 750° F. In other embodiments, the mold is heated to temperatures of from about 180° F to about 450° F.
  • the steps of the methods involve drawing vacuum on the substantially hemispherical-shaped rigid cavity while expanding the flexible member.
  • the rigid cavity when the rigid cavity is constructed from a block of steel, the rigid cavity may be equipped with a vacuum channel that allows a vacuum to be drawn on the cavity portion of the rigid die during the molding process.
  • a vacuum pump which is either an integrated part of the mold or is an external unit that is separate from the mold, may be connected to the vacuum channel to draw the vacuum.
  • Drawing vacuum on the rigid cavity before expanding the flexible member may help stabilize resin-fiber pre-pre material located within the cavity, and may prevent the pre-preg material from shifting prior to compression.
  • Drawing vacuum while expanding the flexible member to compress the resin-fiber pre-preg material ensures removal of gases and other volatiles produced as a result of molding. Because gases and other volatiles are removed under vacuum, they do not become entrapped in the re-solidified resin once it cools. Thus, substantially void-free resin-fiber composite structures, shells, and helmets can be formed. A vacuum may also be used to remove resin overflow during the compression stage of molding. Thus, drawing vacuum during molding may facilitate the production of lighter weight ballistic helmets. [0059] While the molds and methods described herein involve expanding a flexible member within a rigid cavity to compress pre-preg material between the flexible member and the surface of the rigid cavity, these are only specific embodiments and others are contemplated.
  • the configuration is set-up opposite that of the mold configurations previously described.
  • Pre-preg material is loaded in the mold, for example, by draping it over the rigid core, and the flexible member is attached along the periphery to the rigid cavity.
  • Inside and outside areas of the mold in this opposite configuration are likewise reversed compared with the molds previously described.
  • the mold is pressurized with hydraulic medium from the side of the flexible membrane which faces towards the rigid cavity.
  • the flexible member does not expand within the rigid cavity to compress pre-preg material, but instead squeezes around and up against the rigid core in order to compress pre-preg material between these two surfaces to form a desired ballistic structure.
  • Figure 1 shows a cross-sectional view of a helmet mold configuration according to Example 1.
  • the mold has a rigid cavity operatively connected to an expandable member and contains an inside-forming reaction ring.
  • the expandable member in this configuration is a single layer of an elastic membrane.
  • the rigid cavity in this example is constructed from a block of steel and has a substantially hemispherical-shaped surface shown at 12, which is clearly visible when the mold is open.
  • the rigid cavity contains a vacuum port that allows gases and other volatiles or excess resin to be removed during a molding operation.
  • the vacuum port is shown at 14.
  • a rubber mold seal is shown at 16.
  • a removable reaction ring that allows resin-fiber pre-preg material movement during molding is shown at 20.
  • the top part of the mold is shown at 22, and in this example it is constructed from a block of steel.
  • the top part of the mold includes a rigid core, which in this example protrudes outward so that it internests with the rigid cavity when the mold is closed.
  • the top part of the mold also includes a flexible member that is capable of expanding to fill the substantially hemispherical-shaped rigid cavity. The flexible member expands and is used to react against the pre-preg material.
  • the flexible member 24 may expand about 1/2" before contacting the pre-preg material.
  • An exemplary flexible member that is a single layer of an elastic membrane made from rubber is shown at 24.
  • the top part of the mold also contains a hydraulic fluid management system including ports for managing the hydraulic fluid; the hydraulic inlet and outlet ports are shown at 26 and 30 and the hydraulic medium is shown at 32.
  • the member retaining ring is shown at 34.
  • a helmet pre-form to be molded is shown at 36.
  • the helmet pre-form 36 includes at least one resin-fiber pre-preg packet.
  • the helmet pre-form is positioned in the mold relative to the removable reaction ring, shown at 20, so that the helmet is formed on the inside of the reaction ring.
  • the removable reaction ring is not beveled and this will result in the rim of the helmet being formed between two rigid surfaces (the rigid cavity and the inside surface of the reaction ring).
  • a void or air space sufficient to draw vacuum during the molding process is shown at 40.
  • Figure 2 shows a cross-section view of a cross-sectional view of a helmet mold configuration according to Example 2.
  • the mold has a rigid cavity operatively connected to an expandable member and contains an outside-forming reaction ring.
  • the expandable member in this configuration is a single layer of an elastic membrane.
  • the rigid cavity in this example is constructed from a block of steel and has a substantially hemispherical-shaped surface shown at 112, which is clearly visible when the mold is open.
  • the rigid cavity contains a vacuum port that allows gases and other volatiles or excess resin to be removed during a molding operation.
  • the vacuum port is shown at 114.
  • a rubber mold seal is shown at 116.
  • a removable reaction ring is shown at 120.
  • the top part of the mold is shown at 122, and in this example it is constructed from a block of steel.
  • the top part of the mold includes a rigid core, which in this example protrudes outward so that it internests with the rigid cavity when the mold is closed.
  • the top part of the mold also includes a flexible member that is capable of expanding to fill the substantially hemispherical-shaped rigid cavity. The flexible member expands and is used to react against the pre-preg material.
  • An exemplary flexible member that is a single layer of an elastic membrane made from rubber is shown at 124.
  • the top part of the mold also contains a hydraulic fluid management system including ports for managing the hydraulic fluid; the hydraulic inlet and outlet ports are shown at 126 and 130 and the hydraulic medium is shown at 132.
  • the member retaining ring is shown at 134.
  • a helmet pre-form to be molded is shown at 136.
  • the helmet pre-form is positioned in the mold relative to the removable reaction ring, as shown at 20, so that the helmet is formed on the outside of the reaction ring.
  • the removable reaction ring is beveled and all parts of the helmet are formed between the flexible member and a rigid surface (whether the rigid cavity or the outside surface of the reaction ring).
  • the example is directed to a method of molding a helmet using the mold described in Example 1 having a bottom part and a top part.
  • the bottom part contains the rigid cavity and is used to essentially form the exterior shape of the helmet and it is generally made to the precise shape of the desired helmet.
  • the top part contains a rigid core and a flexible member that can be pressurized with a hydraulic medium and used as a reaction point to compress a helmet pre-form to form a ballistic helmet.
  • the helmet pre-form 36 is placed into the bottom piece 10 of the mold (i.e., the rigid cavity).
  • the pre-form 36 can be flat or it can be pre-molded at low pressures in order to de-bulk the helmet prior to the high pressure molding.
  • a removable reaction ring 20 is secured in placed.
  • the reaction ring ensures that a void 40 is maintained in the mold to provide room for the helmet pre-form 36 to expand during high pressure molding.
  • the void 40 is also sufficiently sized to allow a vacuum to be drawn during the molding process, through the vacuum port 14. Applying a vacuum during molding is preferred but is not required.
  • the member retaining ring 34 secures the flexible member 24 along its perimeter to the rest of the top piece of the mold 22. Since the flexible member 24 is only secured to the top piece of the mold 22 along the perimeter, the flexible member 24 can move up and down in conjunction with the top piece of the mold 22 and it can also expand outward from the rigid core and into the rigid cavity as it pressurizes with hydraulic medium 32.
  • the top piece of the mold 22 and the flexible member 24 nest within the bottom piece of the mold 10, which contains the helmet pre-form 36 and the mold is placed under sufficient pressure so that the two pieces come together and the mold closes during the molding cycle.
  • the mold is heated while being pressurized. Temperatures and pressures are selected that are appropriate for the type of helmet resin-fiber material used and one of ordinary skill in the art will recognize that the temperatures and pressure employed are selected based on the type of material used to make the helmet while also considering the end ballistic performance desired. Generally though, the higher the pressure the better will be the ballistic performance.
  • the helmet mold is typically heated to temperatures of from about 18O 0 F to about 750 0 F, and most commonly from about 18O 0 F to about 45O 0 F.
  • the hydraulic medium 32 is introduced through a hydraulic inlet port 26, while the hydraulic outlet port 30 remains closed.
  • the flexible member 24 is pressurized with the hydraulic medium 32 to pressures of from about 14 psi to about 100,000 psi, and most commonly to pressures of from about 3000-10000 psi.
  • the pressurization of the elastic member 24 with the hydraulic medium 32 causes the elastic member 24 to expand into the hemispherical shaped rigid cavity 12 and to compress the helmet pre-form 36 into its final helmet shape.
  • the helmet mold is cooled as appropriate for the end of the molding cycle.
  • the hydraulic medium 24 is evacuated through the hydraulic outlet port 30, causing the flexible member 24 to pull away from the newly molded helmet 36.
  • the mold is then opened.
  • the top piece of the mold 22 is pulled away from the bottom piece of the mold 10 and the reaction ring 20 is removed.
  • the newly molded helmet 36 can then be removed from the rigid cavity 10.
  • the mold system (mold) illustrated in Figure 3 represents an alternate embodiment of the present invention, hi this embodiment, the mold system includes a bottom part 210 of a mold, which represents the rigid cavity, and a top part 222 of the mold, which represents the rigid core.
  • the flexible member 224 is positioned substantially closer to the helmet pre-form 236, which includes at least one resin-fiber pre-preg packet, than the embodiments illustrated in either Figures 1 or 2. In one example, the flexible member 224 only flexes about 1/8", as opposed to the about 1/2" flex of the flexible member 24 in Figure 1.
  • the mold system illustrated in Figure 3 also illustrates an alternate embodiment of the inlet port 226.
  • the inlet port introduces the fluid at a substantially central location 250 in the cavity of the bottom part 210.
  • the embodiment of Figure 3 illustrates the inlet port 226 delivering the fluid at the substantially central location 250
  • the embodiments of Figures 1 and 2 illustrate the inlet ports 26, 30, 126, and 130 introducing the fluid relatively closer to side walls of the cavity of the bottom portion 10, 110.
  • the fluid may be delivered to any location along the flexible member 24 (see Figure 1), 124 (see Figure 2), and 224 (see Figure 3).
  • the mold system (mold) illustrated in Figure 4 represents an alternate embodiment of the present invention.
  • the mold system includes the helmet pre-form 336 (e.g., resin-fiber pre-preg material) on the top part 322 of the mold, which represents the rigid core of the mold. Therefore, in this embodiment, the resin- fiber pre-preg material 336 is between the flexible member 324 and the top part 322 of the mold (rigid core).
  • the resin-fiber pre-preg material 36, 136, 236 is between the respective flexible members 24, 124, 224 and the respective bottom parts 10, 110, 210 of the molds (rigid cavities).
  • the unique methods and mold configurations described and exemplified herein provides for applying continuous and uniform pressures onto a resin-fiber helmet pre-form during each step of the molding procedure.
  • the methods and mold configurations herein allow very high pressures to be applied to the helmet during processing and also, optionally, allow vacuum to be drawn on the mold during the molding process.
  • Helmets can be produced using these mold configurations and methods that have very few voids and that have ballistic properties that may be optimized, by design, to suit a particular use. These helmets may have enhanced ballistic performance in comparison with control helmets produced using various conventional molds and conventional molding processes.
  • Enhancing the ballistic performance of resin-fiber composites by using the mold configurations and the methods for processing herein described, in this way allows ballistic helmets to be constructed that provide better ballistic protection versus control helmets at equal weights as the helmets made by conventional techniques.
  • the molds and processes described herein may also allow current ballistic standards to be met by helmets that are lighter than control helmets produced by conventional means.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention porte sur un procédé pour former une coque composite fibre-résine, lequel procédé comprend l'introduction d'un paquet préimprégné fibre-résine entre une cavité rigide (10) et un noyau rigide (22). Un élément souple (24) est introduit entre la cavité rigide et le noyau rigide. L'élément souple comporte un premier côté et un second côté qui est opposé au premier côté. Le paquet préimprégné fibre-résine (36) est positionné sur le premier côté de l'élément souple. Un fluide est introduit entre l'élément souple et l'une parmi la paroi de cavité et la paroi de noyau afin d'appliquer une pression sensiblement uniforme sur le second côté de l'élément souple. Le premier côté de l'élément souple applique la pression sensiblement uniforme au paquet préimprégné fibre-résine pour former le paquet préimprégné fibre-résine sous la forme de l'une parmi la paroi de cavité et la paroi de noyau.
PCT/US2009/053590 2008-08-12 2009-08-12 Système de moule et procédé pour fabriquer un casque Ceased WO2010019697A1 (fr)

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Cited By (14)

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WO2011128453A2 (fr) 2010-04-15 2011-10-20 Coexpair Procédé et appareil pour mouler des pièces en matériaux composites
DE102010054933B4 (de) * 2010-12-17 2013-01-10 Daimler Ag Vorrichtung und Verfahren zum Herstellen einer komplex-dreidimensional geformten faserverstärkten Preform
DE102010054934B4 (de) * 2010-12-17 2013-01-17 Daimler Ag Vorrichtungen und Verfahren zum Herstellen komplex-dreidimensional geformter faserverstärkter Preforms
WO2013110839A1 (fr) * 2012-01-24 2013-08-01 Mat Global Solutions, S.L. Procédé et appareil pour la fabrication d'un corps de matériau composite ménagé d'une cavité intérieure avec une ouverture sur l'extérieur
EP2646216A4 (fr) * 2011-01-12 2015-02-25 Bae Systems Aerospace & Defense Group Inc Procédé de fabrication de casques de protection légers pour un usage militaire et d'autres usages
CN104802422A (zh) * 2015-03-24 2015-07-29 徐州海伦哲专用车辆股份有限公司 一种绝缘玻璃钢工作平台的制作方法
CN105034403A (zh) * 2015-06-25 2015-11-11 北京卫星制造厂 一种复合材料壳体的制造方法
US9307803B1 (en) 2013-03-15 2016-04-12 INTER Materials, LLC Ballistic helmets and method of manufacture thereof
EP2561978A3 (fr) * 2011-08-25 2017-11-22 General Electric Company Procédés et appareil de moulage et de durcissement de composites
CN111113945A (zh) * 2019-12-17 2020-05-08 湖南中泰特种装备有限责任公司 一种pe头盔制作方法
CN113349501A (zh) * 2021-05-17 2021-09-07 江西联创电声有限公司 一种头盔及其制备方法
CN114619683A (zh) * 2022-01-26 2022-06-14 湖北爱骑士体育用品有限公司 一种安全头盔成型工艺及安全头盔
US20220410503A1 (en) * 2019-08-22 2022-12-29 Siempelkamp Maschinen- Und Anlagenbau Gmbh Method and device for producing a component from a fiber composite material
CN116039121A (zh) * 2023-02-15 2023-05-02 歌尔股份有限公司 碳纤维基复合制件及其制备方法、镜架和眼镜

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Cited By (28)

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Publication number Priority date Publication date Assignee Title
WO2011128453A3 (fr) * 2010-04-15 2012-03-08 Coexpair Procédé et appareil pour mouler des pièces en matériaux composites
BE1019293A5 (fr) * 2010-04-15 2012-05-08 Coexpair Procede et dispositif de moulage de pieces en materiau composite.
AU2011239964B2 (en) * 2010-04-15 2016-06-02 Coexpair Method and apparatus for moulding parts made from composite materials
WO2011128453A2 (fr) 2010-04-15 2011-10-20 Coexpair Procédé et appareil pour mouler des pièces en matériaux composites
US9302433B2 (en) 2010-04-15 2016-04-05 Coexpair Method and apparatus for moulding parts made from composite materials
DE102010054933B4 (de) * 2010-12-17 2013-01-10 Daimler Ag Vorrichtung und Verfahren zum Herstellen einer komplex-dreidimensional geformten faserverstärkten Preform
DE102010054934B4 (de) * 2010-12-17 2013-01-17 Daimler Ag Vorrichtungen und Verfahren zum Herstellen komplex-dreidimensional geformter faserverstärkter Preforms
EP2646216A4 (fr) * 2011-01-12 2015-02-25 Bae Systems Aerospace & Defense Group Inc Procédé de fabrication de casques de protection légers pour un usage militaire et d'autres usages
EP2561978A3 (fr) * 2011-08-25 2017-11-22 General Electric Company Procédés et appareil de moulage et de durcissement de composites
KR20140127828A (ko) * 2012-01-24 2014-11-04 매트 글로벌 솔루션즈, 에스.엘. 외향 개구를 가지는 내부 공동이 구비되는 복합 재료로 이루어지는 본체를 제조하기 위한 방법 및 장치
US9833933B2 (en) 2012-01-24 2017-12-05 Mat Global Solutions, S.L. Method and apparatus for manufacturing a body made of composite material provided with an inner cavity with an outward opening
KR102035880B1 (ko) 2012-01-24 2019-10-23 매트 글로벌 솔루션즈, 에스.엘. 외향 개구를 가지는 내부 공동이 구비되는 복합 재료로 이루어지는 본체를 제조하기 위한 방법 및 장치
CN104136202A (zh) * 2012-01-24 2014-11-05 马特全球解决有限公司 设有向外开口型内腔的复合材料制本体的制造方法和设备
WO2013110839A1 (fr) * 2012-01-24 2013-08-01 Mat Global Solutions, S.L. Procédé et appareil pour la fabrication d'un corps de matériau composite ménagé d'une cavité intérieure avec une ouverture sur l'extérieur
ES2415739R1 (es) * 2012-01-24 2014-02-12 Mat Global Solutions, S.L. Procedimiento y aparato para la fabricación de un cuerpo de material composite provisto de una cavidad interior con una abertura al exterior
CN104136202B (zh) * 2012-01-24 2017-04-19 马特全球解决有限公司 设有向外开口型内腔的复合材料制本体的制造方法和设备
AU2013213498B2 (en) * 2012-01-24 2017-04-20 Mat Product & Technology, S.L.U. Method and apparatus for manufacturing a body made of composite material provided with an inner cavity with an outward opening
US9307803B1 (en) 2013-03-15 2016-04-12 INTER Materials, LLC Ballistic helmets and method of manufacture thereof
US10448695B2 (en) 2013-03-15 2019-10-22 Inter Materials, Inc. Ballistic helmets and method of manufacture thereof
CN104802422A (zh) * 2015-03-24 2015-07-29 徐州海伦哲专用车辆股份有限公司 一种绝缘玻璃钢工作平台的制作方法
CN105034403A (zh) * 2015-06-25 2015-11-11 北京卫星制造厂 一种复合材料壳体的制造方法
US20220410503A1 (en) * 2019-08-22 2022-12-29 Siempelkamp Maschinen- Und Anlagenbau Gmbh Method and device for producing a component from a fiber composite material
US12083750B2 (en) * 2019-08-22 2024-09-10 Siempelkamp Maschinen-Und Anlagenbau Gmbh Method and device for producing a component from a fiber composite material
CN111113945A (zh) * 2019-12-17 2020-05-08 湖南中泰特种装备有限责任公司 一种pe头盔制作方法
CN113349501A (zh) * 2021-05-17 2021-09-07 江西联创电声有限公司 一种头盔及其制备方法
CN113349501B (zh) * 2021-05-17 2022-06-14 江西联创电声有限公司 一种头盔及其制备方法
CN114619683A (zh) * 2022-01-26 2022-06-14 湖北爱骑士体育用品有限公司 一种安全头盔成型工艺及安全头盔
CN116039121A (zh) * 2023-02-15 2023-05-02 歌尔股份有限公司 碳纤维基复合制件及其制备方法、镜架和眼镜

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