Hybrid laminated fiber sheets

• US 20050153098A1
• Filed: 01/12/2004
• Published: 07/14/2005
• Est. Priority Date: 01/12/2004
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Bhatnagar, Ashok, Wagner, Lori, Murray, Harold Lindley Jr.
• Granted Patent: US 7,288,307 B2
• Time in Patent Office: Days
• US Class Current: 428/113
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: F41H 5/0435 the additional layers being only fibre- or fabric-reinforced layers
• CPC Class Codes: F41H 5/0485 all the layers being only fibre- or fabric-reinforced layers
• CPC Class Codes: Y10S 428/906 Roll or coil
• CPC Class Codes: Y10T 428/24058 including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24074 Strand or strand-portions
• CPC Class Codes: Y10T 428/24124 Fibers

Abstract

Hybrid laminated unidirectional fiber sheets, and assemblies thereof, having utility for impact absorption, ballistic-resistance, penetration-resistance, spall shields, structural composites and for other applications.

Claims

1. A laminate comprising N pairs of laminae comprised of unidirectional fibers in a matrix where N is an integer equal to or greater than 2;

the fiber composition of a first lamina of a given pair of laminae being the same as the fiber composition of the second lamina of said given pair;

the fiber direction in said first lamina of said given pair being normal to the fiber direction in said second lamina of said given pair;

the direction of the fibers in a lamina being at an angle relative to the direction of the fibers in adjacent laminae;

the number of pairs of laminae having fiber compositions different from one another being from 2 to N; and

the fiber laminae comprising the laminate being bonded together in stacked array.

2. The laminate of claim 1 where N is from 2 to 10.

3. The laminate of claim 1 where N is from 2 to 4.

4. The laminate of claim 1 in the form of a continuous roll of indefinite length.

5. The laminate of claim 1 having a balanced construction.

6. The laminate of claim 1 having a symmetrical construction about a mid-plane

7. The laminate of claim 1, wherein at least one pair of laminae is comprised of a plurality of fibers having a tenacity greater than 15 grams/denier measured by ASTM 2256.

8. The laminate of claim 1, wherein at least one pair of laminae is comprised of a plurality of fibers having a tenacity greater than 30 grams/denier measured by ASTM 2256

9. The laminate of claim 1, wherein at least one pair of laminae is comprised of a plurality of fibers having a tenacity greater than 40 grams/denier measured by ASTM 2256

10. The laminate of claim 1 wherein said fibers are selected from the group consisting of high molecular weight polyethylene, aramid, PBO, PBT, polyamide, polyester, and ceramic fibers.

11. The laminate of claim 1, wherein said fibers are selected from the group consisting of high molecular weight polyethylene, poly(p-phenyleneterephthalamide), copolymers of p-phenylene terephthalamide, poly(p-phenylene-2-6-benzobisoxazole), poly(p-phenylene-2-6-benzobisthiazole), polyethylene terephthalate, nylon 6, nylon 6,6, nylon 4,6, and ceramic fibers.

12. The laminate of claim 1, wherein said at least one of said fibers is selected from the group consisting of high molecular weight polyethylene, poly(p-phenylene terephthalamide), copolymers of p-phenylene terephthalamide, poly(p-phenylene-2-6-benzobisoxazole), and poly(p-phenylene-2-6-benzobisthiazole).

13. The laminate of claim 1 wherein at least one pair of laminae is comprised of two or more fibers of different composition in essentially periodic array in a direction transverse to the fiber direction.

14. The laminate of claim 1, wherein the content of each chemically distinguishable fiber is from about 1 percent to 99 percent by weight of the laminate.

15. The laminate of claim 1, wherein said matrix is an elastomer having an initial tensile modulus less than 6000 psi (41.4 MPa) measured by ASTM D638.

16. The laminate of claim 1, wherein said matrix material has an initial tensile modulus more than 1×

10⁶ psi (6.9 GPa) measured by ASTM D638.

17. The laminate of claim 1, wherein said matrix comprises from 1 to 25 percent by weight of the laminate.

18. The laminate of claim 1, additionally comprising a plastic sheet as at least one surface of the laminate.

19. The laminate of claim 18, wherein said plastic sheet is selected from the group consisting of polyolefin, polyamide, polyester, polycarbonate, ionomer and polyfluorocarbon.

20. The laminate of claim 19, wherein said plastic sheet is polyethylene.

21. The laminate of claim 19, wherein said plastic sheet comprises from 1 to 40 percent by weight of the laminate.

22. The laminate of claim 1 comprising a first and second pair of laminae of unidirectional fibers in a matrix, consisting in sequence of a first, second, third, and fourth lamina;

said first pair consisting of said first and fourth laminae, the fiber directions in said first and fourth laminae being normal to each other;

said first pair being comprised of a first fiber composition;

said second pair consisting of said second and third laminae, the fiber directions in said second and third laminae being normal to each other;

said second pair being comprised of a second fiber composition different from said first fiber composition;

the fiber direction in said first lamina being normal to the fiber direction in said second lamina;

the fiber direction in said third lamina being normal to the fiber direction in said fourth lamina; and

the laminae comprising the laminate being bonded to each other in stacked array.

23. The laminate of claim 22 in the form of a continuous roll of indefinite length.

24. The laminate of claim 22, wherein at least one of said first and second fibers is selected from the group consisting of high molecular weight polyethylene, poly(p-phenylene terephthalamide), copolymers of p-phenylene terephthalamide, poly(p-phenylene-2-6-benzobisoxazole), and poly(p-phenylene-2-6-benzobisthiazole).

25. The laminate of claim 22, wherein said first and second fibers are high molecular weight polyethylene and aramid, respectively.

26. The laminate of claim 22, wherein said first and second fibers are high molecular weight polyethylene and poly(p-phenylene-2-6-benzobisoxazole), respectively.

27. The laminate of claim 22, wherein said first and second fibers are aramid and poly(p-phenylene-2-6-benzobisoxazole), respectively.

28. The laminate of claim 22, additionally comprising a plastic sheet as at least one surface of the laminate.

29. The laminate of claim 28, wherein said plastic sheet is selected from the group consisting of polyolefin, polyamide, polyester, polycarbonate, ionomer and polyfluorocarbon.

30. The laminate of claim 29 wherein said plastic sheet is polyethylene.

31. The laminate of claim 29 wherein said plastic sheet comprises from 1 to 40 percent by weight of the laminate.

53. A rigid panel comprising a plurality of plies of the laminate of claim 1 or claim 18, bonded together in stacked array and meeting the requirements of NIJ Standard 0101.04 Revision A, for Type IIA body armor.

54. A rigid panel comprising a plurality of plies of the laminate of claim 22 or claim 28, bonded together in stacked array and meeting the requirements of NIJ Standard 0101.04 Revision A, for Type IIA body armor.

56. The rigid panel of claim 54, 55, or 56 having a V50 and SEAT at least as great as the weight average V50 and SEAT of its constituents.

57. A rigid panel comprising a plurality of plies of the laminate of claim 1 or claim 18, bonded together in stacked array and meeting at least the requirements of NIJ Standard 0115.00 for Type 1 stab protection.

58. A rigid panel comprising a plurality of plies of the laminate of claim 22 or claim 28, bonded together in stacked array and meeting the requirements of NIJ Standard 0115.00 for Type 1 stab protection.

60. The rigid panel of claim 58, 59 or 60 having a penetration-resistance at least as great as the weight average penetration resistance of its constituents.

61. A flexible article comprising a plurality of the laminates of claim 18, claim 28, claim 49, and their combination, said laminates being unconnected, or loosely connected to each other and meeting the requirements of NIJ Standard 0101.04 Revision A, for Type IIA body armor.

63. A flexible article comprising a plurality of the laminates of claim 18, claim 28, claim 49, and their combination, said laminates being unconnected, or loosely connected to each other and meeting the requirements of NIJ Standard 0115.00 for Type 1 stab protection.

64. The flexible article of claim 63 having a penetration resistance as least as great as the weight average of its constituents.

32. A laminate comprising two or more laminae of unidirectional fibers in a matrix;

each said lamina being comprised of two or more fibers of different composition in essentially periodic array in a direction transverse to the fiber direction;

the direction of the fibers in one lamina being at an angle relative to the direction of the fibers in adjacent laminae; and

the laminae being bonded together in stacked array.

33. The laminate of claim 32 comprising at least one pair of said laminae, wherein the fiber direction in a first lamina of said pair is normal to the fiber direction of the second lamina of said pair.

34. The laminate of claim 33 wherein the composition and construction of said first lamina of said pair is the same as the composition and construction of said second lamina of said pair.

35. The laminate of claim 32 in the form of a continuous roll of indefinite length.

36. The laminate of claim 32 having a balanced construction.

37. The laminate of claim 32 having a symmetrical construction about a mid-plane.

38. The laminate of claim 32 wherein the periodic distance between fibers of the same composition is not greater than about 9 millimeters.

39. The laminate of claim 32 wherein the periodic distance between fibers of the same composition is not greater than about 5 millimeters.

40. The laminate of claim 32, wherein at least one of said fibers has a tenacity greater than 15 grams/denier measured by ASTM 2256.

41. The laminate of claim 32, wherein at least one of said fibers has tenacity greater than 30 grams/denier measured by ASTM 2256.

42. The laminate of claim 32, wherein at least one of said fibers has a tenacity greater than 40 grams/denier measured by ASTM 2256.

43. The laminate of claim 32, wherein said fibers are selected from the group consisting of polyethylene, aramid, polybenzazole (PBO), polybenzthiazole (PBT), polyamide, polyester, and ceramic fibers.

44. The laminate of claim 32, wherein said fibers are selected from the group consisting of polyethylene, poly(p-phenylene terephthalamide), copolymers of p-phenylene terephthalamide, poly(p-phenylene-2-6-benzobisoxazole), poly(p-phenylene-2-6-benzobisthiazole), polyethylene terephthalate, nylon 6, nylon 6,6, nylon 4,6, and ceramic fibers.

45. The laminate of claim 32, wherein said fibers are aramid and poly(p-phenylene-2-6-benzobisoxazole)

46. The laminate of claim 32, wherein said matrix is an elastomer having an initial tensile modulus less than 6000 psi (41.4 MPa) measured by ASTM D638.

47. The laminate of claim 32, wherein said matrix material has an initial tensile modulus more than 1×

10⁶ psi (6.9 GPa) measured by ASTM D638.

48. The laminate of claim 32, wherein said matrix comprises from 1 to 25 percent by weight of the laminate.

49. The laminate of claim 32, additionally comprising a plastic sheet as at least one surface of the laminate.

50. The laminate of claim 49, wherein said plastic sheet is selected from the group consisting of polyolefin, polyamide, polyester, polycarbonate, ionomer and polyfluorocarbon.

51. The laminate of claim 49, wherein said plastic sheet is polyethylene.

52. The laminate of claim 49, wherein said plastic sheet comprises from 1 to 40 percent by weight of the laminate.

55. A rigid panel comprising a plurality of plies of the laminate of claim 32 or claim 49, bonded together in stacked array and meeting the requirements of NIJ Standard 0101.04 Revision A, for Type IIA body armor.

59. A rigid panel comprising a plurality of plies of the laminate of claim 32 or claim 49, bonded together in stacked array and meeting the requirements of NIJ Standard 0115.00 for Type 1 stab protection.

62. The flexible article of claim 62, having a V50 and SEAT at least as great as the weight average V50 and SEAT of its constituents.