Complex composite article having improved impact resistance

• US 4,737,402 A
• Filed: 12/09/1985
• Issued: 04/12/1988
• Est. Priority Date: 02/28/1985
• Status: Expired due to Term

• Current Assignee: Alliedsignal Inc.
• Original Assignee: Allied Corp. (Honeywell International Inc.)
• Inventors: Kavesh, Sheldon, Palley, Igor, Harpell, Gary A., Prevorsek, Dusan C.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US06/825,040
• Time in Patent Office: 855 Days
• Field of Search: 428/229, 428/246, 428/284, 428/286, 428/287, 428/252, 428/902, 428/911, 428/297
• US Class Current: 442/187
• CPC Class Codes: A42B 3/062 with reinforcing means
• CPC Class Codes: C08J 5/243 using carbon fibres
• CPC Class Codes: C08J 5/246 using polymer based synthetic fibres
• 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 428/902 High modulus filament or fiber
• CPC Class Codes: Y10S 428/911 Penetration resistant layer
• CPC Class Codes: Y10T 442/3049 Including strand precoated with other than free metal or alloy
• CPC Class Codes: Y10T 442/3415 Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
• CPC Class Codes: Y10T 442/3528 Three or more fabric layers
• CPC Class Codes: Y10T 442/607 Strand or fiber material is synthetic polymer
• CPC Class Codes: Y10T 442/656 Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
• CPC Class Codes: Y10T 442/671 Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material

Abstract

The present invention provides an improved, complex composite article of manufacture which comprises a network of high strength fibers having a tensile modulus of at least about 160 grams/denier and a tenacity of at least about 7 g/denier. An elastomeric material substantially coats each of the individual fibers, and has a tensile modulus of less than about 6,000 psi, measured at 25° C. The coated fibers are provided with at least one additional rigid layer on a major surface of the coated fibers to produce a rigid complex composite. Composites of this construction have improved resistance to environmental hazards, improved impact resistance, and are unexpectedly effective as ballistic resistant articles such as armor plate or helmets.

Claims

1. A composite article of manufacture comprising:

(a) fiber having a tensile modulus of at least about 160 g/denier and a tenacity of at least about 7 g/denier substantially coated with an elastomeric material which has a tensile modulus (measured at about 23°

C.) of less than about 6,000 psi (414 MPa); and

(b) at least one rigid material arranged with said coated fiber to form a rigid composite article.

2. An article as recited in claim 1 wherein said article comprises a plurality of said coated fibers.

3. An article as recited in claim 1 wherein said fiber comprises a plurality of filaments.

4. An article as recited in claim 3 wherein each filament of fiber is substantially coated with said elastomeric material.

5. An article as recited in claim 2 further comprising an elastomeric matrix material which has a tensile modulus (measured at about 23°

C.) of less than about 6,000 psi (414 mPa) combined with said coated fibers to form a simple composite.

6. An article as recited in claim 5 wherein said elastomeric matrix material and said elastomeric material are the same material.

7. An article as recited in claim 2 further comprising a matrix material combined with said coated fibers to form a simple composite.

8. An article as recited in claim 5 wherein said at least one rigid material is arranged as a layer on a major surface of said simple composite.

9. An article as recited in claim 7 wherein said at least one rigid material is arranged as a layer on a major surface of said simple composite.

10. An article as recited in claim 1 wherein said article comprises a sheet-like array of a plurality of said fiber.

11. An article as recited in claim 1 wherein said article comprises a plurality of said fiber in a non-woven but regular pattern.

12. An article as recited in claim 5 wherein the volume fraction of fiber in said simple composite is at least about 0.3.

13. An article as recited in claim 5 wherein the volume fraction of said fiber in said simple composite is at least about 0.5.

14. An article as recited in claim 5 wherein the volume fraction of fiber in said simple composite is at least about 0.75.

15. An article as recited in claim 1 wherein said elastomeric matrix material comprises an elastomer having a glass transition temperature of less than about 0°

C.

16. An article as recited in claim 15 wherein said elastomer has a glass transition temperature of less than about -40°

C.

17. An article as recited in claim 15 wherein said elastomer has tensile modulus of less than about 15,000 psi.

18. An article as recited in claim 1 wherein said elastomeric material has a tensile modulus of less than about 2500 psi.

19. An article as recited in claim 1 wherein said fiber is high molecular weight fiber having a tensile modulus of at least about 500 g/denier and a tenacity of at least about 15 g/denier.

20. An article as recited in claim 1 wherein said fiber is selected from the group consisting of:

polypropylene fiber having a weight average molecular weight of at least about 750,000, a modulus of at least about 200 g/denier and a tenacity of at least about 11 g/denier;

polyethylene fiber having a weight average molecular weight of at least about 500,000, a modulus of at least about 500 g/denier and a tenacity of at least about 15 g/denier;

aramid fiber having a modulus of at least about 500 g/denier and a tenacity of at least about 18 g/denier, high molecular weight polyvinyl alcohol fiber having a weight average molecular weight of at least about 750,000, a modulus of at least about 200 g/denier and a tenacity of at least about 10 g/denier; and

, combinations thereof.

21. An article as recited in claim 5 wherein said simple composite is a sheet material to which is laminated at least one additional simple composite sheet material.

22. An article as recited in claim 1 comprising a plurality of said fiber arranged as yarn.

23. An article as recited in claim 22 wherein the yarn is arranged to form a fabric.

24. An article as recited in claim 5 wherein said fiber is arranged to form a woven fabric.

25. An article as recited in claim 1 wherein a plurality of fiber are arranged in a matrix of said elastomer material to form a sheet-like material on which at least two rigid materials in the form of layers are provided, at least one rigid layer being provided on each side of said sheet-like material.

32. An article as recited in claim 19 wherein said fiber is selected from the group consisting of polypropylene fiber having a weight average molecular weight of at least about 750,000, polyethylene fiber having a molecular weight of at least about 500,000 and a tenacity of at least about 15 g/denier, aramid fiber having a modulus of at least about 500 g/denier and a tenacity of at least about 18 g/denier, high molecular weight polyvinyl alcohol fibers having a weight average molecular weight of at least about 750,000, and combinations thereof.

34. Armor plate comprising the ballistic resistant article of claim 32.

35. A helmet comprising the ballistic resistant article of claim 32.

26. A ballistic resistant composite article of manufacture comprising:

(a) fiber having a tensile modulus of at least about 200 g/denier and a tenacity of at least about 10 g/denier substantially coated with an elastomeric material which has a tensile modulus (measured at about 23°

C.) of less than about 6,000 psi (414 MPa); and

(b) at least one rigid material arranged with said coated fiber to form a rigid composite article.

27. An article as recited in claim 26, wherein said fiber is high molecular weight fiber having a tensile modulus of at least about 500 g/denier and a tenacity of at least about 15 g/denier.

28. An article as recited in claim 26 comprising a plurality of said fiber arranged as a sheet-like array.

29. An article as recited in claim 26 wherein the volume fraction of fiber in said coated fiber is at least about 0.5.

30. An article as recited in claim 26 wherein said elastomeric material comprises an elastomer having a glass transition temperature of less than about -40°

C.

31. An article as recited in claim 26 wherein said elastomeric material has a tensile modulus of less than about 2500 psi.

33. An article as recited in claim 27 wherein said at least one rigid material comprises highly oriented ultra-high molecular weight polyethylene fiber in a rigid matrix material.

36. A complex composite comprising:

(a) a simple composite comprising fibers having a modulus of at least about 500 g/denier and a tenacity of at least about 15 g/denier in an elastomeric matrix having a tensile modulus of less than about 6000 psi; and

(b) a rigid material comprising a ceramic arranged adjacent said simple composite.