Impact resistant rigid composite and method for manufacture

• US 6,642,159 B1
• Filed: 08/16/2000
• Issued: 11/04/2003
• Est. Priority Date: 08/16/2000
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Bhatnagar, Ashok, Arvidson, Brian Duane
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): WACHTEL, ALEXIS A
• Application Number:
  US09/639,903
• Time in Patent Office: 1,175 Days
• Field of Search: 442/134, 442/135, 442/327, 428/113, 428/109, 428/292.1, 428/295.1, 428/294.4
• US Class Current: 442/134
• CPC Class Codes: B29C 70/088 and with one or more layers of non-plastics material or non-specified material, e.g. supports
• CPC Class Codes: B29C 70/50 for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• 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 5/0428 Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
• CPC Class Codes: F41H 5/0457 Metal layers in combination with additional layers made of fibres, fabrics or plastics
• CPC Class Codes: F41H 5/0478 Fibre- or fabric-reinforced layers in combination with plastics layers
• CPC Class Codes: Y10T 428/24091 with additional layer[s]
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 442/2615 Coating or impregnation is resistant to penetration by solid implements
• CPC Class Codes: Y10T 442/2623 Ballistic resistant
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

An impact resistant rigid composite has a plurality of fibrous layers, each of which comprise a network of filaments. The fibrous layers are disposed in a matrix, with elastomeric layer(s) therebetween. Prior to curing of the matrix, successive fibrous layers exhibit therebetween a peel resistance of at least about 3 g/cm. The composite has high rigidity combined with superior ballistic properties. When bonded at one or both surfaces to a hard plate selected from the group consisting of metals and ceramics, the composite affords increased protection against armor piercing projectiles.

Claims

1. An impact resistant rigid composite, comprising:

(a) a plurality of fibrous layers, each of said layers comprising a network of filaments having a tenacity equal to or greater than about 7 g/denier, a tensile modulus of at least about 150 g/denier, and an energy-tobreak of at least about 8 J/g, as measured by ASTM D2256, said fibrous layers being in a matrix having a tensile modulus of at least about 1×

10⁶ psi (6895 Mpa,) as measured by ASTM 0638; and

(b) a layer of elastomer disposed between adjacent fibrous layers and having a tensile modulus less than about 6,000 psi (41,300 kPa), as measured by ASTM D638, said elastomer providing a peel resistance of at least about 3 g/cm as determined on uncured fibrous layers with said elastomer therebetween after pressing at 66°

C for 5 seconds at 332 psi (2,290 kPa).

2. An impact resistant composite as recited by claim 1, wherein the filaments in the network are selected from the group consisting of extended chain polyethylene, aramid and polybenzazole.

3. An impact resistant composite as recited by claim 1, wherein the elastomer in the elastomeric layers has a tensile modulus less than about 4000 psi (13,800 kPa) as measured by ASTM D638.

4. An impact resistant composite as recited by claim 1, wherein the elastomer in the elastomeric layers has a tensile modulus less than about 1000 psi (6895 kPa) as measured by ASTM D638.

5. An impact resistant composite as recited by claim 1, wherein the filaments in the network have a tenacity equal to or greater than about 16 g/d, a tensile modulus equal to or greater than about 400 g/d and an energy to break equal to or greater than about 27 J/g.

6. An impact resistant composite as recited by claim 1, wherein the peel resistance is at least about 10 g/cm.

7. An impact resistant composite as recited by claim 1, wherein the matrix comprises about 14 to 30 wt % of the composite and the elastomeric layers comprise between about 2 and about 10 wt % of the composite.

8. An impact resistant composite as recited by claim 1, wherein said fibrous network comprises a sheet-like filament array in which said filaments are arranged substantially parallel to one another along a common filament direction and wherein successive fibrous layers have filament directions rotated with respect to one another.

9. An impact resistant composite as recited by claim 8, wherein the directions of the filaments in successive layers are rotated 90 degrees to one another.

10. An impact resistant composite as recited by claim 8, wherein a plate is bonded to a surface of the composite and wherein the plate comprises one or more materials selected from the group consisting of a metal and a ceramic.

11. An impact resistant composite as recited by claim 8, wherein a plate is bonded to a surface of the composite and the plate comprises one or more materials selected from the group consisting of steel, titanium, aluminum oxide and boron carbide.

12. An uncured composite comprising:

(a) a plurality of fibrous layers, each of said layers comprising a network of filaments having a tenacity equal to or greater than about 7 g/denier, a tensile modulus of at least about 150 g/denier, and an energy-to-break of at least about 8 J/g, said fibrous layers being disposed in an uncured thermosetting matrix which, when fully cured, has a tensile modulus of at least about 1×

10⁶ psi (6895 MPa), as measured by ASTM D638; and

(b) a layer of elastomer between the fibrous layers, said elastomer having a tensile modulus less than about 6000 psi (41,300 kPa), as measured by ASTM D638, and providing a peel resistance of at least about 3 g/cm after pressing at 66°

C. for 5 seconds at 332 psi (2,290 kPa).