Patent Application
20180243967
Body armor is generally shaped to fit snugly onto a user so as to provide the maximum protection while maintaining an acceptable range of motion. Body armor is fabricated of numerous layers, each of which provides a specific function. For example, some layers can include an energy absorbing layer, a penetration resistant layer, a reinforcing layer, an impact absorbing layer, or a fragmentation minimizing layer. Most of the layers are generally flexible, and capable of being laminated onto a substantially planar or non-planar surface. However, where the armor for human body use includes one or more ceramic strike-face layers, the layer can be non-planar, and substantially rigid and non-compliant.
In most body armor systems, each successive functional flexible layer is generally bonded to a non-planar ceramic strike-face using resins that require heat and pressure. Oftentimes, each successive functional layer is bonded sequentially, one layer at a time. To reduce fabrication complexity and cycle time, a need exists for a technology that enables the fabrication of body armor, particularly non-planar armor used in on-body applications, where all functional layers of the armor are bonded and cured in one step.
Some embodiments of the invention include an armor production tool comprising a housing including at least two housing portions which form a substantially air-tight chamber when closed. In some embodiments, the tool can comprise a lower flexible membrane dimensioned to fit within the housing and form at least a portion of a mold, and an upper flexible membrane dimensioned to fit within the housing and engage the lower flexible membrane to thereby form another portion of the mold. Further, the tool can comprise at least one pressure port for insertion of pressurizing fluid to pressurize the chamber and move portions of the mold towards each other, and a locking mechanism for locking the two housing portions together.
In some embodiments, the armor production tool includes a pressurizable lower chamber defined by the lower flexible membrane and a portion of the housing. In some further embodiments, the upper flexible membrane and a portion of the housing can define an upper chamber that can be pressurized.
Some embodiments include an armor production tool claimed where the upper flexible membrane and a portion of the housing define an upper chamber that can be pressurized, and the lower flexible membrane and a portion of the housing define a lower chamber that can be pressurized substantially simultaneously with the upper chamber by the at least one pressure port. In some further embodiments, the upper and lower chambers can be depressurized substantially simultaneously by the at least one pressure port. In some other embodiments, the upper flexible membrane and a portion of the housing define an upper chamber that can be pressurized, and the lower flexible membrane and a portion of the housing define a lower chamber that can be pressurized substantially independently from the upper chamber.
Some embodiments of the invention include a method of producing armor comprising providing a housing including at least two housing portions which form a substantially air-tight chamber when closed. The method includes forming a portion of a mold with a lower flexible membrane dimensioned to fit within the housing, forming another portion of the mold with an upper flexible membrane dimensioned to fit within the housing, and inserting at least one layer of a composite material to be molded between a portion of the lower flexible membrane and a portion of the upper flexible membrane. The method also includes closing and locking the housing portions together to form the substantially air-tight chamber, and adding pressurized fluid to pressurize the chamber and move portions of the mold towards each other.
In some embodiments of the method, the lower flexible membrane and a portion of the housing define a lower chamber that can be pressurized. In some further embodiments of the method, the upper flexible membrane and a portion of the housing define an upper chamber that can be pressurized. In some other embodiments of the method, the upper flexible membrane and a portion of the housing define an upper chamber that can be pressurized, and the lower flexible membrane and a portion of the housing define a lower chamber that can be pressurized substantially simultaneously with the upper chamber by the at least one pressure port.
Some embodiments of the method further include the step of depressurizing the upper and lower chambers substantially simultaneously using the at least one pressure port. In some other embodiments, the method further includes pressurizing an upper chamber defined by the upper flexible membrane and a portion of the housing, and pressurizing, substantially independently from the upper chamber, a lower chamber defined by the lower flexible membrane and a portion of the housing. In some embodiments of the method, the composite material is inserted into a preform cavity defined by the upper and lower flexible membranes.
In some embodiments of the method, the composite material comprises at least one of a polymer comprising aramids (aromatic polyamides), poly(m-xylylene adipamide), poly(p-xylylene sebacamide), poly (2,2,2-trimethyl-hexamethylene terephthalamide), poly(piperazine sebacamide), poly(metaphenylene isophthalamide) (Nomex) and poly(p-phenylene terephthalamide), aliphatic and cycloaliphatic polyamides, including the copolyamide of 30% hexamethylene diammonium isophthalate and 70% hexamethylene diammonium adipate, the copolyamide of up to 30% bis-(-amidocyclohexyl) methylene, terephthalic acid and caprolactam, polyhexamethylene adipamide, poly(butyrolactam), poly(-aminonanoic acid), poly(enantholactam), poly(caprillactam), polycaprolactam, poly(p-phenylene terephthalamide), polyhexamethylene sebacamide, polyaminoundecanamide, polydodecanolacatam, polyhexamethylene isophthalamide, polyhexamethylene terephthal amide, polycaproamide, poly(nonamethylene azelamide), poly(decamethylene azelamide), poly(decamethylenesebacamide), poly[bis-4-aminocyclohexyl) methane 1,10-decanedi-carboxamide](Qiana)(trans), and aliphatic, cycloaliphatic and aromatic polyesters including poly(1,4-cyclohexylidene dimethyl eneterephthalate) cis and trans, poly(ethylene-2,6-naphthalate), poly(1,4-cyclohexane dimethylene terephthalate) (trans), poly(decamethylene terephthalate, poly(ethylene terephthalate), poly(ethylene isophthalate), poly(ethylene oxybenzoate), poly(para-hydroxy benzoate), poly(beta,beta dimethylpropiolactone), poly(decamethylene adipate), or poly(ethylene succinate).
In some other embodiments of the method, the composite material comprises at least one polymer formed of extended chain polymers by the reaction of beta-unsaturated monomers of the formula RIR2-C═CH2, where RI and R2 are either identical or different, and are hydrogen, hydroxyl, halogen, alkylcarbonyl, carboxy, alkoyxycarbonyl, heterocycle or alkyl or aryl, where the alkyl or aryl can be substituted with one or more substituents including alkoxy, cyano, hydroxyl, akyl or aryl, and extended chain polymers including polystyrene, polyethylene, polypropylene, poly(1-octadecene), polyisobutylene, poly(1-pentene), poly(2-methylstyrene), poly(4-methylstyrene), poly(1-hexene), poly(1-pentene), poly(4-methoxy styrene), poly(5-methyl-1-hexene), poly(4-methylpentene), poly(1-butene), poly(3-methyl-1-butene), poly(3-phenyl-1-propene), polyvinyl chloride, polybutylene, polyacrylonitrile, poly(methyl pentene-1), poly(vinyl alcohol), poly(vinyl-acetate), poly(vinyl butyral), poly(vinyl chloride), poly(vinylidene chloride), vinyl chloride-vinyl acetate chloride copolymer, poly(vinylidene fluoride), poly(methyl acrylate, poly(methylmethacrylate), poly(methacrylonitrile), poly(acrylamide), poly(vinyl fluoride), poly(vinyl formal), poly(3-methyl-1-butene), poly(1-pentene), poly(4-methyl-1-butene), poly(1-pentene), poly(4-methyl-1-pentene), poly(1-hexane), poly(5-methyl-1-hexene), poly(1-octadecene), poly(vinyl cyclopentane), poly(vinylcyclohexane), poly(a-vinylnaphthalene), poly(vinyl methyl ether), poly(vinylethylether), poly(vinyl propylether), poly(vinyl carbazole), poly(vinyl pyrrolidone), poly(2-chlorostyrene), poly(4-chlorostyrene), poly(vinyl formate), poly(vinyl butyl ether), poly(vinyl octyl ether), poly(vinyl methyl ketone), poly(methylisopropenyl ketone), or poly(4-phenyl styrene).
In some further embodiments of the method, a ceramic armor plate is inserted into a preform cavity defined by the upper and lower flexible membranes, and resin and flexible armor materials are layered onto the ceramic body plate, and the plate substantially defines the shape of resulting armor throughout at least the majority of the molding process.
Some embodiments of the invention include a molded armor composite comprising at least one strike-face layer, a plate cover layer, a back cover layer, and at least one backing layer, where each of the layers is configured and arranged to be bonded together by resin and molded together in one molding step. In some further embodiments, at least one backing layer includes a plurality of layers. In some other embodiments, at least one backing layer comprises at least one of a strike-face layer, a strike-face reinforcement layer, a catchment layer, and a back-face reduction layer. In other embodiments, at least one of the plate cover layer and the back cover layer comprises a ballistic layer.
The present invention also includes another embodiment of molding tool used to mold the composite armor. The molding tool may include an outer housing that is comprised of a tool upper and a tool lower that when closed define a molding chamber. In one embodiment, tool upper and tool lower are pivotally connected by a hinge. In another embodiment, tool upper and tool lower are moveable between an open position for loading raw materials and unloading the molded product, and a closed position wherein the upper tool and lower tool form the enclosed molding chamber. One of the upper tool or lower tool may be moveable on a frame or other mechanism to the positions described above. The tool upper and tool lower each include a pressure chamber which is separated from the molding chamber by a membrane or a thermal diaphragm. When a pressurized fluid is introduced into the pressure chamber, a pressure force is applied to the thermal diaphragm from the pressure chamber into the molding chamber.
The thermal diaphragm may include a fluid dispersion layer sandwiched between a thermal transfer membrane on the mold chamber side and a pressure bearing membrane on the pressure chamber side. During operation, a heated or cooled fluid can be circulated through the fluid dispersion layer between an inlet and an outlet and heated or cooled fluid can be passed through the thermal transfer membrane to heat or cool the part as it is being molded. The thermal transfer membrane and the pressure bearing membrane may be flexible and may also have elastic properties to conform to the shape of the composite armor part when pressure is applied. The fluid dispersion layer may include a media disposed therein which is a mesh-like or porous material that may be flexible and may also have elasticity. The fluid dispersion media may have a compressive strength that is greater than the pressure to be applied to the during the molding process so that the fluid dispersion layer does not collapse under the pressure applied from the pressure chamber, and allows the heating or cooling fluid to freely circulate through the fluid dispersion layer when pressure is applied. The structure of this embodiment allows for the heated or cooled fluid to be separated from the pressurized fluid and, thereby makes operation of the molding tool safer.
In operation, the layers of a composite molded armor part are placed into the molding chamber and the tool upper and the tool lower are closed and secured in the closed position. Pressurized fluid is introduced into the pressure chamber through an inlet and heated or cooled fluid is introduced into the fluid dispersion layer through an inlet. The molded armor part may be compressed and heated to either cure a resin used or to thermally bond a plurality of layers together to form a resin free composite. The pressure is applied and the heating/cooling fluid is circulated for the desired curing and/or pressing time period to result in a completed molded armor part or composite. Finally, the pressure is released through the pressurized fluid being removed from the pressure chamber through an outlet or the inlet, and the flow of fluid through the fluid dispersion layer may be stopped. Cooling fluid may be circulated through the fluid dispersion layer to cool the part if desired. The tool upper and the tool lower are separated to expose the mold chamber and the molded armor part can be removed. The application of pressure and heating/cooling fluid circulation may be controlled to operate together or may be independently operated or controlled. Moreover, the operation and application of pressure and/or circulation of the heating/cooling fluid may be the same in the tool upper and tool lower or may be independently controlled in the tool upper and tool lower.
Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
The accompanying drawings form a part of the specification and are to be read in conjunction therewith, in which like reference numerals are employed to indicate like or similar parts in the various views, and wherein:
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
Some embodiments of the invention include a body armor composite structure material, and apparatus and methods of fabrication. Some embodiments include a body armor composite structure material that can include stacking a plurality of layers of one or more different materials and bonding the materials to form a substantially monolithic composite article that can function as body armor. For example, as shown
For example, in some embodiments, a back-face reduction layer 150 can be coupled to the catchment layer 140. In some embodiments, an outer layer covering at least a strike-face or front impact receiving side of the body armor composite 10 (the at least one strike-face layer 120) can include a bump guard 100. In some embodiments, the bump guard 100 can include a spacer fabric, or can include polymeric foam. In some embodiments, the desired shape of the armor is defined at least by the strike-face layer 120, and any other layers can be shaped to substantially the same shape as the strike-face layer 120.
In the example embodiments shown in
In some further embodiments, the body armor composite 10 can include at least one wicking layer (not shown). In some embodiments, at least one wicking layer can be configured and arranged to substantially transport perspiration away from a user's body. For example, in some embodiments, at least one wicking layer can be coupled to an external surface of the body armor composite 10 (i.e., either to a bump guard layer 100 and/or the one or more back-face reduction layers 150). In this instance, the at least one wicking layer can be configured and arranged to contact at least one surface of a user.
In some further embodiments, the body armor composite 10 can include more or less layers and/or arrangements of layers than those shown in
In some embodiments, the body armor composite 10, 15 can include at least one strike-face 120. In some embodiments, the strike-face 120 can comprise a ceramic material. In some embodiments, the strike-face 120 can be a substantially flat or substantially planar.
In some other embodiments, particularly those designed to be used as human body armor, the strike-face 120 can include substantially non-planar portions. For example,
In some embodiments, in order to enable forming and manufacture of the body armor composite 10, 15 with one or more layers and/or portions of the body armor composite 10, 15 that can be substantially non-planar, some embodiments include a process that can include at least one manufacturing step where pre-formed layers (e.g., layers 700a positioned on preform 450 shown in
Some embodiments of the invention include methods of forming body armor composite structures utilizing the preforms 400, 450 formed by the methods described earlier. For example, in some embodiments, body armor composite 10 as shown in
In some embodiments, the process 500 can include trimming and shaping the plurality of layers 700a that are initially formed in step 505 to a desired armor shape (e.g. to fit the strike-face 120). In some alternative embodiments, one or more of the layers 700a can be trimmed to a desired shape once the composite lay-up (e.g., 850 in
In some embodiments, resin can be applied to both top and bottom surfaces of the strike-face 120 (step 550), and the strike-face 120 can be positioned onto the preform 450 (shown as step 560). In some further embodiments, resin can be applied to the top and bottom surfaces of a strike-face reinforcement material 130 (shown as step 570), and steps 560, 570 can be repeated based on the desired number of layers of strike-face reinforcement material 130. Further, in some embodiments, resin can be applied to both top and bottom surfaces of the catchment layer 140 (shown as step 580), which can subsequently be positioned onto the preform 450 (shown as step 590). Steps 580, 590 can be repeated based on the desired number of layers of catchment layer 140. In some embodiments, resin can be applied to the bottom surfaces of the back-face reduction material 150 (shown as step 600), which can subsequently be positioned onto the preform 450 (shown as step 610, and illustrated in
In some embodiments, a release film 50 can be laid into (or otherwise applied to) the surface of the stack in step 620, and the preform 400 can be positioned on the stack (illustrated in
In some embodiments, body armor composite 10, 15 and a wide range of other products can be formed using a method 500 shown in
Some embodiments of the invention include processes for forming body armor composite 15 or other products using flexible mold technologies. For example,
Some embodiments of the invention include preparing an assembly of a plurality of layers 700a within the mold tool 1200, and using the mold tool 1200 to laminate the layers 700a to form a monolithic structure comprising the body armor composite 15. For example, some embodiments of the invention include preparing one or more backing layers 115 in step 665. In some embodiments, one or more layers of the body armor composite 15 can be cut, shaped and/or trimmed to a shape that is substantially the same as a strike-face layer 120. In some embodiments, the strike-face layer 120 can comprise a ceramic material. A resin pre-polymer mixture can be prepared in step 670, and a front cover can be placed in the flexible mold tool 1200 (step 672). In some embodiments, the front cover can comprise a plate cover layer 160. In some embodiments, the plate cover layer 160 can comprise a bump guard 100. In some embodiments, resin can be applied to the strike-face layer 120 in step 674, and the strike-face layer 120 can be placed into the plate cover layer 160 in the mold tool 1200. In some further embodiments, resin can be applied to the one or more backing layers 115 in step 678, and the one or more backing layers 115 can be placed onto the strike-face layer 120 in the mold tool 1200 in step 680. In some embodiments, step 682 can include positioning a back cover layer 165 onto the one or more backing layers 115, and step 684 can include closing the mold tool 1200. In step 686, pressure and/or heat can be applied to the mold tool 1200 for a specific time period, after which the body armor composite 15 can be removed from the mold tool 1200 in step 688.
In some embodiments, the one or more backing layers 115 can comprise a strike-face layer 120, a strike-face reinforcement layer 130, a catchment layer 140, and/or a back-face reduction layer 150. Further, in some embodiments, a bump guard 100 can be placed between the plate cover layer 160 and the strike-face layer 120. In some other embodiments, an optional fabric layer 170 can be placed over either the plate cover layer 160 and/or the back cover layer 165 to form an outer fabric layer. In some embodiments, the composite can be formed by thermally bonding some layers of various materials to themselves under pressure. In some embodiments, various electro-mechancial components can be integrated into the composite structure to form a multi-functional ballistically resistant composite. In some embodiments, a plurality of layers, materials and resins may be vacuum bagged within the mold or tool to evacuate gases and assure no gaseous inclusions compromise the composite.
In some embodiments, either the lower membrane 1230 and/or the upper membrane 1235 can comprise a preform cavity 1237. In some embodiments, the height of the preform cavity 1237 is substantially equal to the thickness of the laminated body armor composite 15. A plurality of layers 700a can then be formed and laminated using the process 660. In the case of the use of the mold tool 1200 in place of the press assembly 800 in the process 500, the height of the preform cavity 1237 can include the thickness of the laminated body armor composite 10, 15 including the preforms 400, 450.
When using either of the processes 500, 660, layers 700a can be laminated by pressurizing the mold tool 1200. In some embodiments, each of the portions 1205a, 1205b can include at least one pressure port 1240. In some embodiments, the pressurizable lower chamber 1210a and upper chamber 1210b can be pressurized using a compressed gas (e.g., air). In some embodiments, the pressurizable lower chamber 1210a and upper chamber 1210b can be at least partially simultaneously pressurized. In some embodiments, after a specific period of time, the pressurizable lower chamber 1210a and upper chamber 1210b of the mold tool 1200 can be substantially depressurized, and opened to enable access to a lamination structure (e.g., such as a body armor composite 15). In some embodiments, a pressure between 100 psi and 150 psi is desirable.
In some embodiments, the housing 1205 can be formed from machined billet aluminum. In some further embodiments, the housing 1205 can comprise other metals such as steel or iron, or other suitable materials including fiber-reinforced plastics, polymers or other composite materials. Some embodiments further include a high durometer silicone frame formed around the perimeter of the interface between the portions 1205a, 1205b.
In some embodiments, one or more layers of body armor composite 10, 15 can be bonded at ambient room temperature. For example, in some embodiments, one or more layers of body armor composite 10, 15 can be bonded at a temperature between about 65° F. and about 80° F. In other embodiments, one or more layers of body armor composite 10, 15 can be bonded at a temperature that is higher than ambient room temperature (i.e., greater than about 80° F.). In some embodiments, the layers and/or the resin can be preheated to 90° F. or other desired temperatures to reduce cycle time.
The bonding temperature can vary depending on at least the composition of one or more layers included in the body armor composite 10, 15. The one or more layers and/or layers of additive bonding material can comprise a polymer and/or a pre-polymer or resin (or a combination thereof) that can be processed at a specified temperature and/or within a specified temperature range. As used herein, the term “pre-polymer” or “resin” can include any material composition that comprises either monomer or a mixture of monomers, and/or a partially reacted polymer or polymers that includes at least some unreacted monomer, and/or a polymer or mixture of polymers, and/or a combination thereof. Further, as used herein, the term “polymer” can included can include a material that comprises a polymer, a copolymer, a homopolymer, a blend of polymers, a blend of copolymers, a blend of homopolymers, or a combination thereof.
In some embodiments, one or more layers of the body armor composite 10, 15 can comprise at least one polymer. For example, in some embodiments, the body armor composite 10, 15 can include at least one strike-face reinforcement layer 130 that comprises at least one polymer. In some embodiments, the reinforcement layer 130 can include polymers that are composed of aramids (aromatic polyamides), poly(m-xylylene adipamide), poly(p-xylylene sebacamide), poly (2,2,2-trimethyl-hexamethylene terephthalamide), poly(piperazine sebacamide), poly(metaphenylene isophthalamide) (Nomex) and poly(p-phenylene terephthalamide) (Kevlar) and aliphatic and cycloaliphatic polyamides, such as the copolyamide of 30% hexamethylene diammonium isophthalate and 70% hexamethylene diammonium adipate, the copolyamide of up to 30% bis-(-amidocyclohexyl) methylene, terephthalic acid and caprolactam, polyhexamethylene adipamide (nylon 66), poly(butyrolactam) (nylon 4), poly(9-aminonanoic acid)nylon 9), poly(enantholactam) (nylon 7), poly(caprillactam) (nylon 8), polycaprolactam (nylon 6), poly(p-phenylene terephthalamide), polyhexamethylene sebacamide (nylon 6,10), polyaminoundecanamide (nylon 11), polydodecanolacatam (nylon 12), polyhexamethylene isophthalamide, polyhexamethylene terephthal amide, polycaproamide, poly(nonamethylene azelamide) (Nylon 9,9), poly(decamethylene azelamide) (nylon 10,9), poly(decamethylenesebacamide) (nylon 10,10), poly[bis-4-aminocyclohexyl)methanel, 10-decanedi-carboxamide](Qiana)(trans), or combination thereof; and aliphatic, cycloaliphatic and aromatic polyesters such as poly(1,4-cyclohexylidene dimethyl eneterephthalate) cis and trans, poly(ethylene-2,6-naphthalate), poly(1,4-cyclohexane dimethylene terephthalate) (trans), poly(decamethylene terephthalate, poly(ethylene terephthalate), poly(ethylene isophthalate), poly(ethylene oxybenzoate), poly(para-hydroxy benzoate), poly(beta,beta dimethylpropiolactone), poly(decamethylene adipate), poly(ethylene succinate) and the like.
In some other embodiments, reinforcement layer 130 can comprise at least one polymer formed of extended chain polymers by the reaction of beta-unsaturated monomers of the formula:
R1R2—C═CH2
where R1 and R2 are either identical or different, and are hydrogen, hydroxyl, halogen, alkylcarbonyl, carboxy, alkoyxycarbonyl, heterocycle or alkyl or aryl, where the alkyl or aryl can be substituted with one or more substituents including alkoxy, cyano, hydroxyl, akyl or aryl. In some embodiments, extended chain polymers can be composed of polystyrene, polyethylene, polypropylene, poly(1-octadecene), polyisobutylene, poly(1-pentene), poly(2-methylstyrene), poly(4-methyl styrene), poly(1-hexene), poly(1-pentene), poly(4-methoxystyrene), poly(5-methyl-1-hexene), poly(4-methylpentene), poly(1-butene), poly(3-methyl-1-butene), poly(3-phenyl-1-propene), polyvinyl chloride, polybutylene, polyacrylonitrile, poly(methyl pentene-1), poly(vinyl alcohol), poly(vinyl-acetate), poly(vinyl butyral), poly(vinyl chloride), poly(vinylidene chloride), vinyl chloride-vinyl acetate chloride copolymer, poly(vinylidene fluoride), poly(methyl acrylate, poly(methylmethacrylate), poly(methacrylonitrile), poly(acrylamide), poly(vinyl fluoride), poly(vinyl formal), poly(3-methyl-1-butene), poly(1-pentene), poly(4-methyl-1-butene), poly(1-pentene), poly(4-methyl-1-pentene), poly(1-hexane), poly(5-methyl-1-hexene), poly(1-octadecene), poly(vinyl cyclopentane), poly(vinylcyclohexane), poly(a-vinylnaphthalene), poly(vinyl methyl ether), poly(vinylethylether), poly(vinyl propylether), poly(vinyl carbazole), poly(vinyl pyrrolidone), poly(2-chlorostyrene), poly(4-chlorostyrene), poly(vinyl formate), poly(vinyl butyl ether), poly(vinyl octyl ether), poly(vinyl methyl ketone), poly(methylisopropenyl ketone), poly(4-phenylstyrene) and the like.
In some embodiments, one or more layers of body armor composite 10, 15 can be bonded to one or more layers of body armor composite 10, 15 using a thermosetting polymer. In some embodiments, thermosetting resin pre-polymer can be applied to at least one side of the at least one of the layers. In some embodiments, a thermosetting resin pre-polymer can be applied to both sides of at least one of the layers. In some embodiments, one or more layers of the body armor composite 10, 15 can be bonded to one or more other layers of body armor composite 10, 15 using an epoxy resin based polymer or pre-polymer. In some other embodiments, one or more layers of body armor composite 10, 15 can be bonded to one or more other layers of body armor composite 10, 15 using a vinyl ester based polymer. In some further embodiments, both an epoxy resin based polymer and a vinyl ester based polymer can be used.
In some embodiments of the invention, the thermosetting resin can comprise an epoxide technology. For example, in some embodiments, epoxies based on saturated or unsaturated aliphatic, cycloaliphatic, aromatic and heterocyclic epoxides can be used. For example, useful epoxides include glycidyl ethers derived from epichlorohydrin adducts and polyols, particularly polyhydric phenols. Another useful epoxide is the dlglycidyl ether of hisphenol A. Additional examples of useful polyepoxides are resorcinol diglycidyl ether, 3,4-epoxy-6-methylcyclohexylmethyl-9,10-epoxystearate, 1,2,-bis(2,3-epoxy-2-methylpropoxy)ethane, diglycidyl ether of 2,2-(p-hydroxyphenyl) propane, butadiene dioxide, dicyclopentadiene dioxide, pentaerythritol tetrakis(3,4 epoxycyclohexanecarboxylate), vinylcyclohexene dioxide, divinylbenzene dioxide, 1,5-pentadiol bis(3,4-epoxycyclohexane carboxylate), ethylene glycol bis(3,4-epoxycyclohexane carboxylate), 2,2-diethyl-1,3-propanediol bis(3,4 epoxycyclohexanecarboxylate), 1,6-hexanediol bis(3,4-epoxycyclohexanecarboxylate),2-butene-1,4-diol-bis(3,4-epoxy-6-methylcyclohexane carboxylate), 1,1,1-trimethylolpropane-tris-(3,4-epoxycyclohexane carboxylate), 1,2,3-propanetriol tris(3,4-epoxycyclohexanecarboxylate), dipropylene glycol bis(2-ethylexyl-4,5-epoxycyclohexane-1,2-dicarboxylate), diethyleneglycol-bis(3,4-epoxy-6-methylcyclohexane carboxylate), triethylene glycol bis(3,4-epoxycyclohexanecarboxylate),3,4-epoxycyclohexyl-methyl-3,4-epoxycyclohexanecarboxylate,3,4-epoxy-1-methylcyclohexyl methyl-3,4-epoxy-1-methylcyclohexane-carboxylate, bis(3,4-epoxycyclohexylmethyl) pimelate, bis(3,4-epoxy-6-methylenecyclohexylmethyl)maleate, bis(3,4-epoxy-6-methylcyclohexylmethyl) succinate, bis(3,4-epoxycyclohexylmethyl) oxalate, bis(3,4-epoxy-6-methylcyclohexylmethyl) sebacate, bis(3,4-epoxy-6-methylcyclohexylmethyl)adipate, bis(3,4-epoxycyclo-hexylmethyl) terephtalate, 2,2′-sulfonyldiethanol bis(3,4-epoxycyclohexanecarboxylate), N,N′-ethylene bis(4,5-epoxycyclohexane-1,2-dicarboximide), di(3,4-epoxycyclohexylmethyl)-1,3-tolylenedicarbamate,-3,4-epoxy-6-methylcyclohexane carboxaldehyde acetal, 3,9-bis(3,4-epoxycyclohexyl) spirobi-(methadioxane), and the like.
As noted above, in some further embodiments, thermosetting resins based on vinyl ester technology can be used. For example, in some embodiments, thermosetting resins based on aromatic vinyl esters can be used. These can include a condensation product of epoxide resins and unsaturated acids usually diluted in a compound having double bond unsaturation such as vinyl aromatic monomer (e.g., styrene and vinyl toluene, and diallyl phthalate). Illustrative of useful vinyl esters are diglycidyl adipate, diglycidyl isophthalate, di(2,3-epoxybutyl) adipate, di(2,3-epoxybutyl) oxalate, di(2,3-epoxyhexyl) succinate, d(3,4-epoxybutyl) maleate, d(2,3-epoxyoctyl) pimelate, di(2,3-epoxybutyl) phthalate, di(2,3-epoxyoctyl) tetrahydrophthalate, di(4,5-epoxy-dodecyl) maleate, di(2,3-epoxybutyl) terephthalate, di(2,3-epoxypentyl) thiodipropionate, di(5,6-epoxy-tetradecyl) diphenyldicarboxylate, di(3,4-epoxyheptyl) sulphonyldibutyrate, tri(2,3-epoxybutyl) 1,2,4 butanetricarboxylate, di(5,6-epoxypentadecyl) maleate, di(2,3-epoxybutyl) azelate, di(3,4-epoxybutyl) citrate, di(5,6-epoxyoctyl) cyclohexane-1,3-dicarboxylate, di(4,5-epoxyoctadecyl) malonate, bisphenol-A-fumaric acid polyester and the like.
In some embodiments, at least a portion of the body armor composite 10, 15 can include a filler material. For example, some embodiments can include a thermoplastic or thermosetting resin that includes at least some filler material dispersed through at least a portion of the body armor composite 10, 15. In some embodiments, the filler material can be dispersed substantially homogenously through at least a portion of at least one layer of the body armor composite 10. In some other embodiments, the filler material can be substantially unevenly distributed through at least a portion of the body armor composite 10, 15. For example, in some embodiments, the filler material can be dispersed substantially unevenly through at least a portion of at least one layer of the body armor composite 10, 15. In some embodiments, the filler material can be amorphous or crystalline, organic or inorganic material. In some other embodiments, the particle size of the filler material can be between 1-10 microns. In some other embodiments, at least some portion of the filler material can be sub-micron. In some in some other embodiments, the thermosetting resin can contain nano-sized particle filler material.
In some embodiments, one or more layers of the body armor composite 10, 15 can comprise an inorganic material. In some embodiments, at least a portion of the aforementioned filler material can comprise an inorganic material. For example, in some embodiments, the body armor composite 10, 15 can include at least one strike-face reinforcement layer 130 that comprises at least one inorganic material. The body armor composite 10, 15 can include at least one strike-face 120, and in some embodiments, the strike-face 120 can comprise at least one inorganic material. The inorganic material can include a ceramic material, a glass material, a metal material, or a combination thereof. In some embodiments, the inorganic material can include materials comprising S-glass, E-glass, silicon carbide, asbestos, basalt, alumina, aluminum oxynitride, spinel (such as MgAb04), alumina-silicate, quartz, zirconia-silica, and/or sapphire. In some embodiments, the inorganic material can comprise a fibrous, whisker, and/or filament type material. For example, in some embodiments, the inorganic material can comprise a ceramic filament, boron filament, and/or carbon filaments. In some other embodiments, metallic or semi-metallic filaments composed of boron, aluminum, steel and titanium can be used.
In some embodiments, one or more layers of the body armor composite 10, 15 can comprise a polymer with an ultra-high molecular weight. For example, in some embodiments, the body armor composite 10, 15 can include at least one catchment layer 140, and in some embodiments, the catchment layer 140 can comprise ultra-high-molecular-weight polyethylene (“UHMWPE”), also known as high-modulus polyethylene (“HMPE”). In some embodiments, the molecular weight of the UHMWPE can approach 1 million. In some further embodiments, the molecular weight of the UHMWPE can be in the range 1-3 million. In some other embodiments, the molecular weight of the UHMWPE can be in the range 3-6 million. In some other embodiments, the molecular weight of the UHMWPE can exceed 6 million. In some further embodiments, one or more layers of the body armor composite 10, 15 can comprise a highly crystalline or high oriented polymer or copolymer of polypropylene.
In some further embodiments, the body armor composite 10, 15 can include at least one enhanced protection region 25. For example, as shown in
Some embodiments can include a plate cover layer 160. For example, in some embodiments, the body armor composite 10, 15 can be fabricated with a plate cover layer 160 and/or a back cover layer 165. The use of at least one cover layer including a plate cover layer 160 and/or a back cover layer 165 can control delamination, reduce spall and provide an encapsulation of the ballistic plate, and can provide environmental protection, and reduce back-face deformation. The cover layers 160, 165 can also provide waterproofness, provide a cosmetic appearance, and provide surface for attaching labeling. In some further embodiments, functional devices can be included (e.g., embedded) in the layers 160, 165 such as for example RFID chips, and one or more sensors (e.g., impact sensors, and heath monitoring sensors). Combining the molding pressure and heat can reduce the temperature required for curing and, therefore, allows more sensitive electronics to be incorporated into the the molded part 10 and 15
In some embodiments, the plate cover layer 160 and/or the back cover layer 165 can comprise a ballistic layer or a ballistic reinforcement layer. The plate cover layer 160 and/or the back cover layer 165 can include or comprise a monocoque structure (e.g., a monocoque truss structure). In some embodiments, the layers 160, 165 can be fabricated onto the previously formed body armor composite 10, 15 using the methods as described herein, and can include hot pressure molding, and pre-heated materials and cold pressure forming. In some embodiments, the layers 160, 165 can be fabricated and formed on a tool at a temperature between about 65° F. and about 80° F. In some embodiments, the layers 160, 165 can be formed using a resin based on an epoxide based polymer or a vinyl ester based resin. In some other embodiments, the layers 160, 165 can be formed using a resin based on any one of the epoxide based polymer or vinyl ester based resin polymers. In some embodiments, the layers 160, 165 can incorporate a bump guard 100. In some embodiments, the layers 160, 165 can be any shape, and cover any type or shape from flat to multi-curve armor. In some embodiments, the layers 160, 165 can be any combination of a top and bottom, front and back, front all sides and a two dimensional back piece for closure. Moreover, in some embodiments, the layers 160, 165 can be one piece, two pieces or any number of parts.
Ballistic plates produced by the materials and methods described herein have been tested under the 16.0 mm BFD, 124 grain 9×19 mm FMJ RN projectile requirement.
In some embodiments, the mold tool 1200 can be fabricated in various sizes and shapes to accommodate different armor structures. For example,
Fluid dispersion layer 1520 may comprise a fluid dispersion media of a material allowing fluid to flow through the media, but having a compressive strength greater than the pressure applied to body armor composite 10 formed therein. In one embodiment, fluid dispersion media is a mesh-like material or a porous material. Thermal transfer membrane 1516 and pressure bearing membrane 1518 are preferable a flexible membrane and, in one embodiment, may have elastic capabilities to stretch as necessary to conform with the shape of the molded body armor composite 10 when pressure is applied. In one embodiment, the membranes used may be made from one or more of high temperature silicone, food grade silicone, chemically resistant silicone, chemically resistant silicone, fabric reinforced silicone or any elastomer with the same properties.
The application of heat and pressure may be maintained in tool 1500 until the molding of body armor composite 10 is complete or otherwise as desired. At this time, the flow of heating fluid is stopped and a cooling fluid may be introduced into the fluid dispersion layers 1520a and 1520b to reduce the temperature of the part for handling, and the pressurized fluid may be removed through inlet 1528 or 1530, which operate as an outlet, or through another stand-alone fluid drain or outlet (not shown). The locking mechanism may be disengaged and the body armor composite tool 10 may be removed from molding chamber 1503 of the molding tool 1500.
Advantages of the construction of tool 1500 are that the heat transfer fluid does not need to be pressurized, which reduces the equipment needed and increases the overall safety of the tool 1500. Further, in one embodiment, the fluid dispersion media in fluid dispersion layers 1520a and 1520b may be include one or more baffles 1537 arranged to direct the flow of fluid to create thermal flow patterns based upon the needs of the body armor composite 10 being formed. The flow pattern in the media may be combined with the location of the inlets and outlets to provide distinct thermal zones that are created and controlled independently to optimize the molding process. Moreover, the upper and lower thermal diaphragm systems described herein may also be controlled in concert or independently.
The flexible molding processes described herein can also be used to form kayaks, wing spars, vehicle body panels and a wide range of other products. Some embodiments of the invention enable better control of resin content without inducing significant localized stresses in the resulting composites. Some embodiments also enable the replacement of pre-impregnated materials with unimpregnated materials which can offer excellent structural characteristics at lower cost.
It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein.
This application is a continuation-in-part of U.S. patent application Ser. No. 14/267,858 titled “BALLISTIC PLATE MATERIALS AND METHOD” filed on May 1, 2014, which claims the benefit of filing date of U.S. Provisional Application Ser. No. 61/818,352 titled “BODY ARMOR MATERIALS AND METHOD” filed on May 1, 2013, and U.S. Provisional Application Ser. No. 61/885,354 titled “BALLISTIC PLATE MATERIALS AND METHOD” filed on Oct. 1, 2013, the specifications of which are each incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61885354 | Oct 2013 | US | |
| 61818352 | May 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14267858 | May 2014 | US |
| Child | 15876021 | US |
