U.S. patent application number 10/664233 was filed with the patent office on 2005-03-31 for hard armor composite.
Invention is credited to Park, Alexander J., Park, Andrew D., Park, Dave, Perciballi, William J..
Application Number | 20050066805 10/664233 |
Document ID | / |
Family ID | 34194744 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050066805 |
Kind Code |
A1 |
Park, Andrew D. ; et
al. |
March 31, 2005 |
Hard armor composite
Abstract
A hard armor composite includes a rigid facing and a ballistic
fabric backing. The fabric backing is carried by the facing, and
includes an array of bundled high-performance fibers. The fibers
have a tensile strength greater than 7 grams per denier and a
denier per filament ratio of less than 5.4.
Inventors: |
Park, Andrew D.;
(Midlothian, VA) ; Park, Dave; (Walnut, CA)
; Park, Alexander J.; (Midlothian, VA) ;
Perciballi, William J.; (Phoenix, AZ) |
Correspondence
Address: |
SCHWARTZ LAW FIRM, P.C.
6100 FAIRVIEW ROAD
SUITE 530
CHARLOTTE
NC
28210
US
|
Family ID: |
34194744 |
Appl. No.: |
10/664233 |
Filed: |
September 17, 2003 |
Current U.S.
Class: |
89/36.02 |
Current CPC
Class: |
Y10T 428/249951
20150401; F41H 5/0464 20130101; F41H 5/0435 20130101 |
Class at
Publication: |
089/036.02 |
International
Class: |
F41H 005/02 |
Claims
We claim:
1. A hard armor composite, comprising: (a) a rigid facing; and (b)
a ballistic fabric backing carried by said facing, and comprising
an array of bundled high-performance fibers, said fibers having a
tensile strength greater than 7 grams per denier and a denier per
filament ratio of less than 5.4.
2. A hard armor composite according to claim 1, wherein said fabric
backing comprises a plurality of overlying fabric layers.
3. A hard armor composite according to claim 2, wherein said fabric
layers are laminated under heat and pressure to form a unitary
ballistic structure.
4. A hard armor composite according to claim 1, and comprising
means for adhering said fabric backing to said facing.
5. A hard armor composite according to claim 4, wherein said means
for adhering comprises an adhesive selected from the group
consisting of a thermoplastic polymer resin matrix and a
thermosetting polymer resin matrix.
6. A hard armor composite according to claim 4, wherein said means
for adhering comprises a polymer film.
7. A hard armor composite according to claim 4, wherein said means
for adhering comprises an adhesive selected from the group
consisting of an epoxy adhesive, a polysulfide adhesive, a
polyurethane adhesive, a phenolic adhesive, a polyester adhesive, a
polyvinyl butyral adhesive, a polyolefin adhesive, and a vinyl
ester adhesive.
8. A hard armor composite according to claim 1, wherein said facing
is constructed of a material selected from the group consisting of
ceramic, steel, glass, aluminum, titanium, and graphite.
9. A hard armor composite according to claim 1, wherein said
high-performance fibers are selected from the group consisting of
aramid, ultra-high molecular weight polyethylene (UHMWPE),
poly{p-phenylene-2,6-benzobisoxazole} (PBO), and poly {diimidazo
pyridinylene(dihydroxy)phenylene} (M5).
10. A hard armor composite according to claim 1, wherein said rigid
facing comprising a generally flat, continuous monolithic
plate.
11. A hard armor composite according to claim 1, wherein said rigid
facing and fabric backing have a combined thickness of less than
0.900-inches.
12. A hard armor composite according to claim 11, wherein said
rigid facing and fabric backing have a combined weight of less than
5.1 pounds per square foot.
13. A hard armor composite, comprising: (a) a ceramic facing; and
(b) a ballistic fabric backing carried by said facing, and
comprising an array of bundled high-performance fibers, said fibers
having a tensile strength greater than 7 grams per denier and a
denier per filament ratio of no more than 2.0.
14. A hard armor composite according to claim 13, wherein said
ceramic facing comprises a material selected from the group
consisting of boron carbide, silicon carbide, titanium diboride,
aluminum nitride, silicon nitride, sintered silicon carbide,
sintered silicon nitride, and aluminum oxide.
15. A hard armor composite according to claim 13, and comprising
means for adhering said fabric backing to said ceramic facing.
16. A hard armor composite according to claim 15, wherein said
means for adhering comprises an adhesive selected from the group
consisting of an epoxy adhesive, a polysulfide adhesive, a
polyurethane adhesive, a phenolic adhesive, a polyester adhesive, a
polyvinyl butyral adhesive, or a polyolefin adhesive, and a vinyl
ester adhesive.
17. A hard armor composite according to claim 13, wherein said
ceramic facing comprises a generally flat, continuous monolithic
plate.
18. A hard armor composite according to claim 13, wherein said
ceramic facing and fabric backing have a combined thickness of less
than 0.900-inches.
19. A hard armor composite according to claim 18, wherein said
ceramic facing and fabric backing have a combined weight of less
than 5.1 pounds per square foot.
20. A hard armor composite according to claim 13, wherein said
high-performance fibers are selected from the group consisting of
aramid, ultra-high molecular weight polyethylene (UHMWPE),
poly{p-phenylene-2,6-benzobisoxazole} (PBO), and poly{diimidazo
pyridinylene (dihydroxy) phenylene} (M5).
Description
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0001] This invention relates to a hard armor composite, and more
particularly to an improved small arms protection insert (SAPI)
applicable for protecting against multiple small arms bullets and
projectiles. In a preferred embodiment, the invention incorporates
a rigid ceramic plate and a ballistic fabric backing.
[0002] Ceramic armor is typically used for body armor and for the
outer coverings of different types of vehicles, such as various
types of land vehicles, ships, and aircraft. Typically, ceramic
tiles are adhesively secured to a substrate then encapsulated in an
outer cover. The armor system is then attached to a vehicle by a
variety of means or merely placed in a fabric pocket, as in the
case of body armor. An inherent problem in the prior art is that
ceramic armor is configured for a fixed level of protection against
a single ballistic threat.
[0003] The current SAPI incorporates ceramic and an extended chain
polyethylene fiber base material known in the industry as "Spectra
Unidirectional Cross Plied". This material contains fibers produced
by Honeywell International, Inc., and distributed under the brand
Spectra Shield.RTM. PCR and Spectra Shield.RTM. Plus PCR. The
current SAPI has been accepted for application by the United States
military. However, due to limited production and sources of Spectra
Shield.RTM. PCR and Spectra Shield.RTM. Plus PCR, a need exists for
an alternative acceptable ballistic fabric construction which can
be readily obtained from multiple sources.
[0004] A further need exists for a reduced-weight fabric
construction which offers at least comparable and preferably
increased ballistic performance. Military specifications call for a
SAPI which meets predetermined maximum weight and performance
criteria. The ballistic fabric used in the current SAPI has a
denier per filament (dpf) ratio of 5.4--denier being defined as a
weight measurement in grams per 9000 meter of fiber length; and
denier per filament (dpf) defined as denier divided by the number
of filaments in a fiber bundle. For an example, Spectra Shield.RTM.
PCR comprises a nominal 1300 denier fiber with 240 filaments (or,
5.4 dpf). The present invention uses a lower dpf fiber which meets
or exceeds the required ballistic performance criteria. The reduced
fiber weight enables use of a heavier, less costly ceramic in a
SAPI which further satisfies the required maximum weight
criteria.
SUMMARY OF INVENTION
[0005] Therefore, it is an object of the invention to provide a
hard armor composite which incorporates a fabric backing including
high performance, low denier-per-filament (dpf) fibers.
[0006] It is another object of the invention to provide a hard
armor composite which offers substantial ballistic performance and
is relatively lightweight.
[0007] It is another object of the invention to provide a hard
armor composite which enables use of a less costly and heavier
ceramic material without sacrificing ballistic performance.
[0008] It is another object of the invention to provide a hard
armor composite which provides protection against multiple types of
ballistic projectiles including NATO 7.62.times.51 mm--80 Ball,
Soviet 7.62 mm.times.54R Ball Type LPS, and U.S. 5.56 mm.times.M855
Ball.
[0009] It is another object of the invention to provide a hard
armor composite which may be used alone or as a supplementary armor
system to provide increased protection from ballistic
projectiles.
[0010] It is another object of the invention to provide a small
arms protection insert (SAPI) applicable for being worn by military
and law enforcement personnel.
[0011] It is another object of the invention to provide a hard
armor composite which, when placed in a body armor vest pocket,
provides ballistic protection from 5.56 mm and 7.62 rounds.
[0012] It is another object of the invention to provide alternate,
lighter, new and useful means of protecting against ballistic
projectiles attack.
[0013] It is another object of the invention to provide a new and
useful means of arranging ceramic tile armor elements carried on a
ballistic fabric backing.
[0014] It is another object of the invention to provide a new and
useful means of arranging a composite armor backing in conjunction
with a ceramic facing.
[0015] These and other objects of the present invention are
achieved in the preferred embodiments disclosed below by providing
a hard armor composite including a rigid facing and a ballistic
fabric backing. The fabric backing is carried by the facing, and
includes an array of bundled high-performance fibers. The fibers
have a tensile strength greater than 7 grams per denier and a
denier per filament ratio of less than 5.4.
[0016] The term "carried by" means that the fabric backing is
bonded or otherwise secured, either directly or indirectly, to the
rigid facing.
[0017] According to another preferred embodiment of the invention,
the fabric backing includes a plurality of overlying fabric layers.
The fabric layers may be woven, non-woven, partially non-woven, or
knitted. Alternatively, the layers may comprise unidirectional tape
which is cross-plied in any angle, or three-dimensional woven or
knitted fabrics.
[0018] According to another preferred embodiment of the invention,
the fabric layers are laminated under heat and pressure to form a
unitary ballistic structure.
[0019] According to another preferred embodiment of the invention,
means are provided for adhering the fabric backing to the
facing.
[0020] Preferably, the means for adhering is an adhesive selected
from the group including a thermoplastic polymer resin matrix and a
thermosetting polymer resin matrix.
[0021] According to another preferred embodiment of the invention,
the means for adhering is a polymer film.
[0022] According to another preferred embodiment of the invention,
the means for adhering is an adhesive selected from the group
including an epoxy adhesive, a polysulfide adhesive, a polyurethane
adhesive, a phenolic adhesive, a polyester adhesive, a polyvinyl
butyral adhesive, a polyolefin adhesive, and a vinyl ester
adhesive.
[0023] According to another preferred embodiment of the invention,
the facing is constructed of a material selected from the group
including ceramic, steel, glass, aluminum, titanium, and
graphite.
[0024] Preferably, the high-performance fibers are selected from
the group including aramid, ultra-high molecular weight
polyethylene (UHMWPE), poly {p-phenylene-2,6-benzobisoxazole}
(PBO), and poly {diimidazo pyridinylene (dihydroxy)phenylene}
(M5).
[0025] Preferably, the high-performance fibers comprise one or a
combination of the following commercial synthetic fibers:
Twaron.RTM., manufactured and distributed by Teijin Twaron.RTM. in
Conyers, Ga.; Spectra Shield.RTM. PCR, manufactured and distributed
by Honeywell International, Inc. of Colonial Heights, Va.; PBO
Zylon.RTM., manufactured and distributed by Toyobo, Japan; and
M5.
[0026] Alternatively, the fabric backing may comprise multiple
layers including one or a combination of Dyneema.RTM. UD75 HB2
unidirectional cross-plied material, manufactured and distributed
by DSM of Greenville, N.C. and DSM of the Netherlands; and
T-Flex.TM. unidirectional cross-plied material, manufactured and
marketed by PTI Armor Systems of Glendora, Calif.
[0027] According to another preferred embodiment of the invention,
the rigid facing includes a generally flat, continuous monolithic
plate. The plate may also have a slight single, double, or compound
curvature.
[0028] Preferably, the rigid facing and fabric backing have a
combined thickness of less than 0.900-inches.
[0029] Preferably, the rigid facing and fabric backing have a
combined weight of less than 5.1 pounds per square foot.
[0030] According to another preferred embodiment of the invention,
the rigid facing is constructed of a ceramic material selected from
the group including boron carbide, silicon carbide, titanium
diboride, aluminum nitride, silicon nitride, sintered silicon
carbide, sintered silicon nitride, and aluminum oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Some of the objects of the invention have been set forth
above. Other objects and advantages of the invention will appear as
the description proceeds when taken in conjunction with the
following drawings, in which:
[0032] FIG. 1 is a perspective view of a hard armor composite
according to one preferred embodiment of the present invention, and
showing a portion of the outer cover torn away to expose the
interior elements;
[0033] FIG. 2 is a cross-sectional view of the hard armor composite
taken substantially along line 2-2 of FIG. 1; and
[0034] FIG. 3 is a perspective view of a hard armor composite
according to a second preferred embodiment of the present
invention, and showing a portion of the outer cover torn away.
DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE
[0035] Referring now specifically to the drawings, a hard armor
composite according to the present invention is illustrated in FIG.
1, and shown generally at reference numeral 10. In one application,
the composite 10 is a small arms protection insert (SAPI) designed
to protect against multiple small arms bullets and projectiles. The
composite 10 is constructed according to United States military
specifications, CO/PD 00-03D dated Jan. 13, 2003, in sizes X-small,
small, medium, large, and X-large ranging in weight from 2.85 to
5.35 pounds. All SAPI sizes have a uniform nominal areal density of
5.1 pounds per square foot or less. The dimensional measurements
are indicated in Drawing Nos. 2-6-265, 2-6-266, 2-6-267, 2-6-268,
and 2-6-269 of CO/PD 00-03D. The entire subject matter of CO/PD
00-03D, including text, drawings, tables, and charts, is
incorporated herein by reference.
[0036] As shown in FIGS. 1 and 2, the hard armor composite (SAPI)
10 comprises a ceramic plate 11 and ballistic fabric backing 12
encased in an outer cover 14. The cover 14 may be formed of a
single knit material, such as nylon fabric, or may be a rubberized
coating formed by dipping, or may be a combination of fabric, rigid
plastic, and foam or honeycomb structure that protects the ceramic
from wear-and-tear, and which contains ceramic particles on impact
as appropriate. Preferably, the cover 14 includes a bake panel 15
that either partially or completely covers the rear surface of the
composite 10.
[0037] The ceramic plate 11 is a rigid facing defining a first
level of hard armor protection in the composite SAPI. The ceramic
plate 11 may include a number of individual elements, such as
ceramic tiles, or may be a singular (monolithic) structure that is
either flat or molded to a desired shape. The plate 11 is made of
any suitable ceramic material, such as boron carbide, silicon
carbide, high purity aluminum oxide, titanium diboride, aluminum
nitride or silicon nitride or sintered silicon carbide and sintered
silicon nitride ceramics. Alternatively, a ceramic matrix composite
or metal matrix composite containing any of above-mentioned
ceramics could be used. Although ceramic thickness may be varied to
suit the specific SAPI need, the preferred ceramic arrangement
ranges from 0.080-inches to 0.40-inches in thickness.
[0038] The fabric backing 12 is bonded or otherwise secured, either
directly or indirectly, to the ceramic plate 11, and provides a
second level of protection against ballistic penetration.
Preferably, the ceramic plate 11 and fabric backing 12 are joined
together by a layer 16 of adhesive, such as a thermoplastic or
thermoset polymer, an elastomeric resin matrix, or a film, such as
epoxy, polyurethane, polysulfide, polyolefin, phenolic, polyester,
vinyl ester, polyvinyl butyral.
[0039] The backing 12 is constructed of bundled, high-performance,
low denier per filament (dpf) fibers comprising any one or a
combination of aramid, extended chain ultra-high molecular weight
polyethylene (UHMWPE), poly {p-phenylene-2,6-benzobisoxazole}
(PBO), and poly {diimidazo pyridinylene (dihydroxy) phenylene}
(M5). Each of these fibers has a tensile strength greater than 7
grams per denier. Suitable commercial fibers include: Twaron.RTM.
micro-denier fiber of less than nominal 1000 denier and 1.5 dpf or
lower; Spectra Shield.RTM. PCR fiber of less than nominal 1300
denier and less than 5.4 dpf; Dyneema.RTM. UD (unidirectional)
fiber of nominal 1600 denier and 2.0 dpf or lower; PBO Zylon.RTM.
fiber of nominal 1000 or 500 denier and 1.5 dpf or lower; and
aramid Kevlar.RTM. fiber of nominal 1500 denier and 1.5 dpf. The
fibers are preferably HM (high modulus) grade with low moisture
content. The preferred embodiment utilizes high-performance fibers
having less than 5.4 dpf, and more preferably, less than 2.0 dpf,
and most preferably, less than 1.5 dpf.
[0040] The fibers are incorporated in multiple, stacked layers
comprising knit, woven, or non-woven fabrics, non-woven or woven
unidirectional tapes, felts, and three-dimensional structures. The
stacked layers are laminated under heat and pressure together with
any of a variety of polymer compounds to create a dense, rigid,
unitary ballistic structure ranging in thickness from 0.130-inches
to 0.350-inches. Lamination occurs via autoclave, press molding, a
resin transfer mold, and/or an oven with vacuum pressure. According
to one embodiment, the fabric backing 12 is further encased in a
polymer matrix or film, specifically, a thermoplastic or thermoset
matrix. The matrix may include any suitable polymer resin or film,
such as phenolic, polysulfide, phenolic, polyvinyl butyral rubber
blends, polyester, vinyl ester, polyurethane, and polyolefin resins
or combinations thereof. When using a polymer resin matrix, the
preferred resin content ranges from fifteen to twenty-four percent
by weight.
[0041] In an alternate embodiment shown in FIG. 3, the hard armor
composite (SAPI) 20 includes an arrangement of individual ceramic
tiles 21 defining a rigid facing, an adhesive layer 22, and a
ballistic fabric backing 23. The ceramic tiles 21 can be square or
otherwise shaped to suit the dimensional needs of a particular
application. The fabric backing 23 incorporates high-performance,
low dpf fibers, and is constructed in a manner identical to that
described above. The adhesive layer 22 joins the tile elements and
fabric backing together to form a unitary ballistic composite.
[0042] In each of the above embodiments, the hard armor composite
10, 20 forms a SAPI which meets or exceeds the ballistic
performance criteria outlined in CO/PD 00-03D. Specifically,
Section 3.9.3 of CO/PD 00-03D states that the SAPI when inserted in
a nylon cordura carrier will be capable of defeating three impacts
(2 impacts at 0-degrees obliquity and 1 impact at 30-degrees
obliquity) from each of the following threats:
[0043] a. NATO 7.62.times.51 mm--80 Ball at 2,750+50 feet per
second.
[0044] b. Soviet 7.62 mm.times.54R Ball Type LPS at 2,300+50 feet
per second.
[0045] c. U.S. 5.56 mm M855 Ball at 3,250+50 feet per second.
[0046] The use of a ballistic fabric backing incorporating
high-performance, low dpf fibers not only reduces the overall
weight of the composite, but offers increased ballistic performance
as compared relatively high dpf fibers. The current commercial SAPI
incorporates high-performance fibers with a 5.4 dpf. The V50
ballistic performance of fabric constructed of this fiber is
compared in the table below with fabric of lower dpf fibers.
[0047] V50 data with 9 mm 124 grams per Mil-STD 662.
[0048] UHMWPE fiber based fabric:
1 Dpf V50(fps) ADT(Areal density) psf Spectra Shield .RTM. 5.4 1590
.91 Dyneema .RTM. UD 2.0 1679 .91
[0049] Aramid fiber based fabric:
2 Kevlar .RTM. 29 1.5 1290 .80 Kevlar .RTM. 29 1.5 1400 1.0 Twaron
.RTM. 1.0 1483 .87 Twaron .RTM. 1.0 1562 .91 T-Flex .TM. 1.0 1520
.80 T-Flex .TM. 1.0 1590 .93
[0050] A hard armor composite is described above. Various details
of the invention may be changed without departing from its scope.
Furthermore, the foregoing description of the preferred embodiment
of the invention and best mode for practicing the invention are
provided for the purpose of illustration only and not for the
purpose of limitation--the invention being defined by the
claims.
* * * * *