U.S. patent application number 12/928205 was filed with the patent office on 2011-04-21 for non-ceramic hard armor composite.
Invention is credited to Alexander J. Park, Andrew D. Park, Dave Park, William J. Perciballi.
Application Number | 20110088542 12/928205 |
Document ID | / |
Family ID | 34574708 |
Filed Date | 2011-04-21 |
United States Patent
Application |
20110088542 |
Kind Code |
A1 |
Park; Andrew D. ; et
al. |
April 21, 2011 |
Non-Ceramic hard armor composite
Abstract
A hard armor composite includes a rigid non-ceramic 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.; (Ashburn,
VA) ; Park; Dave; (Glendora, CA) ; Park;
Alexander J.; (Midlothian, VA) ; Perciballi; William
J.; (Phoenix, AZ) |
Family ID: |
34574708 |
Appl. No.: |
12/928205 |
Filed: |
December 7, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12657640 |
Jan 25, 2010 |
7845265 |
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12928205 |
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10730805 |
Dec 9, 2003 |
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12657640 |
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Current U.S.
Class: |
89/36.02 ;
442/135; 89/915 |
Current CPC
Class: |
Y10T 442/2615 20150401;
Y10T 442/2738 20150401; F41H 5/0464 20130101; Y10T 442/2623
20150401 |
Class at
Publication: |
89/36.02 ;
442/135; 89/915 |
International
Class: |
F41H 5/04 20060101
F41H005/04 |
Claims
1. A hard armor composite, comprising: (a) a rigid non-ceramic
facing comprising high-performance fibers having a tensile strength
greater than 7 grams per denier and at least one non-ceramic
element, and said high-performance fibers and said non-ceramic
element being arranged in a structure selected from a group
consisting of woven layers, non-woven unidirectional layers, knit
layers, a three-dimensionally knit structure, and a
three-dimensionally woven structure; (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; and (c) said rigid facing and fabric backing having
a combined thickness of less than 0.900-inches, and a uniform areal
density of no more than 5.1 pounds per square foot.
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
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).
9. A hard armor composite according to claim 1, wherein said rigid
facing comprising a generally flat, continuous monolithic
plate.
10. A hard armor composite, comprising: (a) a rigid non-ceramic
facing comprising high-performance fibers having a tensile strength
greater than 7 grams per denier and at least one non-ceramic
element, and said high-performance fibers and said non-ceramic
element being arranged in a structure selected from a group
consisting of woven layers, non-woven unidirectional layers, knit
layers, a three-dimensionally knit structure, and a
three-dimensionally woven structure; (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; and (c) said rigid facing and fabric backing
having a combined thickness of less than 0.900-inches, and a
uniform areal density of no more than 5.1 pounds per square
foot.
11. A hard armor composite according to claim 13, and comprising
means for adhering said fabric backing to said non-ceramic
facing.
12. 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.
13. A hard armor composite according to claim 13, wherein said
non-ceramic facing comprises a generally flat, continuous
monolithic plate.
14. 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 non-ceramic facing 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 relatively heavy, and 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 SAPI 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 combined with a
lighter, less costly non-ceramic facing forms a novel SAPI superior
in regards to both weight and performance. The overall weight of
the non-ceramic SAPI is well below that prescribed by United States
military specifications. In addition, the non-ceramic SAPI is
easily molded for enhanced curvature, and has improved field
durability as compared to a ceramic SAPI. The ceramic SAPI is
extremely hard and brittle, and difficult to shape.
SUMMARY OF INVENTION
[0005] Therefore, it is an object of the invention to provide a
hard armor composite which incorporates a non-ceramic rigid facing
and fabric backing including high performance, low
denier-per-filament (dpf) fibers. The rigid facing and fabric
backing are preferably separately formed and subsequently joined
together to create the hard armor composite. Alternatively, the
facing and backing may be integrally-formed together under heat and
pressure in a single step process.
[0006] It is another object of the invention to provide a
non-ceramic hard armor composite which offers substantial ballistic
performance, is relatively lightweight, and easily molded for
enhanced curvature.
[0007] It is another object of the invention to provide a
non-ceramic hard armor composite which enables use of a less costly
and lighter facing without sacrificing ballistic performance.
[0008] It is another object of the invention to provide a
non-ceramic 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
non-ceramic 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
non-ceramic small arms protection insert (SAPI) applicable for
being worn by military and law enforcement personnel, and which has
improved field durability as compared to a ceramic SAPI.
[0011] It is another object of the invention to provide a
non-ceramic 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 constructing a hard armor composite.
[0014] It is another object of the invention to provide a new and
useful means of incorporating a composite armor backing with a
non-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 non-ceramic 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. The term "non-ceramic facing" refers to a rigid
facing constructed of less than 5% ceramic material, and more
preferably, without a trace of ceramic material. Preferably, the
entire hard armor composite is constructed without a trace of
ceramic material.
[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 rigid
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 rigid facing is constructed of a material selected from the
group including 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 non-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 non-ceramic 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 non-ceramic hard
armor composite taken substantially along line 2-2 of FIG. 1;
and
[0034] FIG. 3 is a perspective view of a non-ceramic 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 non-ceramic
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 rigid non-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 plate from wear-and-tear, and which contains any
fragmentation upon 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 plate 11 comprises a rigid, non-ceramic facing defining
a first level of hard armor protection in the composite SAPI. The
rigid plate 11 may incorporate any of the above-mentioned
high-performance, low dpf fibers combined with a number of
individual non-ceramic elements, such as S-2 glass fiber, carbon
fiber, silicone-carbide, and graphite, arranged in either woven
layers, non-woven unidirectional layers, or knit layers, or
three-dimensionally knit or woven structures. The resulting
composite is either flat or molded to any desired rigid form.
Although plate thickness may be varied to suit the specific SAPI
need, the preferred structural 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 rigid plate 11, and provides a
second level of protection against ballistic penetration.
Preferably, the rigid 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. In addition to the above,
the backing 12 may incorporate other non-ceramic elements, such as
S-2 glass fiber, carbon fiber, silicone-carbide, and graphite.
[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
non-ceramic tiles 21 defining a rigid facing, an adhesive layer 22,
and a ballistic fabric backing 23. The tiles 21 can be square or
otherwise shaped to suit the dimensional needs of a particular
application. The tiles 21 may be formed of steel, glass, aluminum,
titanium, graphite, or other suitable non-ceramic material. 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.
TABLE-US-00001 Dpf V50(fps) ADT(Areal density) psf UHMWPE fiber
based fabric: Spectra Shield .RTM. 5.4 1590 .91 Dyneema .RTM. UD
2.0 1679 .91 Aramid fiber based fabric: 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
[0048] A non-ceramic 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.
* * * * *