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WO2002043949A2 - Structure composite rigide profilee et procede associe - Google Patents

Structure composite rigide profilee et procede associe Download PDF

Info

Publication number
WO2002043949A2
WO2002043949A2 PCT/US2001/044763 US0144763W WO0243949A2 WO 2002043949 A2 WO2002043949 A2 WO 2002043949A2 US 0144763 W US0144763 W US 0144763W WO 0243949 A2 WO0243949 A2 WO 0243949A2
Authority
WO
WIPO (PCT)
Prior art keywords
contoured
fabric
laminated
fiber structure
resin
Prior art date
Application number
PCT/US2001/044763
Other languages
English (en)
Other versions
WO2002043949A3 (fr
Inventor
Mansour Mohamed
Grey Parker
William Everitt
Original Assignee
3Tex, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3Tex, Inc. filed Critical 3Tex, Inc.
Priority to AU2002227028A priority Critical patent/AU2002227028A1/en
Publication of WO2002043949A2 publication Critical patent/WO2002043949A2/fr
Publication of WO2002043949A3 publication Critical patent/WO2002043949A3/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0485—Layered armour containing fibre- or fabric-reinforced layers all the layers being only fibre- or fabric-reinforced layers
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/06—Impact-absorbing shells, e.g. of crash helmets
    • A42B3/062—Impact-absorbing shells, e.g. of crash helmets with reinforcing means
    • A42B3/063—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4807—Headwear
    • B29L2031/4814—Hats
    • B29L2031/4821—Helmets

Definitions

  • the present invention relates generally to the composite structures and applications thereof, more particularly, to contoured rigid composite structures including multilayer laminate fabrics and methods for making same.
  • triangular cut-out regions were required for each layer of fabric to avoid fabric bunching, creasing, and/or non-uniform overlap areas during processing, which remain in the final product, creating uneven surfaces and non-uniform performance characteristics in those regions.
  • the triangular cut-out regions are positioned in predetermined locations whereby the surface area of each fabric layer resembles a pinwheel shape.
  • the pinwheel cuts require additional processing time to form, as well as to position each layer during lamination such that the triangular cut-out regions are not juxtapositioned directly or nearly above or below another cut-out region.
  • the contoured rigid laminated structure of the present invention provides increased impact resistance, resistance to delamination, shear resistance, strength, and overall performance due to the uninterrupted dissipation of energy spread throughout the entire surface area of the fabric and the uniform surface area presented in the finished product.
  • the transfer of energy is uninterrupted and other performance characteristics of the multilayer contoured laminate structure of the present invention because no seams, creases, wrinkles, or non- uniformities are present in the fabric performs before, during, or after lamination, treatment, and molding to form the finished product.
  • the absence of seams provides increased resistance to delamination.
  • the present invention is directed to a contoured multilayer laminated fiber composite structure having resistance to delamination, high strength and impact resistance, and shear resistance. Additionally, the invention is directed to a method for making the same.
  • the invention is applicable to military helmets having ballistic resistance. Additionally, the invention is applicable to sporting goods, including but not limited to boats, canoes, skateboards, surfboards, coolers, and protective wear including helmets, knee and elbow protective coverings or shields, and the like.
  • Advantages of the invention include lightweight, moldable multilayer laminated performs that do not crease, wrinkle, fold, or overlap to create non-uniform surface regions before, during, or after processing; as such, the present invention provides superior structural uniformity and performance characteristics.
  • the method of manufacturing contoured multilayer laminated fiber composite structures according to the present invention does not require patterning, creating cut-out regions or overlapping material within a given fiber layer in order to conform to a predetermined contoured shape.
  • the contoured composite structure according to the present invention may be molded, compression molded, pressed, or otherwise manipulated into a contoured shape without delamination, creasing, folding, or making non-uniformities within layers forming the laminated structure.
  • one aspect of the present invention is to provide a contoured multilayer laminated fiber composite structure for applications requiring substantially uniform characteristics across all contoured areas of the composite structure.
  • Another aspect of the present invention is provide a contoured multilayer laminated fiber composite structure for use in a military helmet having ballistic resistance.
  • Figure 1 is a side view of a component of a preferred embodiment according to the present invention.
  • Figure 2 is top view of prior art.
  • Figure 3 is a top view of an alternative preferred embodiment of the present invention.
  • Figure 4 is a side view of the preferred embodiment shown in Figure 3 constructed according to the present invention.
  • like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward”, “rearward”, “left”, “right”, “upwardly”, “downwardly', and the like are words of convenience and are not to be construed as limiting terms.
  • FIG. 1 shows a protective helmet, generally referenced 10, which is formed of a unitary, seamless construction using at least one layer of a 3-D woven material.
  • a protective helmet generally referenced 10
  • a complete disclosure of this material is provided in U.S. Patent No. 5,085,252 and 5,465,760 owned by the present applicant, and incorporated herein by reference in its entirety, hi the embodiment shown in Figure 1, the material provided for forming the helmet embodiment does not require any slitting or cutting at all.
  • the material is cut to a substantially circular shape having a diameter or cross-sectional area that is sufficient to form a protective helmet to fit a human head, e.g., a generally circular or octoganol template having an approximately 20" diameter.
  • a protective helmet to fit a human head
  • a generally circular or octoganol template having an approximately 20" diameter.
  • slits or cuts are necessary to ensure that creasing and/or folding of the material used to form the helmet is diminished or reduced.
  • the material or fabric is formed of at least one high-performance fiber array with a three-dimensional weave construction and at least one warp layer:
  • the 3-D fabric is molded to form a predetermined contour shape.
  • the 3-D fabric is impregnated with a resin and cured using a conventional prepreg machine. Between about 1 and about 15 plies of the resin-coated fabric are then placed in a helmet mold. The fabric remains in the mold under pressure for approximately three minutes at 300 degrees Fahrenheit. The increased interstices of the 3-D fabric promote resin flow within the fabric and significantly reduce, resin cure time.
  • the preferred density range for each ply of fabric is from between 0.10 lbs/sq ft to 1.5 lbs/sq ft.
  • the preferred thickness of each ply is from between 0.03 inches to 0.36 inches.
  • the density of 0.36 inches of fabric is 1.43 lbs/sq ft.
  • the overall thickness of the helmet is preferably between 0.275 to 0.360 inches.
  • the present invention is used to form a helmet constructed of 3-D woven fabric, the finished helmet, which may be used in a military, ballistic-resistant application is best seen in Figure 5.
  • a complete disclosure of this fabric is provided in U.S. Patent No. 5,085,252 commonly owned by the present assignee, and incorporated herein by reference, and shown in Figure 1.
  • the 3-D woven fabric generally referenced 10, shows three substantially perpendicular yarn systems, respectively positioned in an X direction, a Y direction, and a Z direction, as shown.
  • the 3-D woven fabric includes at least one high performance fiber array in one of the X, Y, or Z directions.
  • the warp direction, or X direction comprises high performance fibers.
  • the Y and Z directions also include high performance fibers for increased impact and ballistic resistance.
  • the fabric is formed of high-performance fiber selected from the group consisting of aramid fibers, polyolefins, ultra high molecular weight polyethylene and high molecular weight polyethylene, high modulus vinylon, and liquid crystal polymer-based fiber, and in a preferred embodiment KENLAR 129, with a three- dimensional engineered fiber construction of between about 10 to about 30 ends per inch, preferably about 20 ends/inch, between about 15 to about 35 picks per inch, preferably 25 picks/inch, and between about 1 to 5 warp layers, preferably 2 warp layers.
  • High- performance fibers having a tensile strength of greater than about 5 grams per denier may be used; preferably, the high performance fibers have a tensile strength of greater than 7 grams per denier.
  • the engineered fiber construction may be woven, multiaxial, braided, non-woven, or similar means of constructing multilayer fiber arrays within an integrated fabric body.
  • the fabric remains in the mold under pressure for between about one to about six minutes, preferably approximately three minutes at between about 150 to about 350 degrees Fahrenheit, preferably about 200 to about 250 degrees Fahrenheit.
  • the increased interstices of the 3-D fabric promote resin flow within the fabric, uniform resin distribution throughout the contour-shaped fabric, and significantly reduce resin cure time.
  • the resin type will influence the time and temperature required for cure. In some cases, ambient curing is effective.
  • the preferred density range for each ply of fabric is from between about 0.05 lbs/sq. ft. to about 2.0 lbs/sq.
  • each ply is approximately between about 0.02 inches to about 0.42 inches, preferably between about 0.03 inches to about 0.36 inches. In a preferred embodiment wherein the fabric thickness is about 0.36 inches the density of the fabric is about 1.43 lbs/sq ft.
  • the overall thickness of the helmet is preferably between about 0.250 inches to about 0.450 inches, preferably between about 0.275 to about 0.360 inches.
  • a preferred embodiment of the present invention is further directed to a military ballistic resistant helmet shown in Figure 1 having at least one layer of a 3-D woven material combined with a second 2-D material layer, both of which include at least one array of high performance, substantially unidirectionally-oriented fibers, more preferably having a second array of high performance, substantially unidirectionally-oriented fibers cross-plied at an angle with respect to the first array of fibers or interwoven therewith in a traditional, woven fabric, and laminated to the first array of fibers via the use of adhesives and or bonding agents.
  • the contoured shape forms a canoe or boat having at least one opening 31 into which a person can be positioned for operating the boat.
  • the preferred embodiment forming a boat or canoe is advantageously constructed from a combination of high performance fibers selected from the group consisting of Kevlar, fiberglass, carbon, Nectran, and the like, and combinations thereof.
  • the at least one 3-D fabric used to form the canoe embodiment was constructed of a combination of 3-D and 2-D woven materials using Kevlarl29, fiberglass, and carbon fibers.
  • the combinations may be used in particular to provide reinforcement via stiffening ribs that run crosswise (shown as direction A in Figure 3).
  • Kevlar 129 was used in a 3-D woven fabric at 2.5 density and two layers of that fabric were used to form the base or hull 32 of the boat.
  • the process used for forming the composite from these fabric combinations was a closed-mold vacuum resin transfer molding (NARTM) method. While an open-mold process may be used, environmental concerns as well as optimized processing make the closed-mold method more desirable. Prior to setting the material(s) into the mold, it is possible to pre-wet the fabric with a resin, although this is not necessary in most cases to achieve adequate saturation of the matierals.
  • Additional materials including but not limited to wood, particularly balsa wood, may be combined with the material(s) in the mold, in the centerline along the boat length or crosswise for stability and stiffness.
  • foam may be advantageously incorporated into cross-wise stiffening ribs to increase the bending moment in that direction.
  • top and bottom sections are joined via stitching or wiring or otherwise adhering and sealing together; in the prototype, the top and bottom sections were joined together by wire that was run through drilled holes in each section and then twisted together. Additional sealant may be provided by fiberglass taping or covering of the joints. Finally, sanding or other smoothing of the surfaces may be done to provide a smooth surface finish. Also, gel coatings may be applied to further enhance the surface smoothness and to provide less resistance and drag in the water.
  • the present invention is further directed to a method for forming a contoured laminated multilayer composite fiber structure for protective body armor and/or sporting goods applications including the steps of providing at least one 3-D engineered fiber structure, molding or otherwise manipulating the structure to produce a predetermined contour shape, and treating and stabilizing the structure via heat and/or pressure.
  • An additional step may include introducing a resin into the at least one 3-D engineered fiber structure prior to molding the structure.
  • Another step may include providing at least one two-dimensional engineered fabric laminated with the at least one 3-D engineered fabric prior to molding or otherwise manipulating the multilayer laminate into a predetermined contoured shape.
  • Still another additional step may include applying a finish to the surface of the contoured laminated multilayer composite fiber structure after it has been stabilized.
  • the finish may include water-resistant finish, water-rep ellant finish, scratch- resistant finish, shine-resistance, shine enhancer, wax, color, and the like, depending upon the application for which the finished structure will be used. Additional applications include using the contoured laminated multilayer composite fiber structure for forming the body of a cooler, hi this application, insulating material may be introduced within or between the multilayer fabrics for ensuring that goods stored within the cooler will retain their initial temperature.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne une structure composite lamellée multicouche profilée qui présente une surface efficace uniforme avant, pendant et après le traitement, ceci assurant des caractéristiques améliorées et uniformes pour le produit fini et une meilleure efficacité pour des applications de gilet de protection balistique et/ou d'articles de sport. La structure lamellée rigide profilée selon la présente invention assure une résistance aux impacts, une résistance au décollement, une résistance au cisaillement, une solidité et une qualité globale accrues du fait de la dissipation ininterrompue de la répartition de l'énergie sur toute la surface efficace du textile et de la surface efficace uniforme que présente le produit fini.
PCT/US2001/044763 2000-11-28 2001-11-28 Structure composite rigide profilee et procede associe WO2002043949A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2002227028A AU2002227028A1 (en) 2000-11-28 2001-11-28 Contour rigid composite structure and method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US72373000A 2000-11-28 2000-11-28
US09/723,730 2000-11-28

Publications (2)

Publication Number Publication Date
WO2002043949A2 true WO2002043949A2 (fr) 2002-06-06
WO2002043949A3 WO2002043949A3 (fr) 2002-08-29

Family

ID=24907414

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/044763 WO2002043949A2 (fr) 2000-11-28 2001-11-28 Structure composite rigide profilee et procede associe

Country Status (2)

Country Link
AU (1) AU2002227028A1 (fr)
WO (1) WO2002043949A2 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004029538A1 (fr) * 2002-09-30 2004-04-08 Rabintex Industries Ltd. Coiffe pour casque de protection balistique
CN102313492A (zh) * 2011-08-26 2012-01-11 山东三达科技发展公司 一种复合材料防弹头盔及其制造方法
CN102338595A (zh) * 2011-09-26 2012-02-01 江西长江化工有限责任公司 一种防弹头盔盔体成型的工艺方法
EP2250309A4 (fr) * 2008-02-26 2013-07-17 Honeywell Int Inc Composite souple pour gilet pare-balles de faible poids et à durabilité élevée utilisant des revêtements topiques de cire

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4737402A (en) * 1985-02-28 1988-04-12 Allied Corporation Complex composite article having improved impact resistance
US5112667A (en) * 1987-08-03 1992-05-12 Allied-Signal Inc. Impact resistant helmet
KR890701976A (ko) * 1987-08-03 1989-12-22 로이 에이취.멧신길 충격 저항성 헬멧
US5075904A (en) * 1989-08-05 1991-12-31 Toyo Boseki Kabushiki Kaisha Helmet with reinforcement

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004029538A1 (fr) * 2002-09-30 2004-04-08 Rabintex Industries Ltd. Coiffe pour casque de protection balistique
EP2250309A4 (fr) * 2008-02-26 2013-07-17 Honeywell Int Inc Composite souple pour gilet pare-balles de faible poids et à durabilité élevée utilisant des revêtements topiques de cire
TWI474926B (zh) * 2008-02-26 2015-03-01 Honeywell Int Inc 使用局部蠟塗層之輕量及高耐久性軟防彈衣複合物
CN102313492A (zh) * 2011-08-26 2012-01-11 山东三达科技发展公司 一种复合材料防弹头盔及其制造方法
CN102338595A (zh) * 2011-09-26 2012-02-01 江西长江化工有限责任公司 一种防弹头盔盔体成型的工艺方法

Also Published As

Publication number Publication date
WO2002043949A3 (fr) 2002-08-29
AU2002227028A1 (en) 2002-06-11

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