High-speed impact protection composite helmet and preparation method thereof

Abstract

The invention provides a high-speed impact protection composite helmet and a preparation method thereof.The composite helmet is formed by sequentially stacking and hot-pressing a plurality of curved-surface prefabricated modules made of continuous fiber reinforced composite materials layer by layer, each curved-surface prefabricated module comprises a curved-surface fabric layer and a resin layer, the curved-surface fabric layer is made of curved-surface fabric, and the resin layer is made of resin. The resin layer is compounded on the surface of at least one side of the curved fabric layer. The curved fabric is adopted, the helmet structure can be integrally manufactured, tailoring and splicing are not needed, the utilization rate of high-cost fiber raw materials is high, consumption is greatly reduced, and the production cost of the composite helmet can be greatly reduced; a curved surface prefabricated module composite preparation mode is adopted, the processes of piece cutting, manual lamination and the like are simplified, and the production efficiency can be remarkably improved; the fibers in the helmet are continuous, the high-strength effect of the fibers is more effective, the resin content can be accurately controlled at a low level, the helmet has more excellent impact resistance, the mass of the composite helmet can be effectively reduced, and the composite helmet has the advantages of being light in weight and excellent in cost performance.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of bulletproof helmets, and particularly relates to a high-speed impact protection composite helmet and a preparation method thereof. BACKGROUND

[0002] A helmet is an important personal protective equipment, and a fiber reinforced resin-based composite material is a commonly used helmet shell material. Due to the complex curved surface structure of the helmet, a traditional helmet is usually made of a planar weftless cloth or woven fabric prepreg, and the preparation process includes cutting, splicing, lamination and then compression molding. For example:

[0003] A Chinese patent with the application number CN97115106.7 discloses a bulletproof helmet manufacturing method. The process is as follows: there is a circulating running glue coating belt, one end of the belt is provided with a resin glue pool, the middle part is provided with a heating plate, and the other end is provided with a cooling plate. One end of the aramid cloth belt is wound on a raw material roller, and the other end is wound on a cooked material roller, and is wound from the raw material roller to the cooked material roller. After the glue coating belt is hung with glue, it is combined with the aramid cloth belt, and is heated by the heating plate to transfer the resin glue to the surface of the aramid cloth. The aramid cloth with the resin glue is punched into a multi-petal flower-shaped blank by a mold, and the blank is stacked together in multiple layers in turn, and is then put into a molding mold for compression and heating molding.

[0004] A Chinese patent with the application number 201821358970.9 discloses a composite material bulletproof helmet, which is molded into one body by three layers of fiber cloth layers. The three layers of fiber cloth layers are as follows: the helmet surface layer is a polyethylene fiber resin prepreg layer, the middle layer of the helmet is a carbon fiber resin prepreg layer, and the innermost layer of the helmet is an aramid fiber resin prepreg layer.

[0005] A Chinese patent application with the application number CN94105876.X discloses a one-piece bulletproof helmet manufacturing method. 3000D fiber yarns are woven into strong fiber cloth, and are extruded into a film with resin. The fiber cloth and the resin film are rolled into a composite fiber layer. The composite fiber cloth is cut into a spiral blade shape and bent into a bowl shape. The bowl-shaped composite fiber cloth is stacked layer by layer, and reinforcing fiber cloth is placed at the top of the center of the upper layers to facilitate extrusion and stretching. The stacked bowl-shaped composite fiber cloth is pressed by a film under high temperature and high pressure to tightly combine and form a high-density fiber shell with fine organization. The product is automatically cut off from the waste material, and is sprayed with a high-temperature-resistant fireproof coating to become a one-piece bulletproof helmet with high strength, good bulletproof ability and light weight.

[0006] In the above technical solution, each lamination unit is cut into a wind wheel or petal shape (see the attached Figure 1 The cutting process not only causes waste of raw materials, but also shortens the continuous length of the fibers. The fiber strength utilization rate is low, the manual layering process is time-consuming, the comprehensive performance is difficult to improve, and the production and manufacturing efficiency is low.

[0007] Chinese patent application No. 201110248291.2 discloses a composite material bulletproof helmet and a manufacturing method thereof, which uses a fiber reinforced resin-based composite material with protective ability as a main material, uses a whole structure fabric cover similar to the shape of the helmet as a reinforcing material, lays the fabric cover in a direction consistent with the shape of the helmet, uses a general composite material forming process to form, and obtains the product through post-processing. In the technical solution, the resin glue solution is still used for impregnation, the content of the resin is not controlled, and there is no impact resistance detection data, so the bulletproof effect cannot be determined.

[0008] Therefore, it is of great significance to provide a composite helmet with high fiber strength utilization rate, obvious improvement in comprehensive performance of the helmet, and high production efficiency.

[0009] Therefore, the present application is proposed. SUMMARY

[0010] The present application aims to solve the problems in the prior art, and provides a high-speed impact protection composite helmet and a preparation method thereof. In the present application, a curved fabric is used to integrally form the helmet structure, without cutting and splicing, so that the continuity of the fabric fibers is not damaged, and the helmet impact resistance performance is more favorable, and the raw material utilization rate and the fiber strength utilization rate are high. The curved preform module is suitable for various helmets, simplifies the cutting and layering process in the existing process, and can significantly improve the production efficiency. Meanwhile, the content of the resin can be accurately controlled, so that the helmet has more excellent impact resistance performance. Overall, the prepared high-speed impact protection composite helmet has the characteristics of low cost, light weight and high protection.

[0011] To solve the above technical problems, the basic idea of the technical solution of the present application is as follows:

[0012] The first object of the present application is to provide a high-speed impact protection composite helmet, which is made of a plurality of curved preform modules of continuous fiber reinforced composite material stacked and hot pressed in sequence, each curved preform module comprising a curved fabric layer and a resin layer, the curved fabric layer being a curved fabric, and the resin layer being combined on at least one side of the surface of the curved fabric layer.

[0013] The composite helmet of the present application is hot-pressed by sequentially stacking a plurality of curved preform modules layer by layer, which simplifies the processes of cutting and stacking in the current process, can significantly improve the production efficiency, and the curved preform module is suitable for various helmets. In each curved preform module, the curved fabric layer is made of curved fabric prepared by special equipment, which can match the complex curved surface structure of the helmet, so it can be integrally made into the helmet structure without cutting and splicing, avoiding the damage of fiber continuity caused by cutting during subsequent helmet shell forming, which can effectively improve the utilization rate of raw materials, the utilization rate of fiber strength, and the bulletproof performance, and help the lightweight of the bulletproof helmet. In addition, the resin layer is compounded on the surface of the curved fabric layer instead of using the impregnation method, which can accurately control the content of the resin, so that the helmet has more excellent impact resistance.

[0014] In a further aspect, when the plurality of curved preform modules are stacked layer by layer, there is at least one resin layer between the curved fabric layers of the two adjacent curved preform modules.

[0015] In a further aspect, the curved fabric is made by a special follow-up printer or a special curved loom according to the prepared helmet mold, which is tightly attached to the surface of the helmet mold without wrinkles.

[0016] The curved fabric layer is a follow-up curved fabric layer made by a follow-up printer or a curved woven fabric layer woven by a curved loom.

[0017] In a further aspect, the follow-up curved fabric layer and the resin layer are compounded to obtain a follow-up curved preform module A, and the curved woven fabric layer and the resin layer are compounded to obtain a curved fabric preform module B; the follow-up curved preform module A and the curved fabric preform module B are separately stacked or cross combined according to a certain order and proportion according to the requirements of the ballistic limit speed and the back surface depression depth of the helmet shell.

[0018] Preferably, the separate stacking or cross combination is pA, qB, mA+nB, xB+yA, hB+jA+kB, uA+vB+wA; wherein p, q, m, n, x, y, h, j, k, u, v, w are all integers greater than 1.

[0019] In a further aspect, in each curved preform module, the areal density of the curved fabric layer is 100-800 g / m 2 , preferably 200-500 g / m 2 .

[0020] In a further aspect, in each curved preform module, the curved fabric layer is composed of one or more than two fibers;

[0021] The fiber refers to high-strength fiber with fiber strength greater than 22 cN / dtex, preferably at least one of para-aramid fiber and its modification, ultra-high molecular weight polyethylene, polyimide, poly-p-phenylene benzobisoxazole, poly-2,5-dihydroxy-1,4-phenylene pyridine and imidazole, carbon fiber.

[0022] The curved fabric in each curved preform module can be composed of a common single high-strength fiber, such as para-aramid fiber, ultra-high molecular weight polyethylene fiber, polyimide fiber, carbon fiber, etc. high-strength fiber; or can be composed of one or more fibers to form an in-layer hybrid system, such as para-aramid fiber / ultra-high molecular weight polyethylene fiber, polyimide / ultra-high molecular weight polyethylene fiber, poly-p-phenylene benzobisoxazole / carbon fiber, etc.

[0023] The helmet shell is usually composed of multiple layers of curved preform modules, and the curved preform modules in different layers can be the same (single high-performance fiber system or in-layer hybrid system) or different (i.e. interlayer hybrid).

[0024] In a further aspect, in each curved preform module, the resin forms a resin layer on the surface of the curved fabric layer in the form of scraping, spraying or film coating;

[0025] Preferably, the resin is a thermosetting resin or a thermoplastic resin;

[0026] Preferably, the thermosetting resin is selected from at least one of phenolic resin and epoxy resin;

[0027] Preferably, the thermoplastic resin is selected from at least one of polyolefin, polyamide, polyurethane and polylactic acid.

[0028] In this aspect, the resin is attached to the surface of the curved fabric layer in the form of scraping, spraying or film coating, so that the resin content in the helmet can be accurately controlled while the adhesion of the curved fabric layers of adjacent modules can be better ensured.

[0029] In a further aspect, in each curved preform module, the mass fraction of the resin is 8-25%,

[0030] Preferably, the mass fraction of the resin is 10%-15%.

[0031] In the prior art, the resin glue solution is generally used to impregnate the fiber, and in this way, the fiber is soaked in the resin, and the resin quickly penetrates into the inner layer of the fiber, so that the resin content is high and difficult to control, affecting the protective performance of the helmet. The pre-impregnated glue method is not easy to control the resin content, and it is even more difficult to control the resin content at a low level. Even if the fiber is quickly taken out of the glue solution, the resin content is still high.

[0032] The resin is compounded on the surface of the curved fabric layer in the application, so that the content of the resin can be easily controlled in a suitable range. When the mass fraction of the resin is 8-25%, the protective performance is good and the firmness is good. When the mass fraction of the resin is 10%-15%, the protective performance of the helmet is greatly improved. If the content of the resin is too large, the protective performance of the helmet decreases, and if the content of the resin is too small, the interlayer firmness of the helmet cannot be guaranteed.

[0033] The shell surface density of the high-speed impact protective bulletproof helmet prepared by the application is usually 7.0-8.2 kg / m 2 , preferably 7.2-7.8 kg / m 2 , and the V50 of 1.1 gram simulated fragment protection is higher than 680 m / s.

[0034] The second object of the application is to provide a preparation method of the high-speed impact protective composite helmet as described above, which comprises:

[0035] (1) preparing a plurality of curved preform modules of the same or different continuous fiber reinforced composite materials;

[0036] (2) calculating the number of curved preform modules required according to the surface density required by the finished helmet and the surface density of each curved preform module;

[0037] (3) stacking the plurality of curved preform modules in order, layer by layer, hot pressing, trimming, and assembling accessories to obtain the high-speed impact protective composite helmet.

[0038] In each curved preform module of the present application, the surface density of the curved fabric layer is 100-800 g / m 2 , preferably 200-500 g / m 2 . According to the shell surface density requirement and the curved preform surface density, the required number of layers can be calculated. In this way, the helmet can be designed and combined according to different use requirements, improving the flexibility of helmet design and the efficiency of production.

[0039] In step (3), the hot pressing temperature and pressure of the shell can be selected according to the type of fiber and resin used in the curved preform module.

[0040] Further, as an embodiment, the hot pressing conditions include: the control temperature is 90-220℃, the control pressure is 3-30MPa, and the hot pressing holding time is 10-60min.

[0041] As a feasible embodiment, the curved fabric layer can be obtained by using a curved conformal printer to print a conformal curved fabric layer or by using a curved loom to weave a curved woven fabric layer, and then attaching resin on the surface to make a curved preform module. More specifically, it includes the following:

[0042] 1. A shape-adaptive curved fabric layer made of a shape-adaptive curved fabric layer A:

[0043] A shape-adaptive curved fabric layer is printed by a curved shape-adaptive printer, in which high-strength fiber tapes are cross-stacked and printed into a shape-adaptive curved fabric layer that can change with complex curves. Then, the shape-adaptive curved fabric layer is combined with a predetermined fiber content and resin matrix, which can be a thermosetting or thermoplastic resin, and is coated or sprayed, or can be a thermoplastic resin film, and then is subjected to curved hot pressing to obtain a shape-adaptive curved fabric layer A.

[0044] The curved shape-adaptive printer mainly comprises the following mechanisms:

[0045] A fiber bundle feeding device with controllable tension, a resin film feeding device with controllable tension, a hot pressing composite device, a six-degree-of-freedom intelligent shape-adaptive printing manipulator, which is equipped with an automatic tape heating feeding and cutting mechanism, a multi-degree-of-freedom printing path planning program, and a hot pressing roller that can make the fiber film tape conform to the mold, a printing platform equipped with a three-degree-of-freedom curved shell mold that can be up and down, swing and rotate, and an intelligent control system of the whole machine. The structure of the curved shape-adaptive printer is shown in the following figure: Figure 3 . Figure 3 1 fiber bundle feeding device, 2 resin film feeding device, 3 hot pressing composite device, 4 six-degree-of-freedom intelligent shape-adaptive printing manipulator, 5 hot pressing roller, 6 printing platform, 7 rotatable three-degree-of-freedom curved shell mold, 8 fiber tape.

[0046] The key points of the preparation process of the shape-adaptive curved fabric layer include:

[0047] (1) Fiber bundle or fiber tape feeding: high-strength fiber bundles or high-strength film tapes are fed by a fiber bundle feeding device with controllable tension.

[0048] (2) Resin film feeding: thermoplastic resin film is fed by a resin film feeding device with controllable tension, and the thickness of the resin film can be selected according to the resin content.

[0049] (3) Fiber film tape preparation: high-strength fiber bundles or high-strength film tapes are combined with hot melt resin film through a hot pressing composite device to prepare high-strength fiber film tapes.

[0050] (4) Preparation of Conformal Curved Fabric Layer: The fiber membrane strip is conformally printed on the curved helmet shell on a three-degree-of-freedom printing platform by a six-degree-of-freedom intelligent conformal printing robot. The conformal printing robot can automatically change the curvature and direction of the strip according to a preset path, and can also automatically heat, feed or cut the strip according to a preset program. To ensure that the strip fits tightly with the curved helmet shell mold, the hot pressing roller equipped by the robot can melt the resin of the strip to achieve bonding with the curved helmet shell mold. The multi-degree-of-freedom mold movement of the helmet shell on the printing platform can enable the strip to be quickly printed and firmly bonded at large curvatures. The helmet shell mold can rotate at an angle of 30-270 degrees. After one layer of fiber membrane strip is conformally printed, the second layer of membrane strip can be cross-printed according to the program. Similarly, a conformal curved fabric layer of multiple layers of membrane strips can be prepared. The cross angle between the fiber membrane strip layers is 10-90 degrees, preferably 45-90 degrees.

[0051] The width of the high-strength fiber strip is 2-10 mm, preferably 3-6 mm; the resin content of the fiber strip after hot pressing and compounding is 3-10%.

[0052] The conformable curved surface fabric layer is made by cross-stacked printing of two or more layers of high-strength fiber membrane strips.

[0053] 2. Curved fabric preform B made of curved woven fabric layer

[0054] A fabric with a complex curved surface shape is directly woven using a curved loom, and then compounded with a resin matrix according to a preset fiber content. The fabric can be scraped or sprayed with a thermosetting or thermoplastic resin, or coated with a thermoplastic resin. The curved surface is then hot-pressed to obtain a curved fabric preform B.

[0055] The curved loom is mainly composed of the following mechanisms:

[0056] A warp let-off device or warp beam with controllable single yarn feed amount and adaptive warp tension control;

[0057] a warp opening device comprising a plurality of heald frames;

[0058] Weft insertion device, including rapier, variable feed amount and automatic weft selection;

[0059] Beating-up device, can be equipped with variable warp density reed;

[0060] The curved and special-shaped cloth rolling device is composed of multiple molds; the multiple molds are cut and made for the complex curved surface of the helmet, and the lifting of each mold can be controlled separately;

[0061] Intelligent linkage control device for the entire machine.

[0062] Schematic diagram of curved loom structure Figure 4 . See the schematic diagram of the warp disc and warp beam structure. Figure 5Wherein, 101 - warp disc creel, 102 - warp disc, 103 - warp yarn, 104 - heald frame, 105 - reed, 106 - rapier / shuttle, 107 - weft yarn, 108 - curved surface fabric, 109 - special shaped cloth beam.

[0063] The weaving technical process and key points of the curved surface fabric layer prepared by the curved surface loom:

[0064] (1) Warp feeding: the warp tension self-adaptive individual control beam creel warp feeding or warp disc creel warp feeding can be adopted. Figure 5 ) Wherein the beam creel warp feeding or the warp disc creel warp feeding;

[0065] Preferably, when the beam creel warp feeding is adopted, the total warp roots are calculated according to the width and the warp and weft density, each root of yarn is wound on a separate yarn beam according to the length of the piece, and then arranged on the beam creel at the rear of the loom (including the yarn tension control device), each root is individually introduced into the loom to realize the uniform tension of each root of warp yarn and the rewinding according to the required length;

[0066] Preferably, when the warp disc creel warp feeding is adopted, the total warp roots are calculated according to the width and the warp and weft density, each root of warp yarn is wound on the warp disc, and arranged in groups in series on the warp disc creel, and the creel rotates uniformly in the opposite direction of the warp feeding direction, so as to ensure the uniform tension of each root of warp yarn;

[0067] (2) Opening: the warp yarn is introduced into the loom and passes through the heald frame (the warp yarns with the same interlacing rule can be introduced into the same heald frame, usually the plain weave, twill weave and other small jacquard weaves with the repeat of 16 pages) to realize the opening, the heald frame lifting drives the warp yarns introduced therein to move, and the weaves with different interlacing structures can be realized according to the curvature;

[0068] (3) Weft insertion: the weft yarn is introduced into the opening under the driving of the rapier to realize the interlacing of warp and weft (collaborate with the weft selection mechanism to ensure that different weft yarn heads can be introduced every 2-5 weft continuously, and the introduced weft yarn is cut off after winding is completed);

[0069] (4) Beating-up: the reed swings towards the front of the machine to beat the newly introduced weft yarn into the shed to form cloth (the reed number and the number of warp roots per reed are selected according to the arrangement density of warp yarns);

[0070] (5) Winding: the special shaped cloth beam (the helmet complex curved surface mold is cut into a thin piece combined mold with a thickness of 2-50mm, the lifting of each piece of mold can be individually controlled, and the piece of mold is used as a cloth beam. The lifting of each piece of mold can adjust the warp and weft feeding amount required by the curved surface, and the mold is matched with the constant speed movement towards the front of the machine according to the weft arrangement density to realize the winding fabric speed control.

[0071] The curved surface fabric is designed according to the curvature of the curved surface, the weft arrangement density and the warp and weft arrangement density.

[0072] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0073] 1. The composite helmet of the present invention is made of multiple curved surface prefabricated modules stacked layer by layer in sequence and hot pressed, which simplifies the processes of cutting and laminating in the current technology, can significantly improve production efficiency, and the curved surface prefabricated module method is suitable for helmets with various requirements.

[0074] 2. In each curved prefabricated module of the present invention, the curved fabric layer adopts curved fabric, which can fit the complex curved structure of the helmet. Therefore, the complete fabric can be integrated into the helmet structure without cutting and splicing, avoiding the destruction of fiber continuity caused by cutting during the subsequent helmet shell molding, which can effectively improve the raw material utilization rate, improve the fiber strength utilization rate, and effectively improve the impact resistance of the helmet.

[0075] 3. In the present invention, the resin layer is compounded on the surface of the curved fabric layer instead of being impregnated, so that the resin content can be accurately controlled at a lower level, so that the helmet has more excellent impact resistance.

[0076] 4. The present invention can be widely used in the preparation of various types of bulletproof helmets, high-speed impact protective helmets, bulletproof structural parts, bulletproof plates, high-speed impact resistant composite materials, etc. It can not only improve the protective performance, but also effectively reduce the weight of the composite helmets or components, and has the characteristics of lightweight and excellent cost performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] The accompanying drawings are part of the present invention and are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention, but do not constitute an undue limitation of the present invention. Obviously, the drawings described below are only some embodiments. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without inventive effort. In the accompanying drawings:

[0078] Figure 1 A schematic diagram of the cutting shape of the stacked units in the helmet molding process of the prior art mentioned in the background technology;

[0079] Figure 2 This is a schematic diagram of the helmet shell molding process prepared using the technology of the present invention;

[0080] Figure 3 This is a schematic diagram of the structure of a curved conformable printer;

[0081] Figure 4 Schematic diagram of the curved loom structure;

[0082] Figure 5 Schematic diagram of the warp disc and warp beam structure;

[0083] in,Figure 3 In the figure, 1 is a fiber bundle feeding device, 2 is a resin film feeding device, 3 is a hot-pressing composite device, 4 is a six-degree-of-freedom intelligent following printing manipulator, 5 is a hot-pressing roller, 6 is a printing platform, 7 is a rotatable three-degree-of-freedom curved surface helmet shell mold, and 8 is a fiber tape.

[0084] Figure 4 And Figure 5 In the figure, 101 is a warp disc creel, 102 is a warp disc, 103 is a warp yarn, 104 is a heald frame, 105 is a reed, 106 is a rapier / shuttle, 107 is a weft yarn, 108 is a curved surface woven fabric, and 109 is a special-shaped cloth beam.

[0085] It should be noted that the drawings and the written description are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0086] In order to make the purpose, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments will be described clearly and completely below in combination with the drawings of the embodiments of the present application. The following embodiments are used to illustrate the present application, but not to limit the scope of the present application.

[0087] It should be noted that, without further limitation and description, the mass fraction of the resin defined in each of the following embodiments refers to the total mass fraction of the resin in the prepared helmet, and also the mass fraction of the resin in each preform, that is, the mass fraction of the resin in each preform remains consistent.

[0088] Detection method:

[0089] V50 value: a 1.1-gram mass simulated fragment is fired at a helmet at different speeds within a specified distance, 50% of the bullets penetrate the helmet and 50% do not, that is, a 50% penetration probability is reached, and the average value of the speed of the fired bullets is the V50 value of the helmet. The higher the V50 value, the better the bulletproof performance of the helmet.

[0090] Next, the present application will be further described with specific embodiments.

[0091] As an embodiment of the present application, the embodiment provides a manufacturing method of a high-speed impact protection composite helmet, specifically as follows.

[0092] According to the area density required by the finally prepared helmet and the area density of the curved surface fabric designed for manufacturing the helmet, the number of layers of the curved surface fabric to be used is calculated, and the calculation formula is as follows:

[0093]

[0094] Wherein, p is the areal density of the helmet; pi is the average areal density of the i-th kind of curved fabric; n is the number of different kinds of curved fabric used to make the helmet; mi is the number of the i-th kind of curved fabric.

[0095] In the present application:

[0096] 1. A shaped curved fabric layer made of shaped curved fabric A:

[0097] The high-strength fiber tape is printed into a shaped curved fabric layer with variable complex curved surface by a curved shaped printer, and then the shaped curved fabric layer is combined with a predetermined fiber content and resin matrix, which can be a thermosetting or thermoplastic resin, and the resin matrix can be coated or sprayed, and the shaped curved fabric layer can be coated with a thermoplastic resin film, and then the shaped curved fabric layer is hot-pressed to obtain the shaped curved fabric A.

[0098] The curved shaped printer mainly comprises the following mechanisms:

[0099] The fiber bundle feeding device 1 with controllable tension, the resin film feeding device 2 with controllable tension, the hot-pressing composite device 3, the six-degree-of-freedom intelligent shaped printing manipulator 4 with automatic tape feeding and cutting mechanism, multi-degree-of-freedom printing path planning program and hot-pressing sticking roller that can make the fiber film tape cover the mold well, the printing platform 6 with a rotatable three-degree-of-freedom curved helmet shell mold 7 (which can be up and down, swing and rotate), and the whole machine linkage intelligent control system. Figure 3 .

[0100] The key points of the preparation process of the shaped curved fabric layer include:

[0101] (1) Fiber bundle or fiber tape feeding: The high-strength fiber bundle or high-strength film tape is fed by the fiber bundle feeding device with controllable tension.

[0102] (2) Resin film feeding: The thermoplastic resin film is fed by the resin film feeding device with controllable tension, and the thickness of the resin film can be selected according to the resin content.

[0103] (3) Fiber film tape preparation: The high-strength fiber bundle or high-strength film tape is combined with the hot melt resin film by the hot-pressing composite device to prepare the high-strength fiber film tape.

[0104] (4) Random surface fabric layer preparation: The fiber film strip is printed on the curved surface helmet shell on the three-degree printing platform by the six-degree intelligent random printing manipulator. The random printing manipulator can automatically change the curvature and direction according to the preset path, and can also automatically feed or cut the strip according to the preset program. In order to ensure that the strip is tightly attached to the curved surface helmet shell mold, the hot pressing roller equipped on the manipulator can melt the resin of the strip to realize bonding. The multi-degree of freedom mold movement of the printing platform can make the strip quickly print and firmly bond at the large curvature. The helmet mold can rotate at an angle of 30-270 degrees. After the fiber film strip is randomly printed on one layer, the second layer of film strip can be cross-laid and printed according to the program, and so on, so as to prepare a random surface fabric layer with multiple layers of film strips. The cross-lay angle between the fiber film strip layers is 10-90 degrees, preferably 45-90 degrees.

[0105] The high-strength fiber strip has a width of 2-10 mm, preferably 3-6 mm; and the resin content of the fiber strip after hot pressing and compounding is 3-10%.

[0106] The random surface fabric layer is made by cross-laying and printing two or more high-strength fiber film strips.

[0107] 2. Curved surface fabric preform B made of curved surface woven fabric layer

[0108] The curved surface fabric preform B is obtained by directly weaving a fabric with a complex curved surface shape on a curved surface loom, and then compounding the fabric with a resin matrix according to a preset fiber content. The resin can be thermosetting or thermoplastic, and can be coated or sprayed by scraping or spraying, or can be coated with a thermoplastic resin, and then hot pressed to obtain the curved surface fabric preform B.

[0109] The curved surface loom mainly consists of the following mechanisms:

[0110] The warp beam 101 has a single controllable feed amount and a self-adaptive warp tension control. The warp shedding device includes a plurality of harness frames 104. The weft insertion device includes a rapier 106, which has a variable feed amount and can automatically select weft. The beating-up device can be installed with a variable warp density reed 105. The curved surface special-shaped cloth winding device is composed of a plurality of molds. Each mold is cut and made into a helmet complex curved surface mold, and the lifting of each mold can be controlled independently.

[0111] The structure diagram of the curved surface loom is shown in Figure 4 .

[0112] The structure diagram of the warp beam is shown in Figure 5 .

[0113] The weaving technical process and key points of the curved surface loom for preparing the curved surface fabric layer are as follows:

[0114] (1) Warp feeding: The warp tension self-adaptive single control beam or warp beam 101 can be used for warp feeding.Figure 5 ). Wherein the beam creel is sent or the warp disc creel;

[0115] When the beam creel is sent, the total warp roots are calculated according to the width and the warp and weft density, each root of yarn is wound in a separate yarn cylinder according to the length of the match, and then arranged on the beam creel behind the loom (including yarn tension control device), each root is separately introduced into the loom to realize uniform tension of each root of warp yarn and can be unwound according to the required length;

[0116] When the warp disc creel is sent, the total warp roots are calculated according to the width and the warp and weft density, each root of warp yarn 103 is wound on the warp disc 102, and arranged in groups in series on the warp disc creel 101, the creel rotates uniformly in the opposite direction of the warp yarn feeding direction, so as to ensure that the tension of each root of warp yarn is uniform;

[0117] (2) Opening: the warp yarn 103 is introduced into the loom and passes through the heald frame 104 (the warp yarns with the same interlacing rule can be introduced into the same heald frame, usually plain weave, twill weave and other small jacquard weave structures within 16 pages of heald frame) to drive the movement of the warp yarn introduced therein to realize opening, and different fabric weave structures can be realized according to the curvature to realize interlaced structure different weave structures;

[0118] (3) Weft insertion: the weft yarn 107 is introduced into the opening under the driving of the rapier 106 to realize the interlacing of warp and weft (collaborate with the weft selection mechanism to ensure that different weft yarn heads can be introduced every 2-5 weft yarns in succession, and the introduced weft yarn is cut off after winding is completed);

[0119] (4) Beating-up: the reed 105 swings towards the front of the machine to beat the newly introduced weft yarn into the loom to form cloth (the reed number and the number of warp yarns per reed are selected according to the arrangement density of the warp yarns);

[0120] (5) Winding: a special-shaped cloth winding shaft 109 (cutting a complex curved surface mold of a helmet into a thin piece with a thickness of 2-50 mm to form a combined mold, the lifting of each piece of mold can be controlled individually, and each piece of mold is used as a cloth winding shaft. The lifting of each piece of mold can adjust the warp and weft yarn feeding amount required by the curved surface, and the mold is matched with the constant speed movement towards the front of the machine according to the weft yarn arrangement density to realize the winding speed control of the fabric, and the curved surface woven fabric 108 is obtained.

[0121] The curved surface woven fabric is designed according to the curvature of the curved surface, the arrangement density of the warp and weft yarns.

[0122] The helmet is made by the above preparation method, and the specific steps are as follows:

[0123] Example 1

[0124] The aramid 1414 fiber is used as raw material, and the curved surface loom is used to weave the face density of 410 g / m 2The phenolic resin is compounded on the outer surface of the curved fabric by a blade coating method. The mass fraction of the resin compounded on the surface of the curved fabric is about 13%, and the density of the resin after compounding is 471 g / m 2 The above process of making the curved preform is repeated to make a 16-layer curved preform.

[0125] The 16-layer curved fabric is laminated, and a helmet shell with a surface density of 7549 g / m 2 is made by hot pressing at 150°C and 15 MPa for 30 minutes. The test V50 value is 710.3 m / s.

[0126] Example Two

[0127] An aramid fiber with a surface density of 350 g / m 2 is used as raw material to weave a curved fabric by a curved loom. Polyurethane is compounded on the outer surface of the curved fabric by a film coating method to obtain a curved preform. The mass fraction of the resin in the curved preform is about 12%, and the surface density of the curved preform is about 398 g / m 2 The above process of making the curved preform is repeated to make a 19-layer curved preform.

[0128] The 19-layer curved preform is laminated, and a helmet shell with a surface density of 7560 g / m 2 is made by hot pressing at 120°C and 15 MPa for 30 minutes. The test V50 value is 760.8 m / s.

[0129] Example Three

[0130] A composite fabric obtained by mixing para-aramid fiber and ultrahigh molecular weight polyethylene fiber in a mass ratio of 2:1 is used as raw material to weave a curved fabric with a surface density of 320 g / m 2 Polyurethane is compounded on the outer surface of the curved fabric by a film coating method to obtain a curved preform. The mass fraction of the resin in the curved preform is about 12%, and the surface density of the curved preform is about 364 g / m 2 The above process of making the curved preform is repeated to make a 21-layer curved preform.

[0131] The 21-layer curved preform is laminated, and a helmet with a surface density of 7640 g / m 2 is made by hot pressing at 130°C and 15 MPa for 30 minutes. The test V50 value is 728.6 m / s.

[0132] Example Four

[0133] The aramid curved preform in Example One (with a resin content of about 13% and a surface density of 471 g / m 2)10 layers and the super high molecular weight polyethylene curved preform in example two (the glue content of the curved preform is about 12%, and the areal density is about 398 g / m 2 )7 layers of the molded composite helmet shell.

[0134] The 10 layers of aramid curved preform are preformed after hot pressing at 150 ℃, 15 MPa for 25 minutes to make the outer layer, the 7 layers of super high molecular weight polyethylene curved preform are preformed after hot pressing at 120 ℃, 15 MPa for 15 minutes to make the inner layer, and then the inner and outer layers are hot pressed at 120 ℃, 15 MPa for 15 minutes to form a helmet with an areal density of 7510 g / m 2 , and a test V50 value of 735.7 m / s.

[0135] Example Five

[0136] The pre-impregnated super high molecular weight polyethylene fiber bundle is used to complete the curved composite material laying through the conformal printing mode under the cooperation of the movement of the mechanical arm and the rotation of the curved mold, and the polyolefin resin is compounded on the outer surface of the curved fabric by the film coating method to obtain a curved preform. The areal density is about 650 g / m 2 , and the mass fraction of the resin is 25%.

[0137] The 12 layers of curved preforms are stacked and hot pressed at 120 ℃, 15 MPa for 25 minutes to make a helmet with an areal density of 7800 g / m 2 , and a test V50 value of 748.6 m / s.

[0138] Example Six

[0139] The aramid curved preform (the glue content is about 13%, and the areal density is 471 g / m 2 ) in example one and the super high molecular weight polyethylene curved preform (the glue content of the curved preform is about 25%, and the areal density is about 650 g / m 2 ) in example five are used to form a molded composite helmet shell.

[0140] The 10 layers of aramid curved preform are preformed after hot pressing at 150 ℃, 15 MPa for 20 minutes to make the outer layer, the 5 layers of super high molecular weight polyethylene curved preform are preformed after hot pressing at 120 ℃, 15 MPa for 15 minutes to make the inner layer, and then the inner and outer layers are hot pressed at 120 ℃, 15 MPa for 15 minutes to form a helmet with an areal density of 7960 g / m 2 , and a test V50 value of 725.7 m / s.

[0141] Example Seven

[0142] The aramid curved preform (the glue content is about 13%, and the areal density is 471 g / m2 ) 10 layers of the ultra-high molecular weight polyethylene curved preform in Example Five (the glue content of the curved preform is about 25%, the areal density is about 650 g / m 2 ) 5 layers of the molded composite helmet shell.

[0143] The 5 layers of aramid curved preform were preformed at 150°C, 15 MPa for 20 minutes to make the outer layer, the 5 layers of ultra-high molecular weight polyethylene curved preform were preformed at 120°C, 15 MPa for 15 minutes to make the middle layer, and the other 5 layers of aramid curved preform were preformed at 150°C, 15 MPa for 20 minutes to make the inner layer. Then the inner, middle and outer layers were molded at 120°C, 15 MPa for 15 minutes to finally make a helmet with an areal density of 7960 g / m 2 , and the test V50 value was 728.5 m / s.

[0144] Example Eight

[0145] The ultra-high molecular weight polyethylene curved preform in Example Two (the glue content of the curved preform is about 12%, the areal density is about 398 g / m 2 ) was used as the outer layer of the helmet shell, the ultra-high molecular weight polyethylene curved preform in Example Five (the glue content of the curved preform is about 25%, the areal density is about 650 g / m 2 ) was used as the inner layer of the helmet shell, and a molded composite helmet shell was formed.

[0146] The two preforms were stacked in order and hot-pressed at 130°C, 15 MPa for 30 minutes to make a helmet with an areal density of 7700 g / m 2 , and the test V50 value was 732.9 m / s.

[0147] Comparative Example One

[0148] An aramid 1414 fiber prepreg (the areal density was about 468 g / m 2 , and the phenolic resin content was about 11%) was used as the raw material, and a helmet with an areal density of 7575 g / m 2 was made by cutting and stacking, and the test V50 value was 638.9 m / s.

[0149] The above merely describes preferred embodiments of the present application, and is not intended to limit the present application in any form. Although the present application has been disclosed with the preferred embodiments as above, it is not intended to limit the present application, and any person skilled in the art can make some changes or modifications to the above-mentioned technical content with equivalent embodiments within the scope of the technical solutions of the present application. The embodiments in the above-mentioned embodiments can be further combined or replaced, as long as they do not deviate from the technical solutions of the present application. Any simple modification, equivalent change and modification made to the above-mentioned embodiments according to the technical essence of the present application are still within the scope of the present application.

Claims

1. A high-velocity impact protective composite helmet, characterized by, The composite helmet is hot-pressed by sequentially stacking a plurality of continuous fiber reinforced composite curved preform modules layer by layer, each of the curved preform modules comprising a curved fabric layer and a resin layer, the curved fabric layer being a curved fabric, and the resin layer being compounded on the surface of at least one side of the curved fabric layer.

2. The high-velocity impact protective composite helmet of claim 1, wherein, When the plurality of curved preform modules are stacked layer by layer, there is at least one resin layer between the curved fabric layers of two adjacent curved preform modules.

3. The high-velocity impact protective composite helmet according to claim 1 or 2, characterized in that, The curved fabric layer is a contoured curved fabric layer made by a contoured printing machine, or a curved woven fabric layer made by a curved loom. Preferably, the contoured curved fabric layer and the resin layer are compounded to obtain a contoured curved preform module A, and the curved woven fabric layer and the resin layer are compounded to obtain a curved fabric preform module B; the contoured curved preform module A and the curved fabric preform module B are stacked separately or combined in a certain order and proportion according to the requirements of the ballistic limit speed and the back surface depression depth of the helmet shell. Preferably, the separate stacking or cross combination is pA, qB, mA+nB, xB+yA, hB+jA+kB, uA+vB+wA; wherein p, q, m, n, x, y, h, j, k, u, v, w are all integers greater than 1.

4. The high-velocity impact protective composite helmet according to any one of claims 1-3, wherein, The areal density of the curved fabric layer in each curved preform module is 100-800 g / m 2 , preferably 200-500 g / m 2 .

5. The high-velocity impact protective composite helmet according to any one of claims 1-4, wherein, In each curved preform module, the curved fabric layer is composed of one or more than two kinds of fibers. The fiber is a high-strength fiber with a fiber strength greater than 22 cN / dtex. Preferably, the fiber is at least one of para-aramid fiber and its modification, ultra-high molecular weight polyethylene, polyimide, poly-p-phenylene benzobisoxazole, poly-2,5-dihydroxy-1,4-phenylene pyridine bisimidazole, and carbon fiber.

6. The high-velocity impact protective composite helmet according to any one of claims 1-5, wherein, In each curved preform module, the resin forms a resin layer on the surface of the curved fabric layer in the form of scraping, spraying or film coating. Preferably, in each curved preform module, the mass fraction of the resin is 8-25%, and preferably the mass fraction of the resin is 10%-15%. Preferably, the resin is a thermosetting resin or a thermoplastic resin. Preferably, the thermosetting resin is at least one of phenolic resin and epoxy resin. Preferably, the thermoplastic resin is at least one of polyolefin, polyamide, polyurethane and polylactic acid.

7. The high-velocity impact protective composite helmet according to any one of claims 1-6, wherein, The shell face density of the high-impact protective composite helmet is 7.0-8.2 kg / m 2 , preferably 7.4-7.8 kg / m 2 ; the V50 against 1.1 gram simulated fragment is higher than 680 m / s.

8. A method of manufacturing a high-velocity impact protective composite helmet according to any one of claims 1-7, characterized in that, The preparation method comprises: (1) preparing a plurality of curved preform modules of continuous fiber reinforced composite materials which are the same or different; (2) calculating the number of curved preform modules required according to the areal density of the finished helmet and the areal density of each curved preform module; (3) sequentially stacking the plurality of curved preform modules layer by layer, hot-pressing, trimming, assembling accessories to obtain a high-speed impact protection composite helmet; Preferably, the hot-pressing conditions include: controlling the temperature to be 90-220℃, controlling the pressure to be 3-30MPa, and the hot-pressing holding time being 10-60min.

9. A curved surface conformal printer for preparing a conformal curved surface fabric layer, characterized in that: It comprises: a control system; a fiber bundle feeding device; a resin film feeding device; a hot-pressing composite device; a six-degree-of-freedom intelligent following printing manipulator equipped with an automatic tape heating feeding and cutting mechanism and a hot-pressing roller; a printing platform, wherein the printing platform is loaded with a rotatable three-degree-of-freedom curved helmet shell mold. Preferably, the curved surface conformal printing mechanism is used to prepare the conformal curved surface fabric layer in the high-speed impact protective composite helmet according to any one of claims 1-7. Preferably, the method for preparing the conformal curved surface fabric layer in the high-speed impact protective composite helmet according to any one of claims 1-7 comprises: (1) Fiber bundle or fiber tape feeding: feeding high-strength fiber bundles or high-strength film tapes through a fiber bundle feeding device; (2) Resin film feeding: feeding thermoplastic resin films through a resin film feeding device; (3) Fiber film tape preparation: combining high-strength fiber bundles or high-strength film tapes with hot melt resin films through a hot pressing combination device to prepare fiber film tapes; (4) Conformal curved surface fabric layer preparation: the fiber film tapes are conformally printed on a three-degree-of-freedom curved helmet shell carried on a printing platform by a six-degree-of-freedom intelligent conformal printing manipulator, the conformal printing manipulator automatically changes the curvature and direction of laying according to the preset path, automatically heats and feeds or cuts the tapes according to the preset program, and the hot pressing roller melts the resin of the high-strength fiber film tapes to realize adhesion with the curved helmet shell mold, Preferably, the curved helmet shell mold can rotate at an angle of 30-270 degrees. Preferably, the intersection angle between the fiber film tape layers is 10-90 degrees, preferably 45-90 degrees. Preferably, the width of the fiber film tape is 2-10 mm, preferably 3-6 mm. Preferably, the resin content of the fiber tape after hot pressing combination is 3-10%. Preferably, after conformal printing of the fiber film tape layer, the second layer or multiple layers of film tapes can be cross-laid and printed according to the program to prepare one or more layers of conformal curved surface fabric layers. Preferably, the conformal curved surface fabric layer is prepared by cross-laying and printing two or more layers of high-strength fiber film tapes.

10. A warp knitting machine for making a curved woven fabric layer, characterised in that, It comprises: a control device; a warp feeding device or warp disc beam; a warp shedding device comprising a plurality of harnesses; a weft insertion device comprising a rapier, a variable feeding amount, and automatic weft selection; a beating-up device, which can be installed with a variable density reed; a curved profile cloth winding device, which is composed of a plurality of molds, and each mold is cut and prepared from a helmet complex curved surface mold, and the lifting of each mold can be controlled individually; Preferably, the curved surface loom is used to prepare the curved surface woven fabric layer in the high-speed impact protective composite helmet according to any one of claims 1-7. Preferably, the method for preparing the curved surface woven fabric layer in the high-speed impact protective composite helmet according to any one of claims 1-7 comprises: (1) warp feeding: warp feeding or warp disc beam using warp tension self-adaptive individual control; (2) shedding: after the warp is introduced into the loom, it passes through the harnesses, the harnesses lift the warp passing through them to move to realize shedding, and different fabric organization structures are realized according to the curvature; (3) weft insertion: the weft is introduced into the shed under the action of the rapier weft insertion device to realize warp-weft interlacing; (4) beating-up: the reed swings towards the front of the machine to beat the newly introduced weft into the shed to form cloth; (5) winding: an irregular cloth winding shaft is used, the lifting of each mold can adjust the required warp-weft feeding amount of the curved surface, and the winding fabric speed control is realized according to the constant speed movement of the mold towards the front of the machine according to the weft arrangement density requirement; Preferably, the curved surface woven fabric is designed according to the fabric structure, warp and weft arrangement density of the curved surface curvature; Preferably, the warp feeding device is a creel, the total warp count is calculated according to the width and warp and weft density, each yarn is wound in a single bobbin according to a yardage, arranged on the creel at the rear of the loom, and each is individually introduced into the loom to achieve uniform tension of each warp yarn and to be unwound at the required length; Preferably, when the warp disc beam is used, the total warp count is calculated according to the width and warp and weft density, each warp yarn is wound on a warp disc, and is arranged in groups on the warp disc beam, and the beam rotates uniformly in the opposite direction of the warp feeding direction, thereby ensuring uniform tension of each warp yarn.

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