Composite material; a ballistic resistant article made from same and method of making the article
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example 1
[0078]The 4 harness satin weave fabric described above was impregnated with a thermoplastic resin dispersion, Michem® Prime 2960, to make a suitable wet prepreg for manufacture of a helmet shaped composite. The resin is available from Michelman Inc., Cincinnati, Ohio. The dry resin content of the prepreg was 8 percent by weight of the fabric plus the dry resin. The resin is an ethylene / acrylic acid copolymer. Plies for creating a helmet shaped article were made by cutting either 432 mm×432 mm squares or 230 mm diameter circles.
[0079]A first fabric square ply was draped over a male mold plug that modeled the shape of a medium sized Personnel Armor System for Ground Troops (PASGT) helmet. Each of the 4 corners of the first ply were tensioned so as to cause the fabric to distort and conform to the shape of the helmet mold as it was draped in place. A second fabric ply was then placed on top of the first fabric ply. This second ply was also conformed to the shape of the mold by distorti...
example 2
[0083]The plain weave fabric described above was was impregnated with a thermoplastic resin dispersion, Michem® Prime 2960, to make a suitable wet prepreg. The dry resin content of the prepreg was 8.5 percent by weight of the fabric plus the dry resin. Plies for creating a helmet shaped article were made by cutting either 432 mm x 432 mm squares or 230 mm diameter circles.
[0084]A medium sized PASGT helmet preform was created as described in Example 1, by wet lay-up of the square and circular ply shapes. A total of 55 plies were again used to create the helmet preform. The ply sequencing and orientation of the first, second and third plies was as in Example 1. The preform was similarly dried, and pressed as in Example 1 to create a medium PASGT shaped helmet shell. A finished helmet was cut to the contours of a typical Advanced Combat Helmet. The final helmet had a trimmed weight of 1.06 kg, with an average thickness of 7.06 mm. The outer plies of the formed helmet were examined and ...
example 3
[0086]Eight sheets of Dyeema® HB-26 were cut into circular plies having a diameter of 483 mm. Four slots each having a length of 165 mm were cut into each circular ply as shown at 50 in FIG. 5. A further eight sheets were cut in the shape of a cross. Plies cut in the shape of a cross all had a length of 483 mm and a width of 108 mm as shown as L and W respectively in FIG. 4. The sixteen plies (8 circles and 8 crosses) were lightly tacked into a net helmet shape with an ultrasonic welding tool and stacked in an alternating fashion. The assembled stack was placed into a matched die PASGT helmet compression mold with a gap of 8.13 mm which was preheated to 129 degrees C. and the mold closed for 15 seconds, just long enough to make a partially consolidated first sub-assembly which was then immediately removed from the mold.
[0087]The 4 harness satin weave aramid fabric previously described was impregnated with Michem® Prime 2960 resin to make a wet prepreg. The dry resin content of the p...
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