A lightweight and highly efficient bulletproof and stab-resistant composite armor and its preparation method

Abstract

The present invention provides a lightweight and high-efficiency bulletproof and stab-resistant composite armor and a preparation method thereof. The composite armor is characterized in that it comprises a bullet-facing layer, a transition layer and a back plate layer. The bullet-facing layer and the transition layer, as well as the transition layer and the back plate layer, are bonded through a glue film. The bullet-facing layer is a multi-axial three-dimensional woven structure. In the present invention, the multi-axial three-dimensional woven fabric used for the bullet-facing layer not only has a low density, but also the particularly reinforced composite material has a high hardness similar to that of ceramics. Using the resin matrix composite material reinforced by this fabric as the bullet-facing surface, it will not undergo large-area fragmentation after being hit by a bullet, nor will it generate fragment splashing. Therefore, the introduction of a crack arrest layer is not required, reducing the preparation process of the composite armor.

Description

Technical Field

[0001] The present invention belongs to the field of bulletproof armor, and particularly relates to a lightweight and highly efficient bulletproof and stab-proof composite armor and a preparation method thereof. Background Art

[0002] Existing inserts are all made by compounding ceramic + fiber composite plates. At the same time, a crack arrest layer is also provided on the ceramic surface to prevent secondary damage caused by the fragmentation of the ceramic after being impacted. In addition, the ceramic layer belongs to a hard bullet-facing surface layer, which is mainly used to blunt the bullet and weaken the impact force. The backboard fiber composite material layer is an energy-absorbing support layer, which further weakens the impact of the bullet. There is a large transition in hardness and other aspects between the two plates with different physical properties, and the impedance matching degree is poor, resulting in the bulletproof performance of the composite armor plate not being fully exerted.

[0003] For example, Patent No. 201921318395.4 provides a bulletproof insert. The bulletproof insert includes a buffer layer, a crack arrest layer, a ceramic layer, and a support layer arranged in sequence along the thickness direction of the insert body. In this bulletproof insert, the crack arrest layer can prevent the fragments from splashing and causing harm to the human body after the ceramic layer is broken. The buffer layer is arranged on the bullet-facing side. When a bullet shoots at the bulletproof plate, the bullet can first pass through the buffer layer. The buffer layer can reduce the impact of the bullet on the ceramic layer, reduce the possibility of the ceramic layer being broken, thereby reducing the harm to the human body and achieving a better buffering effect. Moreover, the buffer layer is bonded to the bullet-facing side of the crack arrest layer. When the bulletproof insert accidentally falls, the buffer layer contacting the ground can prevent the ceramic layer from being broken due to the impact between the bulletproof insert and the ground.

[0004] Patent No. 201920946066.8 also discloses a bulletproof insert structure based on anti-ballistic ceramic chips, including a front armor plate at the front, a rear armor plate at the rear, and a ceramic armor plate between the front armor plate and the rear armor plate. The ceramic armor plate includes at least two layers of ceramic chip layers, and each layer of ceramic chip layer is composed of a plurality of ceramic chips spliced together. The splicing seams of the ceramic chips in adjacent two layers of ceramic chip layers are arranged staggeredly. The ceramic armor plate of the present utility model is stacked in a manner that at least two layers of ceramic chip layers are arranged with the ceramic chip layer joints staggered, and the multi-layer staggered stacking method makes up for the deficiencies of the single-layer paving method and improves the anti-ballistic performance of the ceramic chips.

[0005] Patent No. 201910009265.0 discloses a composite bulletproof armor plate and a preparation method thereof, which introduce a metal restraint plate between the ceramic plate and the fiber plate, and support the ceramic with a fiber-metal laminated plate and a porous metal sandwich plate to enhance the anti-ballistic performance of the bulletproof armor plate. However, the metal has a large density compared with the fiber composite material, which does not conform to the current development trend of lightweight.

[0006] In the prior art, there are few cases where high-performance fiber composites are directly used as the bullet-facing surface of armor plates, or when only high-performance fiber composites are used for armor plate protection, the defense level is generally relatively low. The main reason is that compared with ceramic plates, ordinary high-performance fiber composites generally lack sufficient hardness and do not have the ability to blunt the bullet and weaken the impact force of the bullet. Summary of the Invention

[0007] In view of this, the present invention aims to overcome the defects in the prior art and proposes a lightweight and highly efficient bulletproof and stab-proof composite armor and its preparation method.

[0008] To achieve the above object, the technical solution of the present invention is realized as follows:

[0009] A lightweight and highly efficient bulletproof and stab-proof composite armor, comprising a bullet-facing layer, a transition layer, and a back plate layer. The bullet-facing layer and the transition layer, as well as the transition layer and the back plate layer, are bonded by a film adhesive. The bullet-facing layer and the transition layer are inorganic fiber-reinforced resin-based composites, and the back plate layer is an organic fiber-reinforced resin-based composite. The volume content of inorganic fibers in the bullet-facing layer is 60%-90%, and the volume content of resin is 10%-40%. The bullet-facing layer is a multi-axial three-dimensional woven structure.

[0010] Preferably, the bullet-facing layer is made of a fabric obtained by weaving surface-sized inorganic fibers through a multi-axial three-dimensional weaving process and is formed by a compression molding process, a vacuum bag molding process, or an autoclave process.

[0011] Preferably, the bullet-facing layer is formed by curing a fabric obtained by weaving inorganic fibers through a multi-axial three-dimensional weaving process using a resin transfer molding (RTM) process.

[0012] Preferably, the volume content of inorganic fibers in the transition layer is 40%-70%, and the volume content of resin is 30%-60%.

[0013] Preferably, the transition layer is prepared by laying up unidirectional fiber prepregs or two-dimensional fabric prepregs in a 0° / 90° cycle, a 0° / ±45° / 90° cycle, or a 0° / 30° / 60° / 90° cycle.

[0014] Preferably, the inorganic fibers in the bullet-facing layer and the transition layer are independently selected from any one or a mixture of two or more of silicon carbide fibers, alumina fibers, boron carbide fibers, glass fibers, quartz fibers, and carbon fibers.

[0015] Preferably, the inorganic fibers in the bullet-facing layer are any one or a mixture of two or more of silicon carbide fibers, alumina fibers, or boron carbide fibers.

[0016] Preferably, the inorganic fiber in the transition layer is any one or a hybrid of two or more of glass fiber and carbon fiber.

[0017] Preferably, the resin in the bullet-facing layer and the transition layer is a thermosetting resin or a thermoplastic resin. More preferably, the thermosetting resin is any one or a combination of two or more of epoxy, phenolic, and unsaturated polyester; more preferably, the thermoplastic resin is any one or a combination of two or more of polyethylene, polyurethane, polyester, and nylon.

[0018] Preferably, the volume content of the organic fiber in the back panel layer is 70%-90%, and the resin content is 10%-30%.

[0019] Preferably, the back panel layer is prepared by a molding process after being cyclically laminated with unidirectional fiber prepregs at 0 / °90°, 0° / ±45° / 90°, or 0° / 30° / 60° / 90°.

[0020] Preferably, the organic fiber in the back panel layer is any one or a hybrid of two or more of ultra-high molecular weight polyethylene fiber, aramid fiber, and PBO fiber.

[0021] Preferably, the resin in the back panel layer is any one or a combination of two or more of polyethylene, polyurethane, polyester, and nylon.

[0022] Preferably, the substrate of the adhesive film is polyethylene, EVA, polypropylene, polyamide, polyurethane, or epoxy resin.

[0023] The multi-axial three-dimensional weaving technology is a new type of weaving technology, and the multi-axial three-dimensional woven fabric is a reinforcing preform for advanced composites. Since the yarns in the traditional three-dimensional woven fabric structure are in a bent state, there are limitations in increasing the fiber volume content by increasing the weaving density, etc., so that the performance of high-performance fibers in the fabric cannot be fully exerted, thereby affecting the performance of the composite material. The multi-axial three-dimensional woven fabric has improved the disadvantages of low fiber content and modulus of common three-dimensional woven fabrics due to the introduction of multi-directional oblique yarns, thus having better structural stability and impact resistance. In addition, due to the limited application environment of multi-axial three-dimensional woven fabrics with high fiber volume content, there are relatively few reports on their applications. However, multi-axial three-dimensional woven fabrics with high fiber volume content woven from high-performance inorganic fibers have very high impact strength. Especially, the high-density axial fiber arrangement in the direction of bullet impact during use can form fiber accumulation along the impact direction during the bullet impact process, greatly increasing the impact resistance of the bullet; at the same time, the rigid characteristics of the inorganic fiber can also blunt the bullet warhead and further weaken the impact force of the bullet. Compared with high-performance fiber-reinforced composite materials with two-dimensional laminated structures, the protection level can be greatly improved.

[0024] In addition, the present invention also provides a method for preparing the above-mentioned lightweight bulletproof and stab-proof composite armor plate, which includes:

[0025] S1: Preparation of the bullet-facing layer:

[0026] Pre-treat the inorganic fibers by sizing, and control the sizing rate on the surface of the inorganic fibers at 10%-40%; then use a multi-axial three-dimensional weaving process to weave a multi-axial three-dimensional fabric with an inorganic fiber volume content of 60%-90%, and then use a molding process or a vacuum bag pressing process or an autoclave process for curing and forming to obtain the bullet-facing layer;

[0027] Or directly use a multi-axial three-dimensional weaving process to weave a multi-axial three-dimensional fabric with an inorganic fiber volume content of 60%-90% from the inorganic fibers, and then use a resin transfer molding (RTM) process for curing and forming to obtain the bullet-facing layer;

[0028] S2: Preparation of the transition layer:

[0029] Lay up the prepreg of unidirectional fibers made of inorganic fibers or two-dimensional fabrics made of inorganic fibers, and then use a molding process or a vacuum bag pressing process or an autoclave process for curing and forming to obtain a transition layer with an inorganic fiber volume content of 30%-60%;

[0030] S3: Preparation of the back plate layer:

[0031] Lay up the prepreg of unidirectional fibers made of organic fibers, and then use a molding process or a vacuum bag pressing process or an autoclave process for curing and forming to obtain a back plate layer with an organic fiber volume content of 70%-90%;

[0032] S4: Preparation of the composite armor:

[0033] Stack and lay up in the order of the bullet-facing layer, the transition layer and the back plate layer, lay a layer of adhesive film in the middle of each layer, and then use a molding process or a vacuum bag pressing process or an autoclave process for final curing and forming to obtain the composite armor. Among them, the fiber volume content and the number of laying layers of the bullet-facing layer, the transition layer and the back plate layer are selected according to the bulletproof level requirements.

[0034] Compared with the prior art, the present invention has the following advantages:

[0035] (1) The lightweight and highly efficient bulletproof and stab-proof composite armor provided by the present invention is composed of a bullet-facing surface layer, a transition layer and a back plate layer; a multi-axial three-dimensional woven fabric reinforced composite material with a high fiber volume content is used as the bullet-facing surface, which is used to passivate the bullet head and weaken the penetration ability of the bullet; a laminated composite material with a medium fiber volume content is used as the transition layer, and the rigidity of this layer is between the bullet-facing surface layer and the back plate layer, which can further weaken the impact force of the bullet and buffer the damage to the back plate layer, so that the energy absorption performance of the back plate layer can be fully exerted; a unidirectional prepreg laminated composite material is used as the back plate layer, which has the characteristics of low hardness and good toughness, and can absorb and dissipate the residual impact force of the bullet through fiber transfer and interlayer damage.

[0036] (2) The multi-axial three-dimensional woven fabric with high fiber volume content used in the bullet-facing surface layer of the present invention is an advanced composite material reinforcement structure. The multi-axial three-dimensional woven fabric with high fiber volume content woven with high-strength and high-modulus inorganic fibers not only has a low density, but the reinforced composite material also has a high hardness similar to that of ceramics. The resin-based composite material reinforced with this fabric is used as the bullet-facing surface. After the bullet hits, there will be no large-scale fragmentation and no fragment splashing, so there is no need to introduce a crack-stop layer, thereby reducing the preparation process of the composite armor.

[0037] (3) The present invention can obtain an impedance-matched composite armor structure by controlling the fiber composition and fiber volume content of the composite material. The anti-ballistic performance of the composite armor can be fully utilized by designing the impedance gradient in the thickness direction. DETAILED DESCRIPTION

[0038] Unless otherwise defined, the technical terms used in the following examples have the same meanings as those generally understood by those skilled in the art to which the present invention belongs. The test reagents used in the following examples, unless otherwise specified, are all conventional biochemical reagents; the experimental methods, unless otherwise specified, are all conventional methods.

[0039] The present invention is described in detail below in conjunction with embodiments.

[0040] Example 1

[0041] A lightweight and efficient bulletproof and stab-proof composite armor, the composite materials and preparation processes of each layer of the composite armor are shown in Table 1, and then the bullet-facing surface layer, EVA film, transition layer, EVA film, and back plate layer are laid in sequence, and the lightweight and efficient bulletproof and stab-proof composite armor is prepared by autoclave compounding. The bulletproof plate prepared by this embodiment can achieve the GA141 police bulletproof vest standard level 4 protection, and the backing lining concave depth is 23mm.

[0042] Example 2

[0043] A lightweight and highly efficient bulletproof and stab-proof composite armor. The composite materials and preparation processes of each layer of the composite armor are shown in Table 1. Then, they are laid in sequence as the bullet-facing layer, EVA film, transition layer, EVA film, and backplate layer, and are prepared into the lightweight and highly efficient bulletproof and stab-proof composite armor through autoclave composite. The bulletproof plate prepared by this example can reach the 4th-level protection standard of GA141 police bulletproof vests, and the depression depth of the back lining is 22 mm.

[0044] Example 3

[0045] A lightweight and highly efficient bulletproof and stab-proof composite armor. The composite materials and preparation processes of each layer of the composite armor are shown in Table 1. Then, they are laid in sequence as the bullet-facing layer, EVA film, transition layer, EVA film, and backplate layer, and are prepared into the lightweight and highly efficient bulletproof and stab-proof composite armor through autoclave composite. The bulletproof plate prepared by this example can reach the 4th-level protection standard of GA141 police bulletproof vests, and the depression depth of the back lining is 25 mm.

[0046] Comparative Example 1

[0047] A bulletproof composite armor. The composite materials and preparation processes of each layer of the composite armor are shown in Table 1. Then, they are laid in sequence as the bullet-facing layer, EVA film, transition layer, EVA film, and backplate layer, and are prepared into the bulletproof composite armor through autoclave composite. The bulletproof plate prepared by this comparative example can reach the 4th-level protection standard of GA141 police bulletproof vests, and the depression depth of the back lining is 21 mm. The thickness of the ceramic panel of the bullet-facing layer in this comparative example is the same as that of the multi-axial three-dimensional woven fabric reinforced resin matrix composite material in Examples 1-3, and the weight is 20%-30% higher than that of the multi-axial three-dimensional woven fabric reinforced resin matrix composite material. This shows that the multi-axial three-dimensional woven composite material used as the bullet-facing panel of the composite armor has the same level of protection ability under the condition of the same weight as the ceramic panel, and can further reduce the weight of the composite armor, meeting the development trend of lightweight bulletproof armor.

[0048] Comparative Example 2

[0049] A bulletproof composite armor. The composite materials and preparation processes of each layer of the composite armor are shown in Table 1. Then, they are laid in sequence as the bullet-facing layer, EVA film, transition layer, EVA film, and backplate layer, and are prepared into the bulletproof composite armor through autoclave composite. The bulletproof plate prepared by this comparative example failed to achieve effective protection in the live-fire test according to the 4th-level protection standard of GA141 police bulletproof vests. The weight of the two-dimensional woven fabric reinforced resin matrix composite material of the bullet-facing layer in this comparative example is the same as that of the multi-axial three-dimensional woven fabric reinforced resin matrix composite material in Examples 1-3. This shows that the multi-axial three-dimensional woven composite material used as the bullet-facing panel of the composite armor has better protection ability under the condition of the same weight and lower thickness as the two-dimensional woven fabric reinforced resin matrix composite material.

[0050] Table 1 Parameters and preparation process of composite materials of each layer of composite armor

[0051]

[0052]

[0053] In summary, the use of the multi-axial three-dimensional woven fabric reinforced composite material of the present invention as the anti-bullet panel of the composite armor not only has the same level of protection capability as the ceramic panel, but also has a lower density, which can realize the lightweight design of the composite armor; at the same time, after the bullet hits, there will be no large-scale fragmentation similar to the ceramic panel, and no fragment splashing will occur, so there is no need to introduce a crack arrest layer, reducing the preparation process of the composite armor. In addition, compared with the composite armor with a two-dimensional woven fabric reinforced composite material as the anti-bullet surface layer, the bulletproof effect is better, and the overall thickness of the armor is reduced, which improves the mobility and flexibility of the human body and protective equipment.

[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A lightweight and high-efficiency bulletproof and stab-proof composite armor, characterized in that: It includes a bullet-facing layer, a transition layer, and a back panel layer. The bullet-facing layer and the transition layer, as well as the transition layer and the back panel layer, are bonded through a film adhesive. The bullet-facing layer and the transition layer are inorganic fiber-reinforced resin-based composite materials, and the back panel layer is an organic fiber-reinforced resin-based composite material. The volume content of inorganic fibers in the bullet-facing layer is 60%-90%, and the volume content of resin is 10%-40%. The bullet-facing layer is a multi-axial three-dimensional woven structure; the volume content of inorganic fibers in the transition layer is 40%-70%, and the volume content of resin is 30%-60%; the transition layer is prepared by laying unidirectional fiber prepregs or two-dimensional fabric prepregs in a 0° / 90° cycle, a 0° / ±45° / 90° cycle, or a 0° / 30° / 60° / 90° cycle; the volume content of organic fibers in the back panel layer is 70%-90%, and the resin content is 10%-30%; the back panel layer is prepared by laying unidirectional fiber prepregs in a 0 / °90° cycle, a 0° / ±45° / 90° cycle, or a 0° / 30° / 60° / 90° cycle and then through a molding process.

2. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The bullet-facing layer is made of a fabric obtained by weaving surface-sized inorganic fibers through a multi-axial three-dimensional weaving process and then through a molding process, a vacuum bag pressing process, or an autoclave process.

3. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The bullet-facing layer is cured and formed by using a resin transfer molding (RTM) process for a fabric obtained by weaving inorganic fibers through a multi-axial three-dimensional weaving process.

4. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The inorganic fibers in the bullet-facing layer and the transition layer are independently selected from any one or a mixture of two or more of silicon carbide fibers, alumina fibers, boron carbide fibers, glass fibers, quartz fibers, and carbon fibers.

5. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The inorganic fibers in the bullet-facing layer are any one or a mixture of two or more of silicon carbide fibers, alumina fibers, or boron carbide fibers.

6. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The inorganic fibers in the transition layer are any one or a mixture of two or more of glass fibers and carbon fibers.

7. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 1, characterized in that: The resins in the bullet-facing layer and the transition layer are thermosetting resins or thermoplastic resins.

8. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 7, characterized in that: The thermosetting resin is any one or a combination of two or more of epoxy, phenolic, and unsaturated polyester.

9. The lightweight and high-efficiency bulletproof and stab-proof composite armor according to claim 7, characterized in that: The thermoplastic resin is any one or a combination of two or more of polyethylene, polyurethane, polyester, and nylon.

10. The lightweight and high-efficiency bulletproof and stab-resistant composite armor according to claim 1, characterized in that: the organic fiber in the back panel layer is any one or a hybrid of two or more of ultra-high molecular weight polyethylene fiber, aramid fiber, and PBO fiber.

11. The lightweight and high-efficiency bulletproof and stab-resistant composite armor according to claim 1, characterized in that: the resin in the back panel layer is any one or a combination of two or more of polyethylene, polyurethane, polyester, and nylon.

12. The lightweight and high-efficiency bulletproof and stab-resistant composite armor according to claim 1, characterized in that: the base material of the adhesive film is polyethylene, EVA, polypropylene, polyamide, polyurethane, or epoxy resin.

13. The preparation method of the lightweight and high-efficiency bulletproof and stab-resistant composite armor according to any one of claims 1-12, characterized in that: it includes the following steps: S1: Preparation of the bullet-facing layer: Pre-impregnate the inorganic fiber, and control the slurry coverage rate on the surface of the inorganic fiber at 10%-40%; then use a multi-axial three-dimensional weaving process to weave a multi-axial three-dimensional fabric with an inorganic fiber volume content of 60%-90%, and then use a molding process, a vacuum bag pressing process, or a autoclave process for curing and forming to obtain the bullet-facing layer; Or directly use a multi-axial three-dimensional weaving process to weave a multi-axial three-dimensional fabric with an inorganic fiber volume content of 60%-90% from the inorganic fiber, and then use a resin transfer molding (RTM) process for curing and forming to obtain the bullet-facing layer; S2: Preparation of the transition layer: Lay up the prepreg of unidirectional fibers made of inorganic fibers or two-dimensional fabrics made of inorganic fibers, and then use a molding process, a vacuum bag pressing process, or a autoclave process for curing and forming to obtain a transition layer with an inorganic fiber volume content of 30%-60%; S3: Preparation of the back panel layer: Lay up the prepreg of unidirectional fibers made of organic fibers, and then use a molding process, a vacuum bag pressing process, or a autoclave process for curing and forming to obtain a back panel layer with an organic fiber volume content of 70%-90%; S4: Preparation of the composite armor: Stack and lay up in the order of the bullet-facing layer, the transition layer, and the back panel layer, lay a layer of adhesive film in the middle of each layer, and then use a molding process, a vacuum bag pressing process, or a autoclave process for final curing and forming to obtain the composite armor.

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