Ballistic protection material for reducing impact trauma

Abstract

A bulletproof protective material is characterized in that it comprises a laminate made of an aramid fabric having one or more layers of a thermoplastic or thermosetting matrix. The resulting composite material can be produced by using a film, by applying powder or resin; the material is very flexible and is in the form of a roll with a desired width and length.

Description

Background of the Invention

[0002] This invention relates to a bulletproof protective material.

[0003] More specifically, the present invention relates to a material used as a base for producing articles equipped with bulletproof protection, particularly as a base for producing bulletproof vests optimized in terms of area density to meet specific standards required for the design of the articles.

[0004] In this context, the material subject matter of the present invention is strategic in reducing trauma caused by projectile impact.

[0005] As described in the present invention, the field of personal protective equipment is characterized by the use of a wide range of materials, with the aim of specifically meeting the requirements for ballistic protection and puncture resistance, but also meeting well-known and considered important requirements according to market research, such as flexibility, optimization of manufacturing waste, etc.

[0006] The functional part of a bulletproof vest is called "soft armoring." Bulletproof solutions for "soft armoring" consist of many layers of different types of materials, each of which performs one or more functions, either fully or partially.

[0007] The list of materials used to compose a ballistic solution is very long, and the combination of these materials is optimized, particularly by means of a trial-and-error approach, in which the first test is defined based on an initial database.

[0008] The products used include the following: aramid fabric, polyethylene fabric, aramid unidirectionals, polyethylene unidirectionals, aramid felt, metal mesh, metal plates, barriers with metal or ceramic sheets, laminates made of resin / film on aramid or polyethylene fabric, and MTP (Multi-Threat Penetration) sheets.

[0009] Among purely ballistic materials, there are identifiable categories capable of performing purely ballistic functions such as stopping projectiles and reducing trauma to the protected subject, due to the material’s ability to absorb and / or disperse the energy released during impact.

[0010] In other words, the pure "trauma reducer" category is flawed, which is a product that is traditionally made of composite material systems, polymer backings and other materials, and is typically characterized by high thickness and / or high rigidity.

[0011] This category does not necessarily include only materials with at least one basic component that is specifically intended to perform "bulletproof function".

[0012] An ideal wound reducer can be defined as a product that, if added to the interior of a ballistic solution operating at the wound limits specified in the reference standard in a minimal manner (e.g., as lightly and flexibly as possible in one or two layers), increases the safety margin by reducing wounds by an average of 3-4 mm without increasing the likelihood of complete perforation of the product.

[0013] Various products for reducing trauma are known.

[0014] The following list comprises products that possess this characteristic (even if only partially), categorized according to how these products perform their functions.

[0015] One category of products includes aramid-based or polyethylene-based ballistic unidirectional materials; these materials are the main components of ballistic packaging. In fact, these materials consist of fibers held together by a certain amount of plastic matrix, and they are already widely present in ballistic solutions (if intended to be part of those solutions), allowing them to perform the general function of wound reduction compared to pure ballistic fabrics.

[0016] Another category includes laminated systems, which typically consist of single or multiple layers of fabric based on aramid / polyethylene fibers, characterized by the presence of a large amount of thermoplastic or thermosetting matrix, making the laminated system generally rigid. The areal density ranges from 200 g / m². 2 Up to 1000g / m 2 In embodiments, one or two layers are typically arranged between the middle and bottom of the packaging. This rigidity helps reduce injury but is generally not favored by bulletproof vest manufacturers. Due to the manufacturing process of the products and to make this characteristic rigidity easier to manage, these products are typically supplied in sheet form rather than rolls.

[0017] Another category includes plastic laminates composed entirely of rigid polymer sheets. These laminates are less effective and have a smaller range of applications compared to the lamination systems described in the previous point, but are much cheaper. These laminates are inserted into ballistic solutions in the same manner.

[0018] Another category includes backing materials, which are typically composed of polymer foam or rubber-based derivatives and serve as the final layer of the packaging. The function of the backing material is to absorb shock waves from impacts and allow the structure to be optimized for other component layers, diverting contact away from the rigid surface of the body behind the vest. The thicker the backing material (typically 1mm to 6mm), the more effective it is theoretically, but this largely depends on its chemical composition.

[0019] US2011 / 005379 A1 relates to a flexible stab-proof and bulletproof panel having an impact surface and a rear surface, wherein a coated textile layer is disposed in the rear surface, the coating comprising a plurality of particles having a diameter of about 20 μm or smaller. Invention Overview

[0021] The purpose of this invention is to provide a bulletproof protective material that overcomes the shortcomings and limitations of the aforementioned prior art materials.

[0022] Within this scope, a specific objective of the present invention is to provide a material that, in terms of its function, is similar to a laminated system but has significantly more advantageous properties.

[0023] Another objective of this invention is to provide a flexible material that can be sold directly in roll form, having a desired width and length that fully meets the user's requirements.

[0024] Another objective of this invention is to provide a material that is highly compatible with the best-performing ballistic protection products available on the market.

[0025] Another objective of this invention is to provide a material that is highly reliable and safe in operation due to its special production characteristics.

[0026] These and other objectives, which will become clearer below, are achieved through the ballistic protective materials claimed in the appended claims. Brief description of the attached diagram

[0028] Further features and advantages of the subject matter of the invention will become clearer upon examination of the description of preferred, but not exclusive, embodiments of the invention, as illustrated in the figures:

[0029] exist Figure 1 An exploded view of the material of the present invention is shown in the figure; and

[0030] exist Figure 2 The image shows laminate 7 with its magnified details.

[0031] Detailed disclosure of preferred embodiments

[0032] The material according to the invention is produced by direct lamination of an aromatic polyamide fabric with one or more layers of a thermoplastic or thermosetting matrix.

[0033] The final composite material can be obtained by using a membrane, by applying powder or resin.

[0034] This produces a very flexible product in the form of a roll with the desired width and length.

[0035] It is important to emphasize that, regardless of the type of trauma-resistant product considered, there is an ideal arrangement in any solution to achieve the best results without altering the overall area density.

[0036] The variables regarding the arrangement of anti-trauma products within ballistic packaging are closely related to the number of layers and all constituent materials, and because it typically constitutes a small but very important part, its arrangement requires specific study for each ballistic embodiment.

[0037] For the purposes of this invention, the production of a wound reduction system with appropriate performance can be obtained from the following components: woven or nonwoven fabrics composed of high-toughness and / or high-modulus textile fibers commonly used in ballistic applications or for the production of composite materials, such as aramid fibers, high-density polyethylene (UHMWPE), polypropylene, polyamide, polyimide, polyester, polyarylate, PBO, S glass, E glass, and carbon fiber.

[0038] In textile fibers, especially referring to aramid fibers and high-density polyethylene fibers, a denier between 110 dtex and 3300 dtex is selected.

[0039] For each specific fabric, there is an ideal amount of matrix to achieve optimal wound reduction performance, which in turn depends on the chemical composition of the matrix and how the matrix interacts with each specific fiber.

[0040] As an example, the following illustrates a series of laminates representing the present invention, which have aramid fabrics using different fiber fineness and matrix percentages as components. In ballistic embodiments, one or two layers are inserted, comprising a total area density of approximately 500 g / m² relative to the ballistic package. 2 -600g / m 2 It is a component of trauma resistance.

[0041] In the table below and all subsequent tables, the abbreviation TDP refers to the mark left on the clay on the back of the panel as a result of a V0 test performed according to NIJ0101.06 using a 44 Mag projectile (i.e., a projectile impacting the sample with maximum energy at a given velocity).

[0042] Figure 1 A bulletproof embodiment 1 consisting of a number of overlapping layers is shown, and this embodiment 1 is divided into several parts to represent the different materials used, as highlighted in the exploded view.

[0043] The front portion 3 is formed of a material layer with pure ballistic protection (i.e., stopping the projectile), wherein element 2 constitutes the first layer and also forms the impact surface. Portion 4 is formed of layers of the laminate 7 of the present invention, each layer consisting of a base fabric 9 and a matrix 8. Portion 5 consists of a 3 mm thick polymer foam layer (also called a backing). Element 6 represents a clay-containing frame on which TDP measurements are performed after the projectile impact.

[0044] Given that the conformability limit indicated by the standard is 44 mm, the lower the TDP value obtained, the more effective the laminate 4 will be in performing its function.

[0045] Table 1

[0046]

[0047]

[0048] *Calculations were performed based on the average value of TDP measurements, which were performed using 44 Mag according to standard NIJ0101.06.

[0049] The table above summarizes how products based on fabric 9 can give significantly different TDP results (column 5), fabric 9 having different fiber fineness (column 2) and a similar percentage of matrix 8 (column 3).

[0050] Among the available matrices, thermoplastic or thermosetting resins with a polymer-based chemical composition are selected, such as: polyethylene, polyurethane, polypropylene, polyamide, polyester, polyarylate, polyvinyl butyral, polycarbonate, phenolic resin, epoxy resin, phenoxy resin, polyurethane resin, and acrylic resin.

[0051] The amount of matrix 8 required relative to the total weight of the laminate can vary from 5% to 50% in percentage terms, and the ideal amount is closely related to the properties of the woven or nonwoven fabric of the matrix combination, as already mentioned in Table 1.

[0052] Table 2 relates to one embodiment, involving a weight of 185 g / m³. 2The aramid fabric, wherein fiber 10 has 1100 dtex; the variable analyzed is the weight percentage of matrix 8 based on the total weight of laminate 7. Keeping the base fabric 9 constituting laminate 7 completely unchanged, and using different percentages of matrix 8, comparisons between laminates TRS1, TRS2 and TRS3 show that there is a quantity of performance that can be optimized in terms of TDP.

[0053] Table 2

[0054]

[0055] *Calculations were performed based on the average value of TDP measurements, which were performed using 44 Mag according to standard NIJ0101.06.

[0056] In the case of fabric 9, in addition to the area weight and fineness of the constituent fibers, the number of threads per centimeter and the type of weave selected are also important parameters.

[0057] Table 3 relates to one embodiment, involving a weight of 185 g / m³. 2 An aramid fabric with 1100 dtex fibers, having the same percentage of matrix 8 and the same weight of laminate 7, with the only variable being the weave structure of fabric 9.

[0058] Table 3

[0059] TRS1 plain weave 36.5 TRS 4 Batavia 2 / 2 42.0 TRS 5 Batavia 4 / 4 43.5 TRS 6 Batavia 3 / 1 40.0

[0060] *Calculations were performed based on the average value of TDP measurements, which were performed using 44 Mag according to standard NIJ0101.06.

[0061] In this case, the TDP value shows that, in the case of TRS1, a very “closed” braid is preferable to a “open” braid, as defined in the braids of laminates TRS 4, TRS 5 and TRS 6.

[0062] In terms of composition Figure 1 Regarding the number of layers in the ballistic protection embodiment 1, the arrangement of the wound-resistant system produced in this way is between 40% and 100% of the packaging, taking layer 2 as the initial position, layer 2 also constitutes the impact surface of the ballistic protection embodiment 1. Figure 1 ).

[0063] The application of matrix 8 can also be asymmetrical relative to the fabric 9 used; in fact, studies have emphasized that applying the same percentage of matrix to one side of the supporting fabric, rather than distributing it evenly on both sides, may be a decisive factor in the performance of the fabric.

[0064] Table 4 shows a comparison of products with symmetrical / asymmetrical matrix arrangements on the fabric. When the laminate of the present invention is asymmetrical, it will have matrix 8 (in Figure 2 In the bulletproof embodiment, one side of the fabric (shown together with the base fabric 9) is inserted, facing as shown. Figure 1 The launch direction is shown (arrow F).

[0065] Table 4

[0066]

[0067] *Calculations were performed based on the average value of TDP measurements, which were performed using 44 Mag according to standard NIJ0101.06.

[0068] The TDP of the two laminates compared highlights that the asymmetrical configuration of TRS1A is significantly more effective than the symmetrical configuration of TRS1S, which uses the exact same base fabric 9 and the same percentage of matrix 8.

[0069] All examples shown in this table use approximately 5.2 kg / m³. 2 Implementation examples ( Figure 1 For reference, this embodiment includes:

[0070] 1 multi-layer Multi-axis layer One layer of antitrauma material + one layer of foam backing 5 (3mm).

[0071] Table 5 shows a comparison between a standard embodiment with two additional layers of XP308 as alternative anti-trauma material, a standard embodiment modified with a commercially available standard anti-trauma material (STD anti-trauma material), and a standard embodiment similarly modified with the anti-trauma TRS 1 subject matter of the present invention; each of these embodiments replaces the multi-axis with a portion of equal weight relative to the multi-axis present in the basic embodiment.

[0072] Table 5

[0073] XP308 5.2 42.0 STD anti-traumatic substances 5.2 40.0 TRS1 (Laminated Component 7) 5.2 36.5

[0074] *Calculations were performed based on the average value of TDP measurements, which were performed using 44 Mag according to standard NIJ0101.06.

[0075] Compared to both Example XP308 and the example modified with the commonly used and market-standard STD anti-wound material, the TDP value detected for the laminate TRS1 of the present invention is a significant improvement.

[0076] Based on all considerations to date, a set of values ​​has been specified within the indicated range of the key parameters analyzed so far. This set of values ​​optimizes the performance of the innovative trauma reducer product proposed here:

[0077] - Aromatic polyamide fibers with fineness of 670 dtex, 940 dtex, 1100 dtex, 1320 dtex, 3140 dtex, and 3300 dtex;

[0078] - For fineness above 3000 dtex, the matrix content is between 15% and 40% by weight, and for intermediate fineness between 670 dtex and 1320 dtex, the resin percentage is between 25% and 40%.

[0079] - Plain weave is ideal for the production of wound reducers, as shown in Table 3;

[0080] - During the testing phase, applying the matrix 8 asymmetrically to the fabric 9 and inserting it with the side having the matrix facing the emission direction is a key factor for performance, as shown in Table 4.

[0081] Therefore, determining the flexibility of the composite material system is crucial for improving compatibility with other purely ballistic products.

[0082] In practice, it has been found that the present invention achieves the intended purpose and objectives.

[0083] In fact, a very flexible material has been provided that can be sold directly in rolls with the desired width and length according to user requirements.

[0084] Due to these special characteristics, the material is highly compatible with the best-performing pure ballistic products available on the market, and is also typically characterized by high flexibility.

[0085] Of course, the materials used and the possible dimensions can be arbitrary, depending on the needs. Furthermore, materials made from different materials (e.g., similar to those used in production) can be used. Figure 1 The foam backing 5 is made of the materials of part 3; however, the foam backing 5 may be omitted. Finally, it may even be possible to provide only a laminate 7.

Claims

1. A ballistic protective material for a ballistic solution (1), comprising: The material layer portion (3) has the function of stopping the projectile, wherein the laminate layer portion (4) is configured to be formed by a laminate (7) made of a flexible material consisting of a base fabric (9) and a matrix (8), wherein the laminate layer portion (4) has the function of absorbing energy in terms of reducing bullet impact trauma, wherein the matrix (8) is made of a resin selected from thermoplastic or thermosetting resins having a polymer-based chemical composition; depending on the characteristics of the base fabric (9) to which the matrix (8) is combined, the percentage of the matrix (8) relative to the total weight of the laminate ranges from 5% to 50%.

2. The bulletproof protective material according to claim 1, characterized in that, The laminate (7) is a laminate made of a flexible aramid fabric having one or more layers of thermoplastic or thermosetting matrix (8).

3. The bulletproof protective material according to claim 2, characterized in that, The base fabric (9) is selected from woven fabrics or nonwoven fabrics, which are composed of high-toughness and / or high-modulus textile fibers, which are selected from aramid fibers, high-density polyethylene, polypropylene, polyamide, polyimide, polyester, polyarylate, PBO, S glass, E glass, and carbon fiber.

4. The bulletproof protective material according to claim 1, characterized in that, The base fabric (9) comprises fibers selected from aramid fibers and high-density polyethylene fibers, the fineness of which ranges from 110 dtex to 3300 dtex.

5. The bulletproof protective material according to claim 4, characterized in that, The base fabric (9) comprises aramid fibers having a fineness selected from 670 dtex, 940 dtex, 1100 dtex, 1320 dtex, 3140 dtex, and 3300 dtex.

6. The bulletproof protective material according to claim 5, characterized in that, For fineness above 3000 dtex, the laminate (7) comprises the matrix (8) in a content between 15% and 40%, and for intermediate fineness between 670 dtex and 1320 dtex, the laminate (7) comprises the resin in a percentage between 25% and 40%.

7. The bulletproof protective material according to any one of claims 1 to 6, characterized in that, The laminate (7) is asymmetrical, with one side having the matrix (8) inserted into the ballistic solution (1) in the direction of bullet firing.

8. The bulletproof protective material according to any one of claims 1 to 6, characterized in that, The base fabric (9) has a plain weave structure.

9. The bulletproof protective material according to any one of claims 1 to 6, characterized in that, It also includes a section made of polymer foam (5).

10. The bulletproof protective material according to any one of claims 1 to 6, characterized in that, The polymer is selected from polyethylene, polyurethane, polypropylene, polyamide, polyester, polyarylate, polyvinyl butyral, polycarbonate, phenolic resin, epoxy resin, phenoxy resin, polyurethane resin and acrylic resin.

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