Flexible nonwoven for providing protection from slashing, stabbing and firing weapons as well as shrapnel
Patent Information
- Application Number
- EP2023772758
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-08-25
- Filing Date
- 2023-08-09
- Publication Date
- 2025-04-16
- Estimated Expiration
- 2043-08-09
AI Technical Summary
Current protective solutions against cutting, stabbing, and shooting weapons, as well as splinters, are either heavy and rigid, offering limited mobility and breathability, and are ineffective against long weapons, with weak points between plate solutions and inadequate protection against splinters.
A flexible protective composite combining soft-ballistic multi-layer fabrics with a three-dimensional wire structure hard-ballistic material, forming a sandwich structure that is lightweight, flexible, and adaptable, providing universal protection without noise and weak points.
The composite offers enhanced protection against a wide range of threats with reduced weight, noise, and improved mobility, allowing for universal shape adaptability and effective use in various applications, including personal and vehicle protection.
Smart Images
Figure 1.1
Abstract
Description
[0001] Flexible protective compound against cutting, stabbing and firearms as well as splinters
[0002] The invention relates to a flexible protective composite against the effects of cutting, stabbing, and firearms, as well as fragments, consisting of a sandwich composite of soft ballistic and hard ballistic protective materials. The protective material offers improved ballistic protection, which is particularly effective against long weapons. The invention finds application, for example, in the fields of personal protection, bullet protection, security vehicle technology, military technology, and aerospace technology.
[0003] Solutions for the protection of people and objects are divided into soft and hard ballistic solutions. Soft ballistic solutions, for example, consist of multi-layer textiles. These only protect against small arms, but not against long guns. For protection against long guns, there are currently mainly plate solutions, particularly made of metal or ceramic. Plates are rigid, inflexible and, in the higher protection classes required against long guns, very heavy. If several plates are combined for better mobility, there are fewer protected areas between the plates. Breathability is almost non-existent. If the wearer moves, falls, or is hit by objects, plate solutions emit noise, which can be disadvantageous, for example, in combat operations. Shaping plate variants is difficult.
[0004] A bulletproof vest consisting of glass fibre mats, synthetic resin and clay plates for rounded chest, body and torso protection is listed in DE 21 35 571 A.
[0005] DE 68 08 297 U describes a bulletproof vest whose front and back sections consist of armored sheets or plates, each enclosed in fabric sheaths. These are arranged in a scale-like, overlapping pattern and surrounded by a closed outer shell made of fabric or similar material, the size of the front or back sections.
[0006] EP 33 77 841 B1 shows that several textile layers are bonded together with a binder matrix in the central part. This central part is pressed. A removable armor plate or a ceramic plate is also located here.
[0007] Describe a solution to defend against 9 mm cartridges
[0008] EP 30 86 077 A4 and EP 30 86 077 A1 . For this purpose, a sandwich solution consisting of alternating polyethylene film and several layers of aramid material is used.
[0009] EP 425 394 A1 describes a two-piece ballistic protective vest consisting of an underarmor and a chest protector. The underarmor consists of several layers of textile and is in a scale-like or folded form. The chest protector consists of a rigid shell made of, for example, metal.
[0010] In EP 30 98 560 A1, many small segments made of a sintered material are bonded independently of one another and not to one another, to a "ballistic" textile by means of a thermoplastic film. In addition, this safety lining contains pockets for accommodating plates for increasing protection.
[0011] EP 34 57 075 A1, for example, describes a vest for protection against bullets and / or bladed weapons. At least one panel and at least one second plate are manufactured. One plate consists of a fabric, in particular of aramid fibers, and a film of thermoplastic material fixed on one side. Each individual plate is provided with reinforcing threads. In the overall structure, the fibers are unidirectional, in that they are arranged at -45° / +45°, or unidirectionally cutting at 0° / 90° / 0° / 90°, depending on the plate. DE 724 202 A describes body protection with a movable protective device that does not hinder body movement. In this case, a protective mass made of a metal ring mesh made of light metal wire is sewn into the garment on a layer of fabric or wadding or into the fabric itself, the shape of which is adapted to the garment part, with the wire ends of the individual ring links being connected by welding.
[0012] Disadvantages of the invention include, among others, that the metal rings are too large for optimal protection against slashing and stabbing weapons, as well as projectiles. The wire ends must be welded. This results in irregularities in the structure. Protection against strong forces, such as long weapons, or against thin weapons, such as a stiletto or syringe, is not provided. The three-dimensional shape is also limited by the metal rings.
[0013] EP 670 466 A1 describes a stab-protection insert for a protective vest comprising a ballistic protection package, which can be placed away from the body. It consists of a steel chain mesh, which is formed into a flexible, inherently stable mat by embedding it in a plastic matrix. The plastic matrix can be a PU matrix. The stab-protection insert, which is held in shape by the plastic matrix, can be inserted into the shell of a protective vest.
[0014] The steel chain net can be formed into a flexible, inherently stable mat by embedding it between two layers of thermoplastic material which are fused together by pressure under the influence of heat.
[0015] The steel chain net can be formed as a flexible, stable mat by embedding it between two layers of fabric coated with thermally activated glue, which are bonded together by pressure under the influence of heat.
[0016] The described solution has weaknesses in the protection of the entire body, especially in the areas between the inserts. It only provides protection against stabbing weapons, but not against projectiles or fragments.
[0017] Solutions for protecting people and objects are divided into soft and hard ballistics. Soft ballistic solutions, such as those made of multi-layered textiles, only protect against small arms, but not against long guns. For protection against long guns, there are currently only plate solutions, e.g., made of metal or ceramic.
[0018] Plates are rigid, inflexible, and very heavy in the higher protection classes, such as those required against long weapons. There is less protection between the plates. Breathability is virtually nonexistent. In the event of a fall, when taking up a position, or when struck by objects, plate solutions emit noise, which can be disadvantageous, for example, in combat. Shaping plate variants is difficult.
[0019] EP 000002384248 B1 relates to a three-dimensional wire structure of lightweight construction consisting of several wires that cross and are interconnected to form a multitude of cells in three-dimensional space. The invention finds applications, for example, in medical technology, vehicle and mechanical engineering, and construction.
[0020] WO 2015 / 026258 A1 relates to the field of wire mesh structures and to fabrics with a special arrangement of threads. A three-dimensional mesh comprising a set of adjacent layers. Each layer is formed by two mutually orthogonal families of threads or rods. The axes of the threads or rods have the shape of helices twisted in the opposite direction to the axes of the threads or rods of the other family. They are arranged in such a way that each thread or rod of one family encloses a thread or rod of the other family with each rotation and at the same time also encloses adjacent threads or rods of its own family. The threads or rods of each layer are interwoven with the threads or rods of the adjacent layers.It is possible to form a combined net that additionally contains threads or rods arranged in the cavities of the net, the threads or rods being provided individually or interconnected by a conventional weave, such as a plain weave. The invention can be used in the manufacture of composite materials, in a range of building structures and original machine parts, as well as in the manufacture of a range of consumer goods: providing cool summer mattresses, eternally dry mats for baths and swimming pools, naturally convection-ventilated car seats, and others.
[0021] The object of the invention is to propose a flexible protective composite against cutting, stabbing, and firearms, as well as splinters, consisting of a composite of soft and hard ballistic protective materials. This composite should be lightweight, highly flexible, and quiet, and should be easy to manufacture and effectively deployable with a readily available and universal design.
[0022] According to the invention, the object is achieved by the features of claim 1. Further features are described in subclaims 2 to 7.
[0023] The flexible protective composite according to the invention against cutting, stabbing and firearms as well as fragments consists of a composite of soft ballistic and hard ballistic protective materials.
[0024] The soft ballistic protective material is a multi-layered sheet material made of high-strength textile materials. The hard ballistic protective material consists of a three-dimensional wire structure in a lightweight design, which consists of several wires that cross and are connected to one another to form a large number of cells in three-dimensional space. The three-dimensional wire structure (2) is formed in each plane from interlocking transverse spirals (3) and longitudinal spirals (4). At least two planes are provided, which are also interconnected. The connection is made at certain nodes, which in turn is achieved by the transverse spirals (3) and longitudinal spirals (4) interlocking, analogous to interlocking in one plane.
[0025] For possible protection against firearms, the maximum cell opening (12) should be smaller than the projectile diameter of the firearm against which protection is to be provided.
[0026] The soft ballistic and hard ballistic protective materials are bonded together in such a way that the individual layers are held stably in their position.
[0027] In a preferred embodiment, particularly for use in body armor, a hard ballistic layer is sandwiched between two soft ballistic layers. This creates a sandwich structure that is particularly flexible and universally applicable for a wide range of applications, particularly for all types of body armor.
[0028] In a special design, several hard ballistic layers are provided, with soft ballistic layers in a sandwich structure between the hard ballistic layers.
[0029] A further embodiment describes that the flexible protective composite is adapted in its shape to the external shapes of the persons or objects to be protected, or at least parts thereof.
[0030] It is advantageous if the soft ballistic sheet materials are connected to the hard ballistic protective material at least in the edge region, in particular by sewing, bonding, welding, resinifying, or fusion. The soft ballistic protective material can preferably consist of synthetic chemical fibers, for example polymer fibers, polymer condensate fibers, polyaddition fibers, polyaromatic fibers, polyheterocyclic and / or homoaliphatic fibers. Polyethylenes with an ultra-high molecular weight (Ultra-High-Molecular-Weight Polyethylene (PE-UHMW) or High-Modulus Polyethylene (HMPE), so-called high-performance polyethylene fibers, such as Dyneema, are particularly suitable. Other materials such as aramid, carbon, or glass are also suitable.
[0031] Surprisingly, it was found that by choosing a three-dimensional wire structure according to EP 00002384248 Bl as the hard ballistic protective material, a particularly high level of protection can be achieved.
[0032] The advantages of the invention are that the flexible protective composite can be dimensioned in various ways, thus offering protection to people, animals, and objects from harmful influences such as stabs, cuts, splinters, small arms, long weapons, and the like. Especially in the higher protection class range, the solution offers a clear weight advantage, is not rigid, and has no weak points in the overall structure. The shape can be customized without compromising the level of protection.
[0033] In the event of falls and impacts, noise is significantly reduced compared to panels. Overall, the resulting flexible protective composite is lightweight, highly flexible, and quiet, and can be used with an easily adaptable and universal design.
[0034] The invention is explained in more detail below using exemplary embodiments. They show:
[0035] Fig. 1 Flexible protective composite in sandwich construction
[0036] Fig. 2 soft ballistic protective material as a multi-layer, multi-axial sheet Fig. 3 Structural design of a hard ballistic protective material
[0037] Fig. 4 hard ballistic protective material in several layers
[0038] First, the basic structure of a flexible protective composite against cutting, stabbing and firearms as well as fragments, consisting of a composite of soft ballistic and hard ballistic protective materials, is described.
[0039] Fig. 1 shows a flexible protective composite which has a sandwich construction and in which the soft ballistic protective material arranged on both sides is a multi-layered sheet material 1 made of high-strength textile materials. High-strength polyethylene threads serve as the basis. The threads are stretched and laid parallel to one another without being connected to one another. This creates a layer 9 consisting of a group of threads. The threads are fixed by means of a fabric bond or mechanically by friction and / or form fit. Depending on the application, further layers 9 are laid on top of this group of threads according to the same principle. To achieve a certain property in several directions, the groups of threads are laid at different angles to the direction of production. Figure 2 shows a schematic representation of the manufacturing process with fixation by sewing using a needle 10 and a sewing thread 11.
[0040] In Fig. 1, for the sake of clarity, only 4 layers 9 are shown on both sides. In reality, however, these fabrics consist of a large number of layers 9. Depending on the intended use, the number can vary from at least 2 to over 100 layers 9. To improve the resistance, the individual layers 9 or groups of layers are arranged offset by an angle. In Fig. 1, the two inner layers 9 are each offset by 90°. The third layer 9 is shown offset by a further 45° and the fourth layer 9 by a further 90° to the 3rd layer (135°). The use of a fabric known commercially as Dyneema, e.g. Dyneema® product SB 115 or Dyneema® product HB 210, has proven particularly advantageous. In these variants, the thread sheets are at angles of 0° and 90°.
[0041] To produce sample test specimens, the pieces are cut to size 500 mm x 500 mm. This is done on the cutting machine. 5 layers of textile are covered with paper, a knife oscillation of 4020 and a speed of 50% are set, and a vacuum of 75-80% is applied. The cut pieces are placed on top of each other in several layers 9 and each layer is rotated 45° relative to the previous layer. The layers are therefore arranged alternately at 0°, 45°, 90°, and 135°. These layers can be loose or combined in layer packages using all possible joining technologies. For example, 50 layers can be joined together by sewing on a saddler's machine, a sewing needle of size Nm 200 of the needle system 70.4, using a sewing thread with a fineness Nm 20 / 3 and a stitch length of 5 mm.
[0042] A hard ballistic protective material is provided between the two soft ballistic surface structures. This is formed from a three-dimensional wire structure 2 in a lightweight construction. The hard ballistic layer consists of several metal meshes made of wires 8 that cross one another to form a large number of cells in three-dimensional space. To construct this, a wire 8, e.g. made of stainless steel 1. 4567, with a wire diameter of, for example, 0.63 mm, is formed into spirals and connected to one another by twisting. The end result is a mesh that is shifted three times inside one another.
[0043] Figs. 3 and 4 show the three-dimensional wire structure in lightweight construction. This consists of a multitude of helically wound wires 8, which are connected to one another in three-dimensional space and cross one another to form cells 7, which are arranged with alternating axes and different planes. An example shown in Fig. 3 is a wire structure composed of two planes, which can be extended as desired by additional planes in the third direction.
[0044] According to Fig. 2, in a first plane, several helical wires 8 running parallel with their axes to one another are configured as a transverse spiral 3 by overlapping at their respective intersection points to form a wire mesh that is positively connected in the x- and y-directions, in which two adjacent wires are connected via an intersection point 13 per turn. By incorporating further wires, the wire mesh can be extended as desired in the y-direction. The length of the wires used determines the extension in the x-direction.
[0045] With reference to Fig. 2, furthermore, transverse to the axes of the transverse spirals 3, a plurality of helical wires 8 are provided as longitudinal spirals 4, running parallel with their axes to one another, which, within the first plane, intersect at their intersection points both with one another and with the intersection points of the transverse spirals 3. For a complete cell 7, four wires are in contact with one another at each of the four intersection points, each of which forms a fully-fledged intersection point in the sense of this structure.
[0046] When two adjacent transverse spirals 3 are positively connected to two adjacent longitudinal spirals 4, they have the smallest distance from each other at one point, the so-called large node 5 . A cell 7 of this level is bounded by four nodes.
[0047] When additional levels are added, connection points are created by the transverse spirals of one level intertwining with the longitudinal spirals of the next level(s). These connection points form a small node 6. The wire mesh of the first level is thus connected congruently to the wire mesh of the second level in the z-direction. This structure is reinforced by the introduction of additional levels. This causes the inserted cells to shift into one another in such a way that the cell sizes become smaller, since there is more material available.
[0048] For a sandwich solution, another multi-layer sheet 1 made of high-strength polyethylene threads can be used as a third component. This, too, is cut into pieces measuring 500 mm x 500 mm using the settings listed to produce a flexible protective composite. 110 pieces of the HB 210 scrim are placed on top of each other, and the individual pieces are rotated by 45°. Thus, viewed individually, the 110 pieces are positioned alternately at 0°, 45°, 90°, and 135°. This ensures that the scrim has the same properties in all directions.
[0049] The flexible protective composite is now manufactured by joining the two multi-layered fabrics 1 and the three-dimensional wire structure 2 together. This connection can be made, for example, at specific points using a two-component polyethylene resin. The soft ballistic and hard ballistic protective materials are bonded to one another in such a way that the individual layers are held securely in place. This can be done by sewing, gluing, welding, resinifying, or fusing. In this way, for example, a structure measuring 500 mm x 500 mm x 5 mm can be manufactured, which can be used for a test specimen or with dimensions 350 mm x 250 mm x 30 mm as an insert for a protective vest.
[0050] The flexible protective composite according to the invention can be used universally against cutting, stabbing and firearms as well as splinters.
[0051] Possible areas of application are as follows:
[0052] protective vest
[0053] Bulletproof cars / trucks / construction equipment for crisis areas Airplanes and helicopters (protection with lighter weight) Ship protection
[0054] Suits for demolition teams (like vests, only the whole person is in protective segments) Bullet-proof walls / tents / containers / mobile garages Shock absorbers for pallet drops from aircraft, e.g. care packages in disaster areas Drone reinforcement Rocket reinforcement against impacts Demolition measures as splinter protection during demolition measures, protective walls during blasting measures, tank reinforcement against explosions or during ammunition transport.
[0055] Bulletproof vests for long-arms protection use so-called plate carriers, which accommodate the corresponding segments and hold them in place. To manufacture these segments, a flexible protective composite measuring 300 mm x 250 mm is manufactured and inserted. They are therefore compatible with existing plate carriers, so no new ones need to be purchased. The segments are located at the level of the left and right chest, two at abdominal height, two each on the back in the upper and lower back area, and one on each shoulder.
[0056] The positions of the segments and their size depend on the application. Shaped segments, such as those suitable for the shoulder, can be manufactured easily due to their flexible formability. Larger segments, right up to the complete vest, are also possible without the need for plate carriers, over-vests and the like. Because a manufactured protective composite is very flexible and lightweight, it can be made larger, especially for protective vests, than conventional, rigid plate solutions. This means that the possible body protection can be extended to cover more lateral parts of the body without the people to be protected having to experience restrictions in movement. Depending on the desired protection class, the segments can be made thinner and more flexible or thicker.In the case of armoured vehicles for land, water and air use, as well as drones, the armour can also be implemented using a protective composite according to the invention. For this purpose, the protective composites are dimensioned according to the desired level of protection; the thicker the composite, the greater the protection against harmful effects. The segments are shaped and manufactured according to their position in the area of application. The segments are then attached in front of or behind the outer panels. In vehicles, they can be located inside the doors, driver's compartments, hoods, trunk lids, vehicle roofs and loading areas. In the case of drones, aircraft and helicopters, the segment is shaped as a corresponding body and inserted. Segments are also embedded in the pilot compartment, its floor and doors. At sea, the segments are shaped accordingly and inserted into the hull and the outer sides. It is also possible to add additional reinforcement to only individual areas.
[0057] When used to protect walls, tents, containers or mobile garages against projectiles or fragments, segments measuring 2.50 m x 2.00 m, for example, can be produced. These segments can be provided with a carrying handle if required. This construction serves as a portable protective wall or shield and can also be of other sizes. Mobile garages or containers can be made from several of these segments. The segments are placed as walls and one is used as a roof. These can then be firmly joined together using adhesive or other joining technologies. The individual segments can also be used directly as a tent, tarpaulin or cover.
[0058] The flexible protective composites are lightweight and highly flexible. They are characterized by low noise during use. They are easy to manufacture thanks to their universal design and can be used simply and effectively. Reference symbols
[0059] 1 multi-layer fabric
[0060] 2 three-dimensional wire structure 3 transverse spiral
[0061] 4 longitudinal spiral
[0062] 5 large knots
[0063] 6 small knots
[0064] 7 cell 8 wire
[0065] 9 Location
[0066] 10 needles
[0067] 11 sewing thread
[0068] 12 Cell opening 13 Crossing point
Claims
Patent claims 1. Flexible protective composite against cutting, stabbing and firearms as well as fragments, consisting of a composite of soft ballistic and hard ballistic protective material, characterized in that - the soft ballistic protective material is a multi-layered fabric (1) consisting of solid textile materials, whereby - individual layers or several layers grouped together in groups of layers are arranged offset from one another by an angle, - the hard ballistic protective material forms a three-dimensional wire structure (2) consisting of several wires (8) which cross over and are interconnected to form a plurality of cells (7) in three-dimensional space, - the three-dimensional wire structure (2) is formed in each plane from interlocking transverse spirals (3) and longitudinal spirals (4), - there are at least 2 levels which are connected to each other in large nodes (5) and small nodes (6), - the soft ballistic and hard ballistic protective material is connected to each other in such a way that they are held stable in their position.
2. Flexible protective composite according to claim 1, characterized in that a hard ballistic layer is provided between two soft ballistic layers and a sandwich structure is formed.
3. Flexible protective composite according to one of claims 1 and 2, characterized in that several hard ballistic layers are provided, with soft ballistic layers being located between the hard ballistic layers and a sandwich structure being formed. Flexible protective composite according to one of claims 1 to 3, characterized in that the flexible protective composite is adapted in its shape to the external shape of a person to be protected or of an object to be protected or at least parts thereof. Flexible protective composite according to one of claims 1 to 4, characterized in that the soft ballistic sheetlike structures (1) are connected to one another with the hard ballistic protective material at least in the edge region. Flexible protective composite according to one of claims 1 to 5, characterized in that the soft ballistic protective material consists of synthetic chemical fibers. Flexible protective composite according to claim 6, characterized in that the synthetic chemical fibers are polymer fibers, polymer condensate fibers, polyaddition fibers, polyaromatic fibers, polyheterocyclic and / or homoaliphatic fibers.