Flexible nonwoven for providing protection from slashing, stabbing and firing weapons as well as shrapnel

Abstract

A flexible protective composite consists of a composite made of soft ballistic and hard ballistic protective materials. It has a low weight, high flexibility and low noise development and be easy to manufacture and effective to use with an easily possible and universal design. The soft ballistic protective material is a multi-layered fabric which consists of high-strength textile materials. The hard ballistic protective material consists of a three-dimensional wire structure in lightweight construction, which consists of several wires intersecting and interconnected to form a plurality of cells in the three-dimensional space. The three-dimensional wire structure is formed on each plane of interlocking transverse spirals and longitudinal spirals. At least two planes are provided, which are also connected to each other.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a national stage application, filed under 35 U.S.C. § 371, of International Patent Application PCT / DE2023 / 100586, filed on Aug. 9, 2023, which claims the benefit of German Patent Application DE 10 2022 121 500.8, filed on Aug. 25, 2022.TECHNICAL FIELD

[0002] The disclosure relates to a flexible protective composite against the effect of slashing, stabbing and firing weapons as well as shrapnel, consisting of a sandwich composite made of soft ballistic and hard ballistic protective materials. The protective material provides an improved degree of ballistic protection, which is also particularly effective against long guns. The flexible protective composite can be used, for example, in the fields of personal protection, bullet protection, safety vehicle technology, military technology, aviation and space technology.BACKGROUND

[0003] Solutions for protecting people and objects are divided into soft and hard ballistic solutions. The soft ballistic solutions consist of multi-layered textiles, for example. These only protect against handguns, but not against long guns. For protection against long firearms, there are currently mainly plate solutions, in particular made of metal or ceramic. Plates are rigid, inflexible and very heavy in terms of weight in the higher protection classes required against long weapons. If several plates are combined for better manoeuvrability, there are fewer protected areas between the plates. Breathability is virtually non-existent. Plate solutions make noise when the person wearing them moves, falls or is hit by objects, which can be unfavourable in combat operations, for example. Moulding is difficult with plate variants.

[0004] A bulletproof vest consisting of glass fibre mats, synthetic resin and clay plates for rounded chest, trunk and body protection is listed in DE 21 35 571 A.

[0005] DE 68 08 297 U describes a bulletproof vest, the front and back parts of which consist of armoured sheets or plates, which are each located in fabric covers. These are arranged to overlap like scales and are surrounded all around by a closed outer shell made of fabric or similar the size of the front or back part.

[0006] EP 33 77 841 B1 shows that several textile layers are connected to a binder matrix in the centre part. This centre part is pressed. In addition, a detachable armoured plate or even a ceramic plate is located here.

[0007] EP 30 86 077 A4 and EP 30 86 077 A1 describe a solution for defending against 9 mm cartridges. A sandwich solution consisting of alternating polyethylene film and several layers of aramid material is used for this purpose.

[0008] EP 425 394 A1 describes a two-part ballistic protective vest consisting of an under-protector and a chest protector. The under protector consists of several layers of textile and is in a scale-like or folded shape. The chest protector consists of a rigid shell made of metal, for example.

[0009] In EP 30 98 560 A1, many small segments which consist of a sintered material are bonded to a “ballistic” textile by means of a thermoplastic film, independently of one another and not bonded to one another. In addition, this safety lining contains pockets to receive plates for increased protection.

[0010] EP 34 57 075 A1, for example, describes a vest for protection from bullets and / or bladed weapons. At least one panel and at least one second plate are produced. A plate consists of a fabric, in particular made of aramid fibres, and a film of thermoplastic material respectively fixed on one side. Each individual plate is provided with reinforcing fibres. In the overall structure, the fibres are unidirectional in that, depending on the plate, they are present at −45° / +45° or unidirectionally cutting at 0° / 90° / 0° / 90°.

[0011] DE 724 202 A describes a body protector with a moveable protective device that does not hinder body movements. Here, a protective mass made of a metal ring mesh consisting 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 protective mass is adapted to the garment part and in which the wire ends of the individual ring links are connected by welding.

[0012] Disadvantages of said invention include the fact that the metal rings are too large for optimum protection from slashing and stabbing weapons and projectiles. The wire ends have to be welded together. This means that there are irregularities in the structure. There is no protection against strong forces, such as long weapons, for example, or thin weapons, such as a stiletto or syringe, for example. The spatial shaping is also restricted 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 in front of the vest away from the body. It consists of a steel chain mesh which is moulded as 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 means of the plastic matrix, can be able to be inserted into the shell of a protective vest.

[0014] The steel chain mesh can be moulded as a flexible, inherently stable mat by embedding it between two layers of thermoplastic material, which are fused together by pressure under the effect of heat.

[0015] The steel chain mesh can be moulded as a flexible, inherently stable mat by embedding it between two layers of fabric coated with thermally activatable glue, which are adhered together by pressure under the influence of heat.

[0016] With the solution described, there are weak points in the protection of the entire body, particularly in the regions between the insertions. It only protects against stabbing weapons but not against bullets or shrapnel.

[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 handguns, but not against long guns. For protection against long firearms, there are currently only plate solutions, e.g. made of metal or ceramic.

[0018] Plates are rigid, inflexible and very heavy in terms of weight in the higher protection classes required against long weapons. There are fewer protected areas between the plates. Breathability is virtually non-existent. In the event of a fall, when moving into position or when exposed to objects, plate solutions inherently make noise, which can have a disadvantageous effect in combat, for example. Moulding is difficult with plate variants.

[0019] EP 000002384248 B1 relates to a three-dimensional wire structure in lightweight construction, which consists of several wires intersecting and interconnected to form a plurality of cells in three-dimensional space. The invention can be used, for example, in medical technology, vehicle construction and mechanical engineering as well as in the construction industry.

[0020] WO 2015 / 026258 A1 relates to the field of wire mesh structures as well as to fabrics with a particular arrangement of threads. A three-dimensional mesh which comprises a set of neighbouring 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 helical lines, which are twisted in the opposite direction in relation 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 a family encloses a thread or rod of the other family with each twist and at the same time also encloses neighbouring threads or rods of its own family. The threads or rods of each layer are interwoven with the threads or rods of the neighbouring layers. It is possible to form a combined mesh which additionally contains threads or rods which are arranged in the cavities of the mesh, wherein the threads or rods are provided individually or are connected to one another by a conventional weave, such as a plain weave, for example. 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, perpetually dry mats for baths and swimming pools, naturally convection ventilated car seats and others.SUMMARY

[0021] The present application discloses a flexible protective composite against slashing, stabbing and firing weapons as well as shrapnel, consisting of a composite made of soft ballistic and hard ballistic protective materials. This should have low weight, high flexibility and low noise development and be easy to manufacture and effective to use with an easily possible and universal design.

[0022] The flexible protective composite against slashing, stabbing and firing weapons as well as shrapnel consists of a composite made of soft ballistic and hard ballistic protective materials.

[0023] The soft ballistic protective material is a multi-layered fabric which consists of high-strength textile materials. The hard ballistic protective material consists of a three-dimensional wire structure in lightweight construction, which consists of several wires intersecting and interconnected to form a plurality of cells in three-dimensional space. The three-dimensional wire structure (2) is formed in each plane of interlocking transverse spirals (3) and longitudinal spirals (4). At least 2 planes are provided, which are also connected to each other. The connection is carried out in certain nodes, which are again created by interlocking the transverse spirals (3) and longitudinal spirals (4), analogously to interlocking in one plane.

[0024] For possible protection against firearms, the maximum cell opening (12) should be smaller than the projectile diameter of the firearm to be protected against.

[0025] The soft ballistic and the hard ballistic protective materials are connected to each other in such a way that the individual layers are kept stable in their position.

[0026] In a preferred design, in particular when used for protective vests, there is a hard ballistic layer between two soft ballistic layers. A sandwich structure is formed that is particularly flexible and universally usable for a wide range of applications, in particular for all types of protective vests.

[0027] In a particular design, several hard ballistic layers are provided, wherein soft ballistic layers are in a sandwich structure between the hard ballistic layers.

[0028] A further design describes that the shape of the flexible protective composite is adjusted to the outer shapes of the persons or objects to be protected or at least parts thereof.

[0029] It is advantageous when the soft ballistic surface structures are connected to the hard ballistic protective material at least in the edge region, in particular when they are sewn, adhered, welded, resinified or melted together.

[0030] The soft ballistic protective material can preferably consist of synthetic chemical fibres, for example polymeric fibres, polymeric condensate fibres, polyaddition fibres, polyaromatic fibres, polyheterocyclic and / or homoaliphatic fibres. Polyethylenes with ultra-high molecular weight (PE-UHMW) or high-modulus polyethylene (HMPE), so-called high-performance polyethylene fibres, such as Dyneema, for example, are particularly suitable. Further materials such as aramid, carbon or glass are also suitable.

[0031] Surprisingly, it has been found that if a three-dimensional wire structure according to EP 00002384248 B1 is chosen as the hard ballistic protective material, a particularly high degree of protection can be achieved.

[0032] The advantages of the invention are that the flexible protective composite can be dimensioned differently and thus offers protection for people, animals and objects from harmful influences such as stabs, cuts, splinters, handguns, long guns and similar. Especially in the higher protection class range, the solution offers a clear weight advantage, is not rigid and offers no weak points in the overall structure. It can be moulded to any shape without compromising the degree of protection. In the event of falls and hits, noise is significantly reduced in comparison to plates. Overall, it can be estimated that the resulting flexible protective composite has a low weight, high flexibility and low noise development and can be used with an easily possible and universal shape.BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The invention is explained in more detail below using exemplary embodiments.

[0034] FIG. 1 shows a flexible protective composite in sandwich construction.

[0035] FIG. 2 shows a soft ballistic protective material as a multilayer, multiaxial surface structure.

[0036] FIG. 3 shows a structural design of a hard ballistic protective material.

[0037] FIG. 4 shows a hard ballistic protective material one several planes.DETAILED DESCRIPTION

[0038] Firstly, the basic structure of a flexible protective composite against slashing, stabbing and firing weapons as well as shrapnel, consisting of a composite made of soft ballistic and hard ballistic protective materials, is described.

[0039] FIG. 1 shows a flexible protective composite which is designed in a sandwich construction and in which the soft ballistic protective material arranged on both sides is a multi-layered fabric 1 which consists of high-strength textile materials. High-strength polyethylene threads serve as the basis. The threads are stretched and laid in parallel to one another without being connected to one another. The result is a layer 9 consisting of a thread group. The fixing is carried out by fabric bonding or mechanically by friction and / or positive locking. Depending on the purpose of the application, further layers 9 are laid on top of this thread group according to the same principle. To achieve a certain property in several directions, the thread groups are laid at different laying angles to the production direction. FIG. 2 schematically depicts the manufacturing process with fixing by sewing by means of a needle 10 and a sewing thread 11.

[0040] For reasons of visualisation, only 4 layers 9 are depicted on both sides in FIG. 1. However, these fabrics actually consist of a plurality of layers 9. Depending on the intended use, the number can range from at least 2 to over 100 layers 9. To improve the resistance, the individual layers 9 or layer groups are arranged offset by an angle. In FIG. 1, the two inner layers 9 are each arranged offset by 90°. The third layer 9 is depicted offset by a further 45° and the fourth layer 9 by a further 90° to the third layer (135°).

[0041] The use of a fabric known commercially as Dyneema®, e.g. Dyneema® product SB 115 or Dyneema® product HB 210, has proved to be particularly advantageous. In these variants, the thread groups are present at angles of 0° and 90°.

[0042] For the exemplary production of test specimens, the parts are cut to size with dimensions of 500 mm×500 mm. This is carried out on the cutting machine. Here, five textile layers are covered with paper, a blade oscillation of 4020 and a speed of 50% are set, and a vacuum of 75-80% is applied. The blanks are laid one above the other in several layers 9, and each layer is further rotated by 45° in relation to the previous layer. The layers are thus alternately at 0°, 45°, 90° and 135°. These layers can be either loose or combined into layer packs using all possible joining technologies. For example, 50 layers can be connected to one another by sewing on a saddler machine, using a sewing needle of strength of Nm 200 of the needle system 70.4, using a sewing thread of fineness of Nm 20 / 3 and a stitch length of 5 mm.

[0043] A hard ballistic protective material is provided between the two soft ballistic fabrics. This is formed from a three-dimensional wire structure 2 in lightweight construction. The hard ballistic layer consists of several metal nettings that intersect to form a plurality of cells in three-dimensional space and are formed with one another from wires 8. For its construction, a wire 8, e.g. made of stainless steel 1.4567, with a wire diameter of 0.63 mm, for example, is moulded into spirals and connected to one another by means of screwing in. The end result is a threefold interlocked netting.

[0044] FIGS. 3 and 4 depict the three-dimensional wire structure in lightweight construction. This consists of a plurality of helically wound wires 8, which are connected to one another in three-dimensional space in an intersecting manner to form cells 7 and which are arranged with their axes alternately aligned and on different planes. An example of a wire structure consisting of two joined planes is shown in FIG. 3, which can be extended by further planes in the third direction as required.

[0045] According to FIG. 2, on a first plane, several helical wires 8 running in parallel to one another with their axes are formed as a transverse spiral 3 by overlapping at their respective crossing points to form a wire netting that is connected in a positive locking manner in the x and y directions, in which two neighbouring wires are connected via a crossing point 13 per turn. By incorporating further wires, the wire netting can be extended in the y-direction as required. The length of the wires used here results in the expansion in the x-direction.

[0046] Furthermore, with reference to FIG. 2, several helical wires 8 running with their axes in parallel to one another are provided transversely to the axes of the transverse spirals 3 as longitudinal spirals 4, which intersect within the first plane at their crossing points as well as with the crossing points of the transverse spirals 3. For a complete cell 7, four wires are respectively in contact with one another at four crossing points, each of which forms a fully-fledged crossing point in terms of this structure.

[0047] When two neighbouring transverse spirals 3 are connected to one another in a positive locking manner with two adjacent longitudinal spirals 4, they have the smallest distance to one another at a point, the so-called large node 5. A cell 7 of this plane is delimited by four nodes.

[0048] When adding further planes, connecting points are created by interweaving the transverse spirals of the one plane with the longitudinal spirals of the further plane(s). These connection points form a small node 6. The wire netting of the first plane is thus congruently connected to the wire netting of the second plane in the z-direction. This structure is reinforced by inserting further planes. In doing so, a shifting of the inserted cells into one another is carried out in such a way that the cell sizes are reduced since more material is present.

[0049] For a sandwich solution, a further multi-layer fabric 1 made of high-strength polyethylene threads can be used as a third component. This is also cut into parts with the dimensions 500 mm×500 mm to produce a flexible protective composite with the settings listed. 110 blanks of the HB 210 fabric are placed one on top of the other and, here, the individual blanks are rotated by 45°. The 110 blanks are alternately stacked at 0°, 45°, 90° and 135° when considered individually. This ensures the same properties of the fabric in all directions.

[0050] The production of the flexible protective composite is now carried out by connecting the two multi-layer fabrics 1 and the three-dimensional wire structure 2 to one another. This connection can, for example, be done point-by-point with a two-component polyethylene resin. The soft ballistic and hard ballistic protective materials are connected to each other in such a way that the individual layers are kept stable in their position. This can be achieved by sewing, gluing, welding, resinifying or fusing. In this way, for example, the production of a structure with dimensions of 500 mm×500 mm×5 mm is carried out, which can be used for a test specimen or as an insert for a protective vest with dimensions of 350 mm×250 mm×30 mm.

[0051] The flexible protective composite can be used universally against slashing, stabbing and firing weapons as well as shrapnel.

[0052] Possible application fields are as follows:

[0053] Protective vest

[0054] Bulletproof cars / lorries / construction vehicles for conflict regions

[0055] Aeroplanes and helicopters (protection with low weight)

[0056] Ship protection

[0057] Suits for demolition squads (such as vests, only the entire body is in protective segments)

[0058] Bulletproof walls / tents / containers / mobile garages

[0059] Shock absorber for dropping packages from aircraft, e.g. care packages in disaster regions

[0060] Drone reinforcement

[0061] Rocket reinforcement from impact

[0062] Demolition measures as shrapnel protection in demolition measures,

[0063] Protective wall in explosion measures,

[0064] Tank reinforcement against explosions or when transporting ammunition.

[0065] So-called plate carriers are used for bulletproof vests for long gun protection, which receive the corresponding segments and keep them in position. To produce such segments, a flexible protective composite with dimensions of 300 mm×250 mm is manufactured and inserted. They are thus compatible with existing plate carriers so that no new ones need to be purchased. The segments are located at the height of the left and right chest, 2× at stomach height, on the back 2× each in the upper and lower back region and on the shoulders 1× each.

[0066] The positions of the segments and their size depend on the application.

[0067] Shaped segments, such as those suitable for the shoulder, among others, can be produced easily due to their flexible mouldability. Larger segments up to complete vests are also possible, without the need for plate carriers, overjackets and similar. Since a produced protective composite is formed to be very flexible and lightweight, it can be manufactured larger than conventional, rigid plate solutions, especially for protective vests. Thus, the possible body protection can also be extended to more lateral parts of the body without restricting the movement of the person to be protected. Depending on the desired protection class, the segments can be formed to be thinner and more flexible or thicker.

[0068] With armoured vehicles for land, water and air use as well as drones, the armouring can also be provided by means of a protective composite. For this purpose, the protective composites are dimensioned corresponding to the desired level of protection: the thicker they are, the higher the protection against damaging effects. The segments are moulded and produced according to the position in the field of application. The segments are then fitted in front of or behind the outer panels. In vehicles, they can be located inside the doors, driver's compartments, bonnets, boot lids, vehicle roofs and loading areas. In drones, aeroplanes and helicopters, the segment is formed and inserted as a corresponding body. Segments are also moulded into the pilot's compartment and its floor and doors. At sea, the segments are moulded correspondingly and inserted into the fuselage and the outer sides. It is also possible to further reinforce individual areas separately.

[0069] When used to protect walls, tents, containers or mobile garages against bullets or shrapnel, for example, 2.50m×2.00m segments can be produced. These segments can be provided with a carrying handle as needed. This construction serves as a portable protective wall or protective shield and can also have other dimensions. Mobile garages or containers can be made from several of these segments. To do so, the segments are used as walls and one is used as a roof. These can then be fixedly connected to one another by means of adhesive or other connection technologies. The individual segments can also be used directly as a tent, tarpaulin or cover.

[0070] The flexible protective composites are lightweight and highly flexible. They are characterised by low noise levels during use. They are easy to produce with a uniform shape and are simple and effective to use.LIST OF REFERENCE NUMERALS1 multi-layered fabric

[0072] 2 three-dimensional wire structure

[0073] 3 transverse spiral

[0074] 4 longitudinal spiral

[0075] 5 large node

[0076] 6 small node

[0077] 7 cell

[0078] 8 wire

[0079] 9 layer

[0080] 10 needle

[0081] 11 sewing thread

[0082] 12 cell opening

[0083] 13 crossing point

Claims

1. -7. (canceled)8. A flexible protective composite against slashing, stabbing, firing weapons, and shrapnel, comprising:a soft ballistic protective material being a multi-layered fabric (1),wherein the fabric (1) is a high-strength textile material, andwherein individual layers or several layers combined in layer groups are arranged offset to one another by an angle; anda hard ballistic protective material forming a three-dimensional wire structure (2),wherein the three-dimensional wire structure (2) consists of several wires (8) that intersect to form a plurality of cells (7) in a three-dimensional space and that are connected to one another,wherein the three-dimensional wire structure (2) is formed on each plane of interlocking transverse spirals (3) and longitudinal spirals (4),wherein at least two planes are present and are connected to one another in large nodes (5) and small nodes (6),wherein the large nodes (5) are formed by two neighboring transverse spirals (3) being connected to one another in a positive locking manner with two adjacent longitudinal spirals (4) at a point having a smallest distance between the two neighboring transverse spirals (3) and the two adjacent longitudinal spirals (4), andwherein the small nodes (6) are formed at connecting points between planes by interweaving transverse spirals of one plane with longitudinal spirals of a further plane,wherein the soft ballistic protective material and the hard ballistic protective material are connected to each other so as to maintain a stable position.

9. The flexible protective composite according to claim 8,wherein a hard ballistic layer comprising the hard ballistic protective material is provided between two soft ballistic layers comprising the soft ballistic protective material, whereby a sandwich structure is formed.

10. The flexible protective composite according to claim 8,wherein several hard ballistic layers are provided, andwherein soft ballistic layers comprising the soft ballistic protective material are located between hard ballistic layers comprising the hard ballistic protective material, whereby a sandwich structure is formed.

11. The flexible protective composite according to claim 8,wherein the flexible protective composite is adjusted in terms of its shape to an outer shape of a person to be protected or an object to be protected or at least parts thereof.

12. The flexible protective composite according to claim 8,wherein the multi-layered fabric (1) are connected to one another with the hard ballistic protective material at least in an edge region.

13. The flexible protective composite according to claim 8,wherein the soft ballistic protective material consists of synthetic chemical fibres.

14. The flexible protective composite according to claim 13,wherein the synthetic chemical fibres are polymeric fibres, polymeric condensate fibres, polyaddition fibres, polyaromatic fibres, polyheterocyclic and / or homoaliphatic fibres.

Images