Multilayer material having ballistic protective properties, method for producing the multilayer material, and use of the multilayer material

Abstract

The invention relates to a multilayer material having ballistic protective properties, to a method for producing the multilayer material, and to the use of the multilayer material. The problem addressed by the invention is therefore that of eliminating the disadvantages of the prior art and providing an alternative multilayer material having ballistic protective properties, wherein the alternative multilayer material provides excellent ballistic protection while having the lowest possible weight, and is easy to process. This problem is solved by means of the features specified in the claims.

Description

1 P2894 Multilayer material with ballistic protection, method for producing the multilayer material and use of the multilayer material Description

[0001] The invention relates to a multi-layer material with ballistic protective effect, a method for producing the multi-layer material and the use of the multi-layer material.

[0002] Products containing materials with ballistic protection, also known as bulletproof products, are designed to protect the human body from bullets and projectiles. A bulletproof product, such as a bullet-resistant vest, is intended to prevent a projectile from penetrating the wearer. The kinetic energy of the projectile is absorbed and distributed over the largest possible area. The projectile itself remains inside the bulletproof product, but can deform it.

[0003] Bulletproof products are manufactured from various materials according to different design principles. A general distinction is made between hard and soft ballistics. Certain protective effects can usually only be achieved by combining both principles.

[0004] In soft ballistics, the projectile impacts a multi-layered mesh or foil structure made of tear-resistant fabric. November 5, 2025 2. P2894 Some of the projectile's energy is absorbed when the projectile sets the individual layers in motion in the direction of entry (acceleration work) and stretches the fibers (tension work). However, the majority of the energy is still retained. The projectile forms a truncated cone-shaped bulge on the side of the tear-resistant tissue facing the body until the projectile and the impacted tissue are moving at the same velocity (inelastic collision).

[0005] In hard ballistics, the projectile strikes a plate made of a hard material and transfers its kinetic energy to it. The plate absorbs this kinetic energy, causing deformation. This principle has long been used in armaments.

[0006] The bulletproof performance of bulletproof products depends on the materials used and their spatial structure.

[0007] Bulletproof materials used in soft ballistics include fully aromatic polyamide fibers, commonly referred to as aramid fibers; para-aramid fibers, which have a structure in which benzene rings are linearly linked by an amide group (-CONH); and non-aramid fibers. Para-aramid fibers possess excellent properties such as high strength and high elasticity. November 5, 2025 3 P2894 exhibits low shrinkage and is frequently used for bulletproof purposes.

[0008] For bulletproof composites, aramid fabrics are typically manufactured using para-aramid fibers. The aramid fabrics are dipped in resin and then dried to produce aramid fabric prepregs. These aramid fabric prepregs are laminated in layers and then cured.

[0009] Bulletproof materials in hard ballistics include ballistic steel and, more recently, polyethylene or oxide ceramic plates, which are mostly produced by laminating several layers of high-strength fabrics, such as aramid fabric, onto appropriate plates.

[0005] However, high-density polyethylene exhibits a high degree of deformation when subjected to physical impact during use, so that bulletproof performance is limited.

[0010] In the conventional ceramic bulletproof plate, for example disclosed by KR 10 0926746 Bl, the ceramic plate, which is bonded to the bulletproof fabric by a thermoplastic adhesive film, has only weak adhesive strength and detaches significantly at high temperatures. Furthermore, November 5, 2025 4 P2894 requires that, in order to manufacture the conventional ceramic bulletproof plate, the thermoplastic adhesive film must be inserted into each of the bulletproof fabrics after cutting, which results in a significant reduction in processability.

[0011] DE 196 53 218 CI discloses a bullet-resistant and impact-resistant layer material, consisting of a hard laminate layer on the object side made of a fabric with high tensile strength, and a layer of non-woven fiber felt applied to it on the attack side, which is hardened by the addition of a binder in such a way that the layer itself is rigid, but under point or small-area load the adhesive bonds and interlocks of the felt fibers are partially broken and the felt fiber material compacts in the direction of the load.

[0012] DE 102017 104 956 Al discloses a weight-optimized and application-adaptable bullet-resistant protective device, in particular for personal or object protection.

[0013] It is therefore desirable to have an alternative multi-layer material with ballistic protection that offers excellent ballistic protection at minimal weight and is easy to process. November 5, 2025 5 P2894 Description of the invention

[0014] The object of the invention is to eliminate the disadvantages of the prior art and to provide an alternative multi-layer material with ballistic protection, wherein the alternative multi-layer material offers excellent ballistic protection at minimal weight and is easy to process.

[0015] This problem is solved by the features listed in the claims.

[0016] The problem is solved by a multilayer material with ballistic protection, wherein the multilayer material with ballistic protection comprises at least a first outer cover layer, at least one textile layer, and at least one energy-absorbing core layer. The at least one energy-absorbing core layer is arranged between the at least one first outer cover layer and the at least one textile layer. The at least one first outer cover layer, the at least one textile layer, and the at least one energy-absorbing core layer are bonded together. The at least one energy-absorbing core layer 4 is formed from a hollow structure. The hollow structure is a honeycomb structure. The ends of the cavities of the honeycomb structure are connected to the at least one first November 5, 2025 6 P2894 outer cover layer 1 and the at least one textile layer 3 arranged.

[0017] According to various embodiments, the multilayer material further comprises at least a second outer cover layer. The at least one textile layer and the at least one energy-absorbing core layer are arranged between the at least one first outer cover layer and the at least one second outer cover layer.

[0018] According to various embodiments, the at least one first outer cover layer and / or the at least one second outer cover layer is / are made of metal (e.g. aluminium) or wood or glass fiber reinforced plastic or carbon fiber reinforced plastic.

[0019] The first outer cover layer and the second outer cover layer can be made of identical or different materials.

[0020] According to various embodiments, at least one textile layer has at least one tear-resistant fabric.

[0021] The at least one tear-resistant fabric is preferably multi-layered. November 5, 2025 7 P2894

[0022] According to various embodiments, at least one tear-resistant fabric contains aramid fibers.

[0023] It is conceivable that at least one tear-resistant fabric alternatively or additionally contains other fibers, for example made of silk.

[0024] A foam can completely or partially fill one or more cavities of the hollow body structure.

[0025] Advantageously, the honeycombs are formed as uniform hexagons. Of all possible hollow body shapes that can be seamlessly joined together, hexagons have the best ratio of wall material to volume, and in this respect represent an optimal shape. Corresponding honeycomb structures exhibit extremely high stability while simultaneously possessing a very low weight. Loads are distributed across the entire structure via the honeycomb walls and thus do not act only at a single point.

[0026] According to various embodiments, the hollow body structure is made of aluminum.

[0027] According to various embodiments, the at least one first outer cover layer, the at least one textile layer, and the at least one energy-absorbing core layer are elastically connected to one another. If the multilayer material has at least one second outer cover layer, this layer is elastically connected to the at least one textile layer. November 5, 2025 8 P2894

[0028] Advantageously, a tough-elastic adhesive is used for this purpose. The tough-elastic adhesive can be, for example, a one-component adhesive, a two-component adhesive, or a resin-based adhesive containing a hardener, which is used in a hot or cold bonding process.

[0029] The problem is further solved by a method for producing the multi-layer material with ballistic protection, wherein the method comprises the following process steps: a. Manufacturing and cutting of at least one first outer cover layer, at least one textile layer and at least one energy-absorbing core layer, b. stacked arrangement of the at least one first outer cover layer, the at least one textile layer and the at least one energy-absorbing core layer, wherein the at least one energy-absorbing core layer is arranged between the at least one first outer cover layer and the at least one textile layer, and wherein November 5, 2025 9 P2894 a tough-elastic adhesive is placed between each of the individual layers, and c. Bonding the stacked arrangement by applying a contact pressure,

[0030] The individual layers are cut to the target size of a specific product, for example a car body component.

[0031] The multilayer material is preferably produced in a room that allows for easy temperature control, for example an oven.

[0032] According to various embodiments, in process step a., at least one second outer cover layer is additionally manufactured and cut to size. In process step b., the at least one first outer cover layer, the at least one second outer cover layer, the at least one textile layer, and the at least one energy-absorbing core layer are stacked together. The at least one textile layer and the at least one energy-absorbing core layer are positioned between the at least one first outer cover layer and the at least one second outer cover layer. A tough-elastic adhesive is applied between each of the individual layers. November 5, 2025 10 P2894

[0033] According to various embodiments, the multi-layer material is manufactured with a use-specific shape.

[0034] Application-specific shaping can be achieved by modulating the individual layers according to a target shape. For example, the first outer layer made of fiberglass-reinforced plastic (FRP) can be produced in a negative mold. A first outer layer made of metal can be pressed into a corresponding target shape. A textile layer can be shaped by applying a flexible textile layer to a layer that already has the target shape. Identical and / or similar shaping processes with the same objective are conceivable for the other layers. A target shape could, for example, be a curved shape to adapt the multilayer material to a body anatomy, such as the ribcage. Application-specific shaping can be achieved during process step a. and / or process step b.

[0035] According to various embodiments, in process step b. multiple textile layers are arranged stacked on top of each other. A tough-elastic adhesive is placed between each individual textile layer. November 5, 2025 11 P2894

[0036] According to various embodiments, the tough-elastic adhesive is a hot melt adhesive film.

[0037] According to various embodiments, the bonding in process step c. takes place under tempering until a melting temperature of the hot melt adhesive film is reached, whereby the melting temperature of the hot melt adhesive film is maintained for a defined period of time.

[0038] The multi-layer material according to the invention can be used for personal protective equipment, for example helmets or vests, building walls, vehicle bodies and / or aircraft fuselages. Implementation of the invention

[0039] The invention is explained in more detail using several exemplary embodiments. For this purpose, we show... Figure 1 Multi-layer material with ballistic protection in schematic view, Figure 2 shows an alternative multi-layer material with ballistic protection in a schematic view.

[0040] The description refers to the attached drawings, which contain specific illustrations. November 5, 2025 Figure 12 P2894 shows embodiments in which the arrangement according to the invention can be implemented. In this respect, directional terminology such as "top", "bottom", etc. is used with reference to the orientation of the described drawings. The directional terminology serves for illustration and is in no way restrictive.

[0041] It is understood that other embodiments may be used and structural or logical modifications made without deviating from the scope of protection of the present invention. It is understood that the features of the various exemplary embodiments described herein may be combined with one another, unless specifically stated otherwise. The following detailed description is therefore not to be interpreted as restrictive, and the scope of protection of the present invention is defined by the appended claims.

[0042] In the figures, identical or similar elements are provided with identical reference symbols where appropriate.

[0043] The multilayer material according to the invention with ballistic properties is shown in Figure 1. The multilayer material comprises at least a first outer cover layer 1, at least one textile layer 3, and at least one energy-absorbing core layer 4. The at least November 5, 2025 13 P2894 An energy-absorbing core layer 4 is arranged between the at least one first outer cover layer 1 and the at least one textile layer 3. The at least one first outer cover layer 1, the at least one textile layer 3, and the at least one energy-absorbing core layer 4 are bonded together. The at least one energy-absorbing core layer 4 is formed from a hollow structure. The hollow structure is a honeycomb structure. The ends of the cavities of the honeycomb structure are arranged at the at least one first outer cover layer 1 and the at least one textile layer 3.

[0044] The multilayer material can, as shown in Figure 1, further comprise at least one second outer cover layer 2. The at least one textile layer 3 and the at least one energy-absorbing core layer 4 are then arranged between the at least one first outer cover layer 1 and the at least one second outer cover layer 2.

[0045] The at least one first outer cover layer 1 and / or the at least one second outer cover layer 2 can be made of metal (e.g. aluminium) or wood or glass fiber reinforced plastic or carbon fiber reinforced plastic. November 5, 2025 14 P2894

[0046] At least one textile layer 3 can consist of a tear-resistant fabric. This tear-resistant fabric can contain aramid fibers.

[0047] As shown in Figure 2, the hollow body structure is a honeycomb structure. The ends of the honeycomb structure's cavities are located at the at least one first outer cover layer 1 and the at least one textile layer 3. The ends here are understood to be the base surfaces of the hollow bodies shaped as polygonal cylinders. The hollow body structure can be made of aluminum.

[0048] The at least one first outer cover layer 1, the at least one textile layer 3, and the at least one energy-absorbing core layer 4 can be elastically connected to each other. If the at least one second outer cover layer 2 is present, it can be elastically connected to the at least one textile layer 3. Reference sign 1 first outer cover layer 2 second outer cover layer 3 textile layers 4 energy-absorbing core layer November 5, 2025

Claims

15 P2894 Claims 1. Multi-layer material with ballistic protection, wherein the multilayer material comprises at least a first outer cover layer (1), at least a textile layer (3) and at least an energy-absorbing core layer (4), wherein the at least one energy-absorbing core layer (4) is arranged between the at least one first outer cover layer (1) and the at least one textile layer (3), wherein the at least one first outer cover layer (1), the at least one textile layer (3) and the at least one energy-absorbing core layer (4) are bonded together, wherein the at least one energy-absorbing core layer (4) is formed from a hollow body structure, wherein the hollow body structure is a honeycomb structure, wherein the ends of the cavities of the honeycomb structure are arranged on the at least one first outer cover layer (1) and the at least one textile layer (3).

2. Multilayer material according to claim 1, further comprising at least a second outer cover layer (2), wherein the at least one textile layer (3) and the at least one energy-absorbing core layer (4) are located between the at least one first outer November 5, 2025 16 P2894 top layer (1) and at least one second outer top layer (2) are arranged.

3. Multilayer material according to claim 1 or 2, characterized in that the at least one first outer cover layer (1) and / or the at least one second outer cover layer (2) is / are made of metal or wood or glass fiber reinforced plastic or carbon fiber reinforced plastic.

4. Multilayer material according to one of the preceding claims, characterized in that the at least one textile layer (3) comprises at least one tear-resistant fabric.

5. Multilayer material according to claim 4, characterized in that the at least one tear-resistant fabric comprises aramid fibers.

6. Multilayer material according to one of the preceding claims, characterized in that the hollow body structure is formed from aluminium.

7. Multilayer material according to one of the preceding claims, characterized in that the at least one first outer cover layer (1), the at least one textile layer (3) and the at least one energy-absorbing core layer (4) are elastically connected to each other.

8. Method for producing the multilayer material with ballistic protection according to claim 1, comprising the process steps: November 5, 2025 17 P2894 a. Manufacturing and cutting of the at least one first outer cover layer (1), the at least one textile layer (3) and the at least one energy-absorbing core layer (4), b. stacked arrangement of the at least one first outer cover layer (1), the at least one textile layer (3) and the at least one energy-absorbing core layer (4), wherein the at least one energy-absorbing core layer (4) is arranged between the at least one first outer cover layer (1) and the at least one textile layer (3), and wherein a tough-elastic adhesive is placed between each layer, and c. the stacked arrangement is bonded by applying pressure.

9. Method for producing the multilayer material according to claim 8, characterized in that in process step a. additionally a manufacturing and cutting of at least a second outer cover layer (2) takes place, and November 5, 2025 18 P2894 that at least one second outer cover layer (2) is added in process step b. of the stacked arrangement, wherein which at least a second outer cover layer (2) is arranged on the side of the at least one textile layer (3) which is opposite the at least one first outer cover layer (1).

10. Method for producing the multilayer material according to claim 8 or 9, characterized in that the multilayer material is produced with a use-specific shape.

11. Method for producing the multilayer material according to one of claims 8 to 10, characterized in that in process step b. multiple textile layers (3) are arranged stacked on top of each other, wherein a tough-elastic adhesive is placed between each of the individual textile layers (3).

12. Method for producing the multilayer material according to one of claims 8 to 11, characterized in that the tough-elastic adhesive is a hot melt adhesive film.

13. Method for producing the multilayer material according to claim 12, characterized in that the bonding in process step c. is carried out under tempering until a melting temperature of the November 5, 2025 19 P2894 Hot melt adhesive film, wherein the melting temperature of the hot melt adhesive film is maintained for a defined period of time.

14. Use of the multi-layer material with ballistic protective effect according to any one of claims 1 to 7 for personal protective equipment, building walls, vehicle bodies and / or aircraft fuselages. November 5, 2025

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