Dicyclopentadiene-based composite armor

Abstract

A device including a core structure having a strike face and a back face. A first composite fiber laminate having a first plurality of composite fiber plies may be bonded to the strike face of the core structure. A second composite fiber laminate having a second plurality of composite fiber plies may be bonded to the back face of the core structure. Each composite fiber ply may be impregnated with a polydicyclopentadiene (PDCPD) resin matrix to enhance ballistic resistance.

Description

529760.000023DICYCLOPENTADTENE-BASED COMPOSITE ARMORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 746,113, filed January 16, 2025, the entire content and disclosure of which is incorporated herein by reference.FIELD OF THE DISCLOSURE

[0001] The present application relates to composite armor systems and, more particularly, to armor plates fabricated using polydicyclopentadiene (PDCPD) in combination with fiber-reinforced materials to enhance ballistic resistance while maintaining lightweight properties.BACKGROUND OF THE DISCLOSURE

[0002] Armor has played a useful role throughout history in providing protection against various threats, from melee weapons in ancient warfare to modern ballistic projectiles. The primary function of armor is to safeguard individuals, vehicles, and infrastructure from damage caused by external forces. In military applications, armor is essential for ensuring the survivability of personnel and equipment in combat scenarios. Similarly, law enforcement agencies rely on armor to protect officers from gunfire and other threats during high-risk operations.

[0003] As such, armor systems are widely employed to protect personnel and equipment from ballistic threats. Conventional armor designs rely on metallic plates or ceramic materials to achieve the required protective capabilities. However, these materials add significant weight, impacting mobility and reducing usability in various applications.

[0004] The evolution of armor technology has been driven by the continuous advancement of weaponry. Early armor designs consisted of heavy metal plates, which provided effective protection but significantly hindered mobility. Over time, the need for lightweight and flexible armor solutions became apparent, leading to the development of advanced materials and529760.000023composite structures. Today, modern armor systems are designed to strike a balance between protection, weight, and mobility, ensuring that users can perform their duties without excessive physical burden.SUMMARY OF THE DISCLOSURE

[0005] This disclosure provides an innovative armor plate system that integrates fiber-reinforced layers with a PDCPD matrix to achieve superior ballistic resistance and structural integrity. The armor plate comprises multiple composite layers bonded to a core structure, with each layer tailored to optimize the distribution of ballistic impact forces. The method of manufacturing the armor involves using a vacuum-assisted resin transfer molding (VARTM) process to ensure uniform distribution of the PDCPD matrix within the fiber layers.

[0006] In a first embodiment of the disclosure, a composite armor system is disclosed. The composite armor system includes a core structure having a strike face and a back face; a first composite fiber laminate bonded to the strike face of the core structure; and a second composite fiber laminate bonded to the back face of the core structure. The first composite fiber laminate includes a first plurality of composite fiber plies. The second composite fiber laminate includes a second plurality of composite fiber plies. Each composite fiber ply is impregnated with a polydicyclopentadiene (PDCPD) resin.

[0007] In another embodiment of the disclosure, a method for manufacturing a composite armor system is disclosed. The method includes preparing a core structure with a strike face and a back face; arranging a first plurality of composite fiber plies to form a first composite fiber laminate; infusing the first composite fiber laminate with a polydicyclopentadiene (PDCPD) resin matrix; curing the resin-infused laminate to create a solid structure; and bonding the first composite fiber laminate to the strike face of the core structure.

[0008] In another embodiment of the disclosure, a method for manufacturing a composite armor system is disclosed. The method includes placing an inflatable bladder within a mold cavity of a mold assembly; positioning a reinforcement layer within the mold cavity; depositing a resin onto the reinforcement layer; closing the mold assembly; inflating the inflatable bladder; and conducting a curing cycle. The curing cycle includes placing the mold assembly at a predetermined temperature for a predetermined duration of time.529760.000023

[0009] In various embodiments, the first composite fiber laminate may include carbon fibers. The second composite fiber laminate may include aramid fibers.

[0010] In various embodiments, the core structure may be perforated.

[0011] In various embodiments, the PDCPD resin matrix may include additives.

[0012] In various embodiments, an outer coating may be applied to the strike face.

[0013] In various embodiments, the first composite fiber laminate and the second composite fiber laminate may include fibers oriented at varying angles.

[0014] In various embodiments, the core structure may be comprised of at least one of steel, aluminum, and ceramic.

[0015] In various embodiments, the composite armor system may include an adhesive layer between each composite fiber laminate and the core structure.

[0016] In various embodiments, the back face may include aramid fibers.

[0017] In various embodiments, the first composite fiber laminate may be infused with the PDCPD resin matrix using a vacuum-assisted resin transfer molding process.

[0018] In various embodiments, the method may include arranging a second plurality of composite fiber plies to form a second composite fiber laminate; infusing the second composite fiber laminate with a PDCPD resin matrix; and bonding the second composite fiber laminate to the back face of the core structure.

[0019] In various embodiments, the method may include applying an outer coating to the strike face.

[0020] In various embodiments, the reinforcement layer may include fibers of at least one of carbon fiber, Kevlar, Spectra, fiberglass, and basalt.

[0021] In various embodiments, the resin may include polydicyclopentadiene (PDCPD).

[0022] In various embodiments, the inflatable bladder may be inflated to a predetermined pressure.

[0023] In various embodiments, the reinforcement layer may include a plurality of reinforcement layers.529760.000023

[0024] In various embodiments, the method may further include removing the reinforcement layer from the mold cavity after completion of the curing cycle and at least one of trimming, machining, or surface finishing the cured reinforcement layer.

[0025] In various embodiments, the composite armor system may have a shape defining one or more curves.

[0026] In various embodiments, the mold cavity may define a shape having one or more curves.

[0027] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The foregoing aspects and many of the intended advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings.

[0029] FIG. 1A is a front elevation view of a composite armor system having a first shape.

[0030] FIG. IB is a front elevation view of a composite armor system having a second shape.

[0031] FIG. 2 is a cross-sectional view illustrating ta layered structure of a core structure of the composite armor system.

[0032] FIG. 3 is a flowchart depicting a manufacturing process of the composite armor system according to a first implementation.

[0033] FIG. 4 is a flowchart depicting a manufacturing process of the composite armor system according to a second implementation.

[0034] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of various features and529760.000023components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present disclosure. The exemplification set out herein illustrates an embodiment of the invention, and such exemplification is not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION

[0035] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. It will be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrative devices and described methods and further applications of the principles of the invention which would normally occur to one skilled in the art to which the invention relates.

[0036] Composite armor represents a significant advancement in armor technology. Unlike traditional metallic armor, composite armor may utilize multiple layers of different materials to achieve superior ballistic resistance. This layered approach allows composite armor to absorb and disperse impact energy more effectively than single-material armor plates.Additionally, composite armor can be tailored to provide protection against specific threats, such as armor-piercing rounds or explosive blasts.

[0037] Composite armor systems are designed to provide enhanced protection by combining the unique properties of various materials. The fundamental concept behind composite armor is to use layers of different materials to achieve a balance between strength, flexibility, and weight. Common materials used in composite armor include carbon fibers, aramid fibers (such as Kevlar), glass fibers, ceramics, and polymer matrices.

[0038] The development of composite armor began in response to the limitations of traditional metallic armor. Metal plates, while effective at stopping projectiles, are often heavy and rigid, making them unsuitable for applications where mobility is useful. Composite materials, on the other hand, offer the advantage of being lightweight while still providing high529760.000023levels of protection. This makes composite armor ideal for use in personal protective equipment, vehicle armor, and structural protection.

[0039] One approach to the development of composite armor technology is the use of fiber-reinforced materials. These materials consist of fibers embedded within a matrix, which holds the fibers in place and distributes the impact energy across the surface of the armor. Fiber-reinforced composites are highly effective at absorbing impact energy, reducing the risk of penetration and minimizing damage to the underlying structure.

[0040] Polydicyclopentadiene (PDCPD), for example, is a matrix material for use in composite armor systems. PDCPD offers several advantages over traditional resins, including low viscosity during molding, rapid polymerization, and excellent impact resistance. These properties make PDCPD an ideal choice for creating durable and lightweight composite armor plates. The use of PDCPD as a matrix material also enhances the overall toughness of the armor, reducing the risk of cracking and delamination under high-stress conditions.

[0041] In addition to its ballistic resistance, composite armor offers superior resistance to environmental factors such as moisture, chemicals, and UV radiation. This makes composite armor suitable for use in a wide range of environments, from arid deserts to humid jungles. The durability of composite armor ensures that it can withstand harsh conditions without compromising its protective capabilities.

[0042] Modem composite armor systems are designed to provide protection against a variety of threats, including high-velocity rifle rounds, armor-piercing rounds, and explosive blasts. By adjusting the materials and configuration of the composite layers, manufacturers can tailor the armor to meet specific performance criteria. For example, some composite armor plates are designed to provide maximum protection against armor-piercing rounds, while others are optimized to reduce the impact of explosive blasts.

[0043] The manufacturing process for composite armor involves several key steps to ensure the integrity and performance of the final product. These steps include preparing the core structure, arranging the composite fiber layers, infusing the layers with a matrix material, curing the resin, and bonding the layers to the core structure.

[0044] The use of advanced manufacturing techniques, such as vacuum-assisted resin transfer molding (VARTM), has further improved the quality and performance of composite armor. VARTM may facilitate uniform distribution of the resin within the fiber layers, mitigating529760.000023or eliminating voids and ensuring consistent performance across the entire armor plate. This process also allows for the production of complex shapes and customized armor solutions to meet specific operational requirements.

[0045] The importance of armor in safeguarding personnel and equipment is significant and widely recognized. The development of composite armor has revolutionized the field of protective equipment, offering lightweight, durable, and highly effective solutions for a variety of applications. By leveraging advanced materials and manufacturing techniques, composite armor systems provide a useful layer of defense in modem combat and security operations.

[0046] Dicyclopentadiene (DCPD) resin is a specialty thermoset polymer derived from the dimerization of cyclopentadiene. Known for its exceptional mechanical and chemical properties, DCPD resin is widely used across various industries, including automotive, marine, construction, and electrical applications. It offers a unique combination of strength, durability, and resistance to environmental degradation, making it a preferred material in manufacturing high-performance composite products.

[0047] One of the defining characteristics of DCPD resin is its low viscosity compared to other thermoset resins, such as unsaturated polyester or epoxy. This low viscosity allows for better fiber wetting and enhanced mold filling during manufacturing processes, resulting in superior composite parts with reduced void content. Furthermore, the reduced viscosity enables faster processing times, improving production efficiency without compromising the mechanical integrity of the final product. This makes DCPD an ideal choice for applications requiring large, complex parts with intricate shapes.

[0048] DCPD resins exhibit exceptional chemical resistance, particularly against hydrocarbons, acids, and bases, which makes them well-suited for environments where exposure to harsh chemicals is common. This property stems from the unique structure of the DCPD molecule, which provides high crosslink density in cured resins. As a result, DCPD-based materials can maintain their structural integrity and performance in aggressive chemical environments, such as storage tanks, pipelines, and chemical containment systems.

[0049] Another notable quality of DCPD resin is its thermal stability and low shrinkage during curing. Unlike many other resins, DCPD exhibits a controlled exothermic reaction during polymerization, reducing internal stresses and minimizing dimensional distortion in the final product. This characteristic makes DCPD particularly advantageous in applications requiring529760.000023tight dimensional tolerances, such as precision tooling and industrial molds. Additionally, its inherent thermal stability enhances its performance in high-temperature environments, maintaining mechanical properties over extended periods.

[0050] Finally, DCPD resin stands out for its cost-effectiveness without sacrificing performance. Compared to more traditional thermoset resins, DCPD offers a balance of affordability and high-end properties, making it a practical choice for manufacturers seeking to optimize performance and reduce production costs. This unique combination of qualities — low viscosity, chemical resistance, thermal stability, and cost efficiency — solidifies DCPD resin as a versatile material for a wide range of demanding applications.

[0051] While both DCPD resin and Kevlar are high-performance materials used in advanced applications, they differ significantly in composition, properties, and primary uses. DCPD resin is a thermosetting polymer known for its chemical resistance, thermal stability, and excellent moldability. It is typically used as a matrix material in fiber-reinforced composites, binding fibers such as fiberglass or carbon fiber to create strong, durable parts. In contrast, Kevlar is an aramid fiber known for its exceptional tensile strength and impact resistance, often used as a reinforcing fiber in composite materials or as a standalone fabric for personal protective equipment like body armor.

[0052] One of the key distinctions lies in the mechanical properties of each material. Kevlar fibers excel in applications requiring high tensile strength and impact resistance, as they are designed to absorb and disperse energy efficiently without breaking. This makes Kevlar ideal for ballistic protection, ropes, and protective clothing. On the other hand, DCPD resin provides compressive strength, dimensional stability, and chemical resistance rather than high tensile properties. It is primarily used to improve the structural integrity of composite components in environments exposed to chemicals, heat, or mechanical stress, such as automotive body panels, industrial tanks, and marine applications.

[0053] Another difference is the role each material may play in composite systems. For example, Kevlar may be typically used as a reinforcing fiber within a composite, while DCPD resin functions as the matrix that binds the reinforcing fibers together. The resin distributes loads across the composite and protects the fibers from environmental degradation. In contrast, Kevlar fibers alone do not possess adhesive or chemical bonding properties and rely on resins, like DCPD or epoxy, to hold them in place within a composite structure. This fundamental distinction529760.000023highlights the complementary roles of DCPD resin as a matrix material and Kevlar as a reinforcing fiber, with each contributing unique performance characteristics depending on the application's needs.

[0054] Now referring to FIG. 1 A, a composite armor plate 1 including a composite armor system 100 is illustrated. While FIG. 1A illustrates a composite armor plate defining a standard shape and size, the composite armor system 100 as described herein may define a variety of shapes and sizes consistent with the application of the composite armor system. For example, in some embodiments, composite armor system 100 may define a shape consistent with that illustrated in FIG. 1A. In other embodiments, composite armor system 100 may define a shape having one or more curves, for example, for armor configured to mold to a female shape, as shown in FIG. IB. In yet other embodiments, composite armor system 100 may define a shape consistent with a vehicle or another person or object. Composite armor system 100 may include a layered core structure 101 as illustrated in the cross-sectional view of FIG. 2, which details the arrangement of the individual material layers that make up the protective system.

[0055] Referring to FIG. 2 in view of FIG. 1, a multilayer core structure 101 is illustrated. Core structure 101 may be designed to provide effective protection by integrating materials with complementary properties. The core structure 101 may include three distinct layers 102, 104, 106, each serving a specific purpose as described further herein. The outermost layer 102 may be formed of ceramic, which is known for its high hardness and ability to disrupt and disperse the kinetic energy of projectiles, such as bullets or shrapnel. Commonly used ceramics include aluminum oxide (AI2O3), boron carbide (B4C), and silicon carbide (SiC), all of which contribute to the system's effectiveness in stopping high-velocity impacts. In other embodiments, outermost layer 102 may be made of aluminum, including an aluminum alloy, or another type of metal or composite.

[0056] Beneath the outermost layer 102 lies a middle layer 104 which may be composed of Kevlar or natural fiber composites. This middle layer 104 is configured to absorb and distribute the residual energy from the outermost layer 102, reducing the likelihood of penetration and minimizing blunt force trauma to the user. Kevlar, known for its high tensile strength and energy absorption capabilities, is a common choice for this purpose, though natural fiber composites may also be employed depending on the specific application.529760.000023

[0057] The innermost layer 106 may be made of aluminum, including an aluminum alloy, which provides structural support and ensures the overall integrity of the armor system under stress. This innermost layer 106 adds rigidity and helps maintain the form of the armor during impacts, complementing the protective properties of the other layers 102, 104. Together, these three layers 102, 104, 106 create a lightweight and highly effective core structure 101 for armored systems, suitable for applications such as personal body armor or vehicle armor. In other embodiments, innermost layer 106 may be made of another type of metal or composite.

[0058] While the layers 102, 104, 106 of core structure 101 are illustrated as having relative thicknesses to each other, such represented thickness may vary. In other words, the representative thickness provided in FIG. 2 is intended to be provided in a schematic format only and is not to scale. Various ratios of thickness between layers 102, 104, 106 are contemplated within the disclosure.

[0059] For example, the composite armor system 100 described herein uses a core structure 101 reinforced with multiple composite fiber layers bonded using a PDCPD resin matrix as described further herein. Each layer is designed to provide specific ballistic resistance properties, with fibers oriented in various directions to optimize energy absorption and minimize the risk of penetration. The core structure 101 is carefully selected for its rigidity and strength to act as a backbone for the entire armor system.

[0060] The core structure 101 in the composite armor system can be made from a variety of materials, including steel, aluminum, and / or ceramic as described above. The selection of the core material depends on the intended application and the level of ballistic protection required. For example, in some embodiments, core structure 101 may be a multilayered structure as described above. In other embodiments, steel cores may be used, e.g. for applications requiring higher impact resistance. In yet other embodiments, aluminum cores may provide a lighter alternative suitable for mobile units. In other embodiments, ceramic cores may offer excellent hardness and may be particularly effective against armor-piercing rounds. The core structure may also include perforations to reduce weight without compromising its structural integrity. In some embodiments, the core structure may include a combination of these materials.

[0061] Composite armor system 100 may use poly di cyclopentadiene (PDCPD) as the primary matrix material in the composite fiber layers. PDCPD is known for its low viscosity during molding, which facilitates thorough impregnation of the fiber layers. Additionally,529760.000023PDCPD polymerizes rapidly and forms a tough, impact-resistant matrix which may significantly enhance the ballistic performance of the armor system. The use of PDCPD may also reduce the risk of cracking and delamination under high-stress conditions.

[0062] Composite fiber layers can be made from a variety of fibers, including carbon fibers, aramid fibers (such as Kevlar), and glass fibers. Each type of fiber offers distinct advantages: carbon fibers provide high strength and stiffness, aramid fibers offer superior energy absorption, and glass fibers are cost-effective and resistant to environmental degradation. By combining different types of fibers, the armor can be tailored to meet specific performance criteria.

[0063] The orientation of the fibers within each composite layer is carefully controlled to optimize impact resistance. Fibers may be arranged in unidirectional, woven, or random orientations, depending on the desired properties of the armor. For example, unidirectional fibers are highly effective at absorbing impact energy along a specific axis, while woven fibers provide multidirectional protection. The combination of various fiber orientations ensures that the armor plate can withstand impacts from different angles.

[0064] The composite layers may be bonded to the core structure 101 using specialized adhesives to facilitate strong, durable bonds which prevent or mitigate delamination. These adhesives may be compatible with both the PDCPD matrix and the core material to facilitate long-term performance. In some embodiments, the bonding process may involve additional mechanical fasteners or surface treatments to enhance adhesion.

[0065] In some embodiments, distribution of the resin within the fiber layers is substantially uniform. Such distribution may be attained by using a vacuum-assisted resin transfer molding (VARTM) process. For example, VARTM involves placing the fiber layers and core structure in a sealed mold and applying vacuum pressure to draw the PDCPD resin into the mold. This process facilitates full impregnation of the fiber layers with the resin, mitigating or eliminating the presence of voids to facilitate consistent performance.

[0066] After the resin has been infused into the fiber layers, the mold may be subjected to controlled temperature conditions to polymerize the PDCPD resin. In other words, the PDCPD resin and fiber layer composite may be subjected to a predetermined temperature for a predetermined period of time. In some embodiments, the curing process may also involve applying additional pressure to further compact the composite layers and improve bonding.529760.000023

[0067] The outer strike face 108 of the composite armor system 100 (e.g., consistent with an outer surface 108 of the outermost layer 102) is designed to be the first point of contact with a ballistic threat. As such, outermost layer 102 may include high-strength fibers such as carbon or aramid fibers, impregnated with the PDCPD matrix, to facilitate durability in view of high-velocity impacts and distribution of energy across the corresponding armor plate 100. The outer strike face 108 may also include additional surface treatments to improve abrasion resistance.

[0068] Beneath outer strike face 108 or outermost layer 102 are one or more intermediate layers (e.g., middle layer 104), which serve to absorb and dissipate the energy of the impact. Middle layer(s) 104 may be composed of composite fibers oriented in various directions to provide multidirectional protection. The use of multiple intermediate layers 104 may allow the armor to gradually absorb impact energy, reducing the likelihood of penetration and minimizing damage to the core structure 101.

[0069] The back face 110 (e.g., consistent with outer surface 110 of the innermost layer 106) of the composite armor system 100 is designed to mitigate or prevent spalling and provide additional impact resistance. For example, in some instances, spalling may occur in conventional armor plates when fragments of the armor plate are ejected upon impact, posing a secondary threat to the wearer. The back face 110 may include aramid fibers, which are known for their ability to absorb energy and prevent or mitigate spalling. This layer also provides a final barrier against penetration.

[0070] In some embodiments, the composite armor system 100 may include additional layers or coatings to enhance its performance. For example, an outer coating may be applied to improve weather resistance or reduce the armor's visibility to certain types of sensors. Additional layers may also be added to improve resistance to specific threats, such as chemical or thermal attacks.

[0071] The weight of the composite armor system described herein may be a consideration in mobile applications, for example. By using lightweight materials such as PDCPD and optimizing the design of the composite layers, the disclosure achieves a balance between protection and mobility. The use of a perforated core structure 101 may further reduce weight without compromising performance.

[0072] The manufacturing process for the composite armor system can be adapted to produce armor of various shapes and sizes. This flexibility is achieved by using molds that can529760.000023be customized to the desired dimensions. The VARTM process also allows for the production of complex shapes, making the armor suitable for a wide range of applications, from personal protective equipment to vehicle armor.

[0073] In some embodiments, damaged composite layers can be replaced or reinforced to restore the armor's protective capabilities. The use of PDCPD as a matrix material simplifies the repair process, as the resin can be re-applied and cured to bond new layers to the existing structure.

[0074] In addition to its ballistic resistance, the composite armor system 100 may offer resistance to environmental factors. For example, the PDCPD matrix may be highly resistant to chemicals, moisture, and UV radiation, ensuring long-term durability. The composite fibers may also be selected for their resistance to environmental degradation, further enhancing the armor's longevity.

[0075] The disclosure can be adapted to provide protection against a wide range of threats. For example, by adjusting the materials and configuration of the composite layers, the armor can be tailored to specific applications. For example, the armor can be optimized to protect against high-velocity rifle rounds, armor-piercing rounds, or explosive blasts. As such, the composite armor system 100 is suitable for a variety of applications, including personal protective equipment, vehicle armor, and structural protection. In personal protective equipment, the armor can be integrated into vests, helmets, and shields. In vehicle armor, it can be used to protect useful areas such as doors, floors, and engine compartments. The system can also be used to protect infrastructure, such as buildings and bridges.

[0076] The use of PDCPD in the composite armor system may also offer environmental benefits. For example, PDCPD can be produced from renewable resources, and the manufacturing process may generate minimal waste. Additionally, the long lifespan of the armor reduces the need for frequent replacements, further reducing environmental impact.

[0077] The composite armor system 100 can be integrated with other protective technologies to enhance its performance. For example, sensors can be embedded in the armor to detect impacts and provide real-time data on the condition of the armor. This information can be used to assess the need for repairs or replacements, ensuring that the armor remains effective over time.529760.000023

[0078] The composite armor system 100 may be customized for a variety of applications. For example, composite armor system 100 may include colored resins, surface coatings, or embedded patterns at the discretion of the manufacturer. Customization options allow the armor to be tailored to specific aesthetic or operational requirements.

[0079] The composite armor system 100 is designed to be compatible with existing protective equipment. This ensures that it can be easily integrated into current systems without requiring significant modifications. The modular design of the armor also allows for easy upgrades and replacements, ensuring long-term usability.

[0080] The disclosed technology encompasses a range of advanced manufacturing techniques and materials to produce high-performance protective systems, including bladder molding as a manufacturing process in some embodiments. Bladder molding may faciltiate the application of higher pressures compared to vacuum-based methods, resulting in improved material consolidation and structural integrity. Additionally, this process reduces manufacturing time, making it particularly advantageous for applications requiring precision, efficiency, and consistent quality.

[0081] The described approach supports the integration of a variety of reinforcing fibers to tailor performance characteristics to specific applications. While carbon fiber is the primary material used across most armor systems due to its exceptional strength-to- weight ratio, other fibers, such as Spectra, fiberglass, and basalt, are strategically employed in specific components to optimize performance. Kevlar, the second most commonly used fiber, is incorporated in select areas to provide additional impact resistance and durability. The flexibility to incorporate a wide range of fibers ensures adaptability to diverse performance requirements and material innovations.

[0082] Now referring to FIG. 3, a method 300 for manufacturing a composite armor system 100 is provided. In some implementations, one or more process blocks of FIG. 3 may be performed by a device.

[0083] At block 302, a core structure (e.g., consistent with core structure 101 of FIG. 2) may be prepared with a strike face (e.g., consistent with outer strike face 108 of FIG. 2) and a back face (e.g., consistent with back face 110 of FIG. 2).

[0084] At block 304, a first plurality of composite fiber plies may be arranged to form a first composite fiber laminate. At block 306, the first composite fiber laminate may be infused529760.000023with a poly di cyclopentadiene (PDCPD) resin matrix. Tn some embodiments, a vacuum-assisted resin transfer molding process may be used for the infusion.

[0085] At block 308, the first resin-infused laminate may be cured to create a first solid structure. At block 310, the formed first solid structure may be bonded to the strike face (e.g., consistent with outer strike face 108 of FIG. 2).

[0086] At block 312, a second plurality of composite fiber plies may be arranged to form a second composite fiber laminate. At block 314, the second composite fiber laminate may be infused with a PDCPD resin matrix.

[0087] At block 316, the second resin-infused laminate may be cured to create a second solid structure. At block 318, the formed second solid structure may be bonded to the back face (e.g., consistent with back face 110 of FIG. 2).

[0088] In some embodiments, method 300 may include additional implementations, such as any single implementation or any combination of implementations described below and / or in connection with one or more other processes described elsewhere herein. In other embodiments, method 300 may not include the arrangement of a second plurality of composite fiber plies or the subsequent illustrated steps.

[0089] In some embodiments, the PDCPD resin matrix may include additives to enhance curing time and impact resistance.

[0090] In some embodiments, method 300 may include application of an outer coating to the strike face (e.g., outer strike face 108 of FIG. 2) to facilitate weather resistance.

[0091] Although FIG. 3 shows example blocks of method 300, in some implementations, method 300 may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted in FIG. 3. Additionally, or alternatively, two or more of the blocks of method 300 may be performed in parallel.

[0092] Now referring to FIG. 4, a second method for manufacturing a composite armor system 100 is provided. In some implementations, one or more process blocks of FIG. 4 may be performed by a device.

[0093] At block 402, a mold assembly is prepared. The mold assembly defines a mold cavity, which may have an inner mold surface defining the desired shape and size of the529760.000023composite armor system to be manufactured. The mold assembly may be configured to additionally accommodate a flexible bladder within the mold cavity.

[0094] At block 404, a flexible bladder is placed within the mold cavity. The bladder may be expandable under pressure and configured to conform to the inner mold surface upon application of pressure.

[0095] At block 406, one or more reinforcement layers may be positioned within the mold cavity. The reinforcement layers may include fibers selected from at least one of carbon fiber, Kevlar, Spectra, fiberglass, basalt, or combinations thereof. In other embodiments, other fibers may be selected as discussed above.

[0096] At block 408, a curable resin may be deposited onto the reinforcement layers. The resin may be, for example, PDCDP as described above. The resin may be configured to impregnate the reinforcement layers upon application of pressure. The resin may be selected to provide desired mechanical and chemical properties in the final composite armor system as described above.

[0097] At block 410, the mold assembly may be assembled, closed, and / or sealed to create a closed molding environment, which facilitates proper alignment of the mold components to maintain dimensional accuracy.

[0098] At block 412, the bladder may be inflated within the mold cavity to a predetermined pressure. The pressure may be sufficient to conform the reinforcement layers and the resin to the inner mold surface, facilitating uniform material distribution and compaction.

[0099] At block 414, the mold assembly may be subjected to a controlled curing cycle. For example, the curing cycle may include a specific combination of predetermined temperature and / or predetermined time duration to facilitate polymerization of the resin and achieve structural integrity in the composite article.[000100] At block 416, the bladder may be deflated upon completion of the curing cycle. The bladder may then be removed from the mold cavity.[000101] Upon completion of method 400, the composite armor system may be removed from the mold for use. In some embodiments, the composite armor system may be trimmed or529760.000023machined in a finalization process. Tn some embodiments, the surface of the composite armor system may be finished in a post-manufacturing process.[000102] In some embodiments, method 400 may include additional implementations, such as any single implementation or any combination of implementations described below and / or in connection with one or more other processes described elsewhere herein.[000103] In some embodiments, the PDCPD resin matrix may include additives to enhance curing time and impact resistance. In some embodiments, method 400 may include application of an outer coating to the composite armor system to facilitate weather resistance.[000104] Although FIG. 4 shows example blocks of method 400, in some implementations, method 400 may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted in FIG. 4. Additionally, or alternatively, two or more of the blocks of method 400 may be performed in parallel.[000105] The following practical examples illustrate specific embodiments and applications of the invention, demonstrating its utility and advantages in various real-world scenarios. These examples are provided to further clarify the technical aspects, performance characteristics, and potential implementations of the disclosed invention. While the examples focus on particular configurations, materials, or processes, they are not intended to limit the scope of the claims. Instead, they showcase how the disclosure can be adapted across a range of use cases to achieve desired outcomes, highlighting both the versatility and innovative nature of the disclosed technology.[000106] In Example 1, a composite armor plate comprising: a core structure having a strike face and a back face, the core structure formed from a material selected from the group consisting of steel, aluminum, and ceramic; a first composite fiber laminate comprising a first plurality of composite fiber plies, wherein each ply is impregnated with a polydicyclopentadiene (PDCPD) resin matrix, said first composite fiber laminate being bonded to the strike face of the core structure to absorb and disperse ballistic impact energy; a second composite fiber laminate comprising a second plurality of composite fiber plies, wherein each ply is impregnated with the PDCPD resin matrix, said second composite fiber laminate being bonded to the back face of the core structure to provide additional structural integrity and spall protection; wherein the PDCPD resin matrix within the first and second composite fiber laminates enhances ballistic resistance529760.000023by improving the energy absorption capacity and mitigating delamination under high-impact conditions.[000107] In Example 2, the composite armor plate as Example 1 describes, wherein the first composite fiber laminate comprises carbon fibers arranged in a woven or unidirectional orientation to optimize tensile strength and stiffness, and the second composite fiber laminate comprises aramid fibers arranged to enhance energy absorption and reduce spalling effects.[000108] In Example 3, the composite armor plate as either of Examples 1 or 2 describe, wherein the core structure is perforated to reduce overall weight while maintaining mechanical strength, with perforation patterns designed to optimize the balance between weight reduction and ballistic resistance.[000109] In Example 4, the composite armor plate as any of Examples 1-3 describe, wherein the PDCPD resin matrix includes additives selected from the group consisting of adhesion promoters, curing agents, and impact modifiers to enhance bonding strength, polymerization rate, and resistance to environmental degradation.[000110] In Example 5, the composite armor plate as any of Examples 1-4 describe, further comprising an outer coating applied to the strike face, said coating comprising a material resistant to abrasion, corrosion, and environmental factors to prolong the lifespan of the armor plate under field conditions.[000111] In Example 6, the composite armor plate as any of Examples 1-5 describe, wherein the first and second composite fiber laminates include fiber plies oriented at varying angles between 0 and 90 relative to a longitudinal axis of the core structure to optimize multidirectional impact resistance.[000112] In Example 7, the composite armor plate as any of Examples 1-6 describe, wherein the core structure comprises a multilayer configuration with alternating layers of metal and composite materials to further enhance ballistic resistance and structural durability.[000113] In Example 8, the composite armor plate as any of Examples 1-7 describe, further comprising an adhesive layer positioned between each composite fiber laminate and the core structure, wherein the adhesive is selected from the group consisting of epoxy-based adhesives, polyurethane adhesives, and thermoplastic adhesives to ensure a durable bond and prevent delamination.529760.000023[000114] In Example 9, the composite armor plate as any of Examples 1-8 describe, wherein the back face is designed to prevent spalling by incorporating a fiber-reinforced layer with high tensile strength to contain fragments generated upon ballistic impact.[000115] In Example 10, the composite armor plate as any of Examples 1-9 describe, wherein the armor plate is manufactured using a vacuum-assisted resin transfer molding (VARTM) process to ensure uniform resin distribution within the composite fiber laminates and reduce void content.[000116] In Example 11, a system for manufacturing a composite armor plate, comprising: a mold configured to hold a core structure and composite fiber layers in a specified arrangement; a vacuum-assisted resin transfer molding (VARTM) system to infuse the composite fiber layers with a polydicyclopentadiene (PDCPD) resin matrix under controlled vacuum pressure; a curing system comprising heating elements and pressure application mechanisms to polymerize the resin and create a solid, impact-resistant composite structure.[000117] In Example 12, the system as Example 11 describes, wherein the mold includes heating elements configured to maintain a consistent curing temperature between 60C and 150C, depending on the catalyst system used in the PDCPD resin matrix.[000118] In Example 13, the system as either of Examples 11 or 12 describe, further comprising an adhesive application system to precisely apply bonding agents between the composite fiber laminates and the core structure to enhance interlayer adhesion and reduce the risk of delamination.[000119] In Example 14, the system as any of Examples 11-13 describe, wherein the VARTM system is equipped with sensors to monitor resin flow and detect voids or air pockets during the infusion process to ensure a high-quality finished product.[000120] In Example 15, the system as any of Examples 11-14 describe, further comprising quality control measures, including non-destructive testing techniques such as ultrasound or X-ray inspection, to verify the integrity and uniformity of the composite armor plate before deployment.[000121] In Example 16, a method for manufacturing a composite armor plate, comprising: preparing a core structure with a strike face and a back face by cleaning and surface-treating the core material to enhance adhesion; arranging a first plurality of composite fiber plies to form a first composite fiber laminate; infusing the first composite fiber laminate with a529760.000023poly di cyclopentadiene (PDCPD) resin matrix using a vacuum-assisted resin transfer molding process to ensure thorough resin penetration and minimize void content; curing the resin-infused first composite fiber laminate under controlled temperature and pressure conditions to form a solid structure; bonding the first composite fiber laminate to the strike face of the core structure using a high-strength adhesive layer.[000122] In Example 17, the method as Example 16 describes, further comprising: arranging a second plurality of composite fiber plies to form a second composite fiber laminate; infusing the second composite fiber laminate with a polydicyclopentadiene (PDCPD) resin matrix using the same vacuum-assisted resin transfer molding process; curing the resin-infused second composite fiber laminate to create a solid structure; bonding the second composite fiber laminate to the back face of the core structure using a high-strength adhesive layer.[000123] In Example 18, the method as either of Examples 16 or 17 describe, wherein the PDCPD resin matrix includes curing agents and impact modifiers to enhance the mechanical properties of the cured composite structure, including increased toughness, adhesion, and resistance to environmental degradation.[000124] In Example 19, the method as any of Examples 16-18 describe, further comprising applying an outer protective coating to the strike face of the composite armor plate, said coating being resistant to abrasion, corrosion, and UV radiation to extend the service life of the armor plate.[000125] In Example 20, the method as any of Examples 16-19 describe, wherein the curing process is conducted in a controlled environment with temperature and pressure parameters optimized for the specific resin and fiber materials used, ensuring consistent polymerization and structural integrity across the entire armor plate.[000126] The foregoing detailed description has been provided for illustrative purposes and is not intended to limit the scope of the invention. It is understood that various changes, modifications, and adaptations may be made to the described embodiments without departing from the spirit and scope of the invention as defined by the claims. The invention encompasses any alternatives, equivalents, and variations that fall within the meaning and range of the claims, as well as all modifications that are within the skill of those in the relevant art.[000127] Unless otherwise indicated, all terms used in the claims are intended to be interpreted in their broadest reasonable sense, consistent with the underlying principles of the529760.000023invention and the ordinary meaning of the terms in the relevant field. Where ranges or values are provided, it should be understood that all intermediate values and subranges are also contemplated, as well as any combination or permutation of the described elements, steps, or features.[000128] The descriptions of specific examples and embodiments are intended to be illustrative and not limiting. It should be understood that the invention is not limited to the specific configurations, methods, or materials disclosed but includes any combinations, modifications, or equivalents that fall within the scope of the claims. The scope of the claims is intended to cover all novel and non-obvious aspects of the invention, whether expressly described herein or inherently present.[000129] Furthermore, it is noted that any features or elements described with reference to a particular embodiment may be combined with features or elements of other embodiments unless explicitly stated otherwise or where such combinations would be incompatible. Accordingly, the invention should not be limited to the examples set forth herein but should be construed in a manner consistent with the claims and their equivalents.

Claims

529760.000023CLAIMSWhat is claimed is:

1. A composite armor system comprising:a core structure having a strike face and a back face;a first composite fiber laminate comprising a first plurality of composite fiber plies, bonded to the strike face of the core structure; anda second composite fiber laminate comprising a second plurality of composite fiber plies, bonded to the back face of the core structure,wherein each composite fiber ply is impregnated with a polydicyclopentadiene (PDCPD) resin.

2. The composite armor system of claim 1, wherein the first composite fiber laminate comprises carbon fibers, and the second composite fiber laminate comprises aramid fibers.

3. The composite armor system of claim 1, wherein the core structure is perforated.

4. The composite armor system of claim 1, wherein the PDCPD resin matrix includes additives.

5. The composite armor system of claim 1, further comprising an outer coating applied to the strike face.

6. The composite armor system of claim 1, wherein the first and second composite fiber laminates include fibers oriented at varying angles.

7. The composite armor system of claim 1, wherein the core structure is comprised of at least one of steel, aluminum, and ceramic.529760.0000238. The composite armor system of claim 1, further comprising an adhesive layer between each composite fiber laminate and the core structure.

9. The composite armor system of claim 1, wherein the back face includes aramid fibers.

10. The composite armor system of claim 1, wherein the composite armor system defines a shape having one or more curves.

11. A method for manufacturing a composite armor system, comprising:preparing a core structure with a strike face and a back face;arranging a first plurality of composite fiber plies to form a first composite fiber laminate; infusing the first composite fiber laminate with a polydicyclopentadiene (PDCPD) resin matrix;curing the resin-infused laminate to create a solid structure; andbonding the first composite fiber laminate to the strike face of the core structure.

12. The method of claim 11, wherein the first composite fiber laminate is infused with the PDCPD resin matrix using a vacuum-assisted resin transfer molding process.

13. The method of claim 11, further comprising:arranging a second plurality of composite fiber plies to form a second composite fiber laminate;infusing the second composite fiber laminate with a polydicyclopentadiene (PDCPD) resin matrix; andbonding the second composite fiber laminate to the back face of the core structure.529760.00002314. The method of claim 11, wherein the PDCPD resin matrix includes additives.

15. The method of claim 11, further comprising applying an outer coating to the strike face.

16. A method for manufacturing a composite armor system, the method comprising:placing an inflatable bladder within a mold cavity of a mold assembly;positioning a reinforcement layer within the mold cavity;depositing a resin onto the reinforcement layer;closing the mold assembly;inflating the inflatable bladder; andconducting a curing cycle, wherein the curing cycle includes placing the mold assembly at a predetermined temperature for a predetermined duration of time.

17. The method of claim 16, wherein the reinforcement layer comprises fibers of at least one of carbon fiber, Kevlar, Spectra, fiberglass, and basalt.

18. The method of claim 16, wherein the resin comprises polydicyclopentadiene (PDCPD).

19. The method of claim 16, wherein the inflatable bladder is inflated to a predetermined pressure.

20. The method of claim 16, wherein the reinforcement layer includes a plurality of reinforcement layers.

21. The method of claim 16, further comprising removing the reinforcement layer from the mold cavity after completion of the curing cycle and at least one of trimming, machining, or surface finishing the cured reinforcement layer.529760.00002322. The method of claim 16, wherein the mold cavity defines a shape having one or more curves.

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