A ballistic armour with a composite layer

Abstract

The present disclosure relates to the field of ballistic protection, including materials, structures, and production methods for improving resistance to ballistic threats, impact forces, and penetration. It includes a ballistic armour (20) comprising composite layer (11, 12). Such layer may be associated with a ballistic core (20) and a hard surface ballistic layer (30), forming the ballistic armour (10). The composite layer (11, 12) of the present disclosure enables an enhanced and reliable binding to a ballistic core (20) – whichever is the type of ballistic core (20) used – and an enhanced protection to heat.

Description

[0001] DESCRIPTION

[0002] A BALLISTIC ARMOUR WITH A COMPOSITE LAYER

[0003] FIELD OF THE INVENTION

[0004]

[0001] The present disclosure relates to the field of ballistic protection, including materials, structures, and production methods for improving resistance to ballistic threats, impact forces, and penetration.

[0005] PRIOR ART

[0006]

[0002] Ballistic protection systems traditionally employ layered configurations, combining a hard strike-face material with an energy-absorbing core to mitigate the impact of ballistic threats.

[0007]

[0003] The hard surface material, typically composed of ceramic (e.g., alumina, silicon carbide, or boron carbide) or steel, serves to disrupt, fragment, and deform incoming projectiles, thereby reducing their penetration capability.

[0008]

[0004] The underlying core, which may consist of polyethylene (e.g., ultra-high-molecular-weight polyethylene - UHMWPE), fibreglass, or aramid fibres (e.g., Kevlar®), functions as an energy dissipation layer, absorbing and distributing the residual kinetic energy of the fragmented projectile.

[0009]

[0005] While these conventional layered systems offer effective ballistic resistance, they are often limited by factors such as weight, bulk, brittleness, and manufacturing constraints.

[0010]

[0006] The present disclosure provides an enhanced protection, suitable for varied solutions, including wearable and vehicular solutions, and which allows to improve the fragmentation capabilities of ballistic cores and to better associate ballistic cores with hard surface materials.

[0011] SUMMARY OF THE DISCLOSURE

[0012]

[0007] The present disclosure comprises a composite layer for a ballistic armour comprising a carbon fabric impregnated with an embedding composite comprising a polyethylene-based composition and at least one carbon-based material, theimpregnation of the embedding composite in the carbon fabric being such that at least one face of the carbon fabric is impregnated.

[0013]

[0008] The ballistic armour comprising a composite layer, a ballistic core and a hard surface ballistic layer, wherein

[0014] the composite layer comprises a carbon fabric impregnated with an embedding composite comprising a polyethylene-based composition or a thermosetting polymer and at least one carbon-based material, the impregnation of the embedding composite in the carbon fabric being such that at least one face of the carbon fabric is impregnated,

[0015] wherein the composite layer is provided between the hard surface ballistic layer and the ballistic core, an impregnated face of the carbon fabric facing the ballistic core and an adhesive being provided on the opposite surface of the composite layer, thereby binding such opposite face to the hard surface ballistic layer, and the ballistic core and the composite layer being bound by means of the embedding composite.

[0016]

[0009] The impregnation may be performed by uniformly depositing the embedding composite over one of the faces of the carbon fabric.

[0017]

[0010] The uniform depositing of the embedding composite over one of the faces of the carbon fabric may be performed by extruding the embedding composite over the said face.

[0018]

[0011] The impregnation of the embedding composite in the carbon fabric may be such that only one face of the carbon fabric is impregnated.

[0019]

[0012] The ballistic core may comprise polyethylene, such as ultra-high-molecular-weight polyethylene (UHMWPE) and the embedding composite is correspondingly a polyethylene-based composition or the ballistic core may comprise aramid fibres and the embedding composite is correspondingly a thermosetting polymer.

[0020]

[0013] The thickness of the deposited embedding composite in the carbon fabric may be of 20-40 pm, optionally 30 pm.

[0021]

[0014] The carbon-based materials may comprise one or more of the following: carbon nanotubes, graphene or carbon black.

[0022]

[0015] The mass per unit area of the carbon fabric may be of at least 100 g / m2, optionally 100-300 g / m2, optionally of 150-250 g / m2, optionally of 200 g / m2.

[0016] The carbon fabric may be formed by a first plurality of threads arranged in a first direction and a second plurality of threads arranged in a second direction, the angle between the first and second directions being between 45° and 90°. The angle may be of 90°.

[0023]

[0017] The carbon fabric may comprise a third plurality of threads arranged in a third direction with the first and second pluralities of threads, the angle between the first and second directions being between substantially of 50-90°, optionally 90°, and the angle between the third and second directions being substantially of 40-50° optionally 45°.

[0024]

[0018] The polyethylene-based composition may comprise, optionally consist of, ultra-high-molecular-weight polyethylene (UHMWPE).

[0025]

[0019] The carbon fabric may be a woven carbon fabric. Alternatively, the carbon fabric may be a non-woven carbon fabric.

[0026]

[0020] The present disclosure may further comprise a ballistic armour comprising the composite layer of the present disclosure and a ballistic core, the ballistic core and the composite layer being bound by means of the embedding composite.

[0027]

[0021] The ballistic armour may further comprise a hard surface ballistic layer, the composite layer being according to claim 4 and being provided between the hard surface ballistic layer and the ballistic core, the impregnated face of the carbon fabric facing the ballistic core and an adhesive being provided on the opposite surface of the composite layer, thereby binding such opposite face to the hard surface ballistic layer.

[0028]

[0022] The hard surface ballistic layer may be a ceramic or steel based surface.

[0029]

[0023] The thermosetting polymer may be based on an epoxy, acrylic, silicone, vinyl ester, polyurethane or a combination thereof.

[0030]

[0024] The ballistic armour may further comprise a second composite layer according to the present disclosure, the second composite layer being bound by means of its embedding composite to a face of the ballistic core opposite to the face in which the first composite layer is provided.

[0031]

[0025] The present disclosure may also comprise a ballistic protection apparatus, such as a vest, jacket, waistcoat, helmet, or fixed shielding, the object comprising the ballistic armour of the present disclosure. The present disclosure may alsocomprise a mobile body, such as a vehicle, satellite, aircraft, drone, train, bus, ship orvessel, the body comprisingthe ballistic armour of the present disclosure.

[0032]

[0026] The present disclosure may also comprise the use of the composite layer of any of the present disclosure as a layer of a ballistic armour, optionally the ballistic armour comprising a ballistic core, and the composite layer is bound by means of the embedding composite.

[0033]

[0027] The present disclosure may also comprise a method for producing a composite layer for a ballistic armour, the method comprising

[0034] providing a carbon fabric,

[0035] providing an embedding composite, the embedding composite comprising a polyethylene-based composition and at least one carbonbased material,

[0036] impregnating the carbon fabric with the embedding composite such that at least one face of the carbon fabric is impregnated.

[0037]

[0028] The present disclosure includes a method for producing ballistic armour comprising

[0038] providing a carbon fabric,

[0039] providing an embedding composite, the embedding composite comprising a polyethylene-based composition and at least one carbonbased material,

[0040] impregnating the carbon fabric with the embedding composite such that at least one face of the carbon fabric is impregnated thereby obtaining a composite layer,

[0041] providing a ballistic core,

[0042] binding the ballistic core and the composite layer by means of the embedding composite,

[0043] providing a hard surface ballistic layer,

[0044] the composite layer being provided on top of the ballistic core and the hard surface ballistic layer being provided on top of the composite layer, such that the impregnated face of the carbon fabric faces the ballistic core,wherein an adhesive is provided on the surface of the composite layer opposite to the ballistic core, facing the hard surface ballistic layer thereby binding such opposite face to the hard surface ballistic layer.

[0045]

[0029] The impregnation may be performed by uniformly depositing the embedding composite over one of the faces of the carbon fabric.

[0046]

[0030] The uniform depositing of the embedding composite over one of the faces of the carbon fabric may be performed by extruding the embedding composite over the said face.

[0047]

[0031] The mixture of the polyethylene-based composition and the carbon-based material may be performed in the extrusion procedure of the embedding composite.

[0048]

[0032] The mixture of the polyethylene-based composition and the carbon-based material may be performed by means of a worm drive.

[0049]

[0033] The impregnation of the embedding composite in the carbon fabric may be such that only one face of the carbon fabric is impregnated.

[0050]

[0034] The impregnation may be such that the thickness of the embedding composite in the carbon fabric is of 20-40 pm, optionally 30 pm.

[0051]

[0035] The carbon-based materials may comprise one or more of the following: carbon nanotubes, graphene or carbon black.

[0052]

[0036] The mass per unit area of the carbon fabric may be of at least 100 g / m2, optionally 100-300 g / m2, optionally of 150-250 g / m2, optionally of 200 g / m2.

[0053]

[0037] The carbon fabric may be formed by a first plurality of threads arranged in a first direction and a second plurality of threads arranged in a second direction, the angle between the first and second directions being between 45° and 90°, optionally 90°, optionally the carbon fabric comprising a third plurality of threads arranged in a third direction with the first and second pluralities of threads, the angle between the first and second directions being between substantially of 50-90°, optionally 90°, and the angle between thethird and second directions beingsubstantially of 40-50°, optionally 45°.

[0054]

[0038] The hard surface ballistic layer may be a ceramic or steel based surface.

[0055]

[0039] The composite layer may be accordingto claim 4 or the method for producing a composite layer is according to claim 15, the method for producing a ballisticarmour being such that a face of the composite layer opposite to the ballistic core is left uncovered, thereby forming an exposed surface of the ballistic armour.

[0056]

[0040] The method of producing a ballistic armour may further comprise providing a second composite layer according to the present disclosure or obtained by means of a method for producing a composite layer according to the present disclosure,

[0057] binding, by means of the embedding composite of the second composite layer, the second composite layer to a face of the ballistic core opposite to the face in which the first composite layer is provided.

[0058]

[0041] The present disclosure mayfurther comprise a drone in turn comprising: a fuselage defining an internal volume for housing a plurality of components including electronic components and a propulsion system;

[0059] at least one wing or lifting surface coupled to the fuselage; and

[0060] an external skin covering at least a portion of the fuselage and the at least one wing or lifting surface,

[0061] wherein the external skin is formed from the ballistic armour of the present disclosure.

[0062] DESCRIPTION OF FIGURES

[0063]

[0042] Figure 1 - a schematic representation of a ballistic armour (10) according to the present disclosure, including a ballistic core (20), a first composite layer (11) provided above the ballistic core (20) and a second composite layer (12) provided below the ballistic core (20), and a hard surface ballistic layer (30) provided above the first composite layer (11). In such case, each composite layer (11,12) has a carbon fabric fully impregnated with the embedding composite.

[0064]

[0043] Figure 2 - a schematic representation of the method for producing a composite layer for a ballistic armour of the present disclosure, the method comprising: providing a carbon fabric (210), providing an embedding composite (220), and impregnatingthe carbon fabric with the embedding composite (230).

[0065]

[0044] Figure 3 - a schematic representation of the method for producing a ballistic armour of the present disclosure, the method comprising: providing a compositelayer (310), providing a ballistic core (320) and binding the ballistic core and the composite layer by means of the embedding composite (330).

[0066] DETAILED DESCRIPTION

[0067]

[0045] The several aspects of the objects of the present disclosure are detailed subsequently.

[0068]

[0046] The present disclosure includes a composite layer (11, 12) for a ballistic armour (10) and the ballistic armour (10). Such layer (11, 12) is associated with a ballistic core (20) or with a ballistic core (20) and a hard surface ballistic layer (30), in both cases forming a ballistic armour (10).

[0069]

[0047] The composite layer (11, 12) of the present disclosure enables an enhanced and reliable binding to a ballistic core (20) - whichever is the type of ballistic core (20) used - and an enhanced protection to heat.

[0070]

[0048] It reaches these enhanced effects by comprising a carbon fabric impregnated with an embedding composite comprising a polyethylene-based composition or a thermosetting polymer and at least one carbon-based material, the impregnation of the embedding composite in the carbon fabric being such that at least one face of the carbon fabric is impregnated. The embedding composite, while impregnating the carbon fabric, forms a film within the carbon fabric.

[0071]

[0049] The ballistic core (20) may comprise polyethylene, such as ultra-high-molecular-weight polyethylene (UHMWPE), in which case the embedding composite is a polyethylene-based composition. The ballistic core (20) may alternatively comprise aramid fibres, in which case the embedding composite is a thermosetting polymer.

[0072]

[0050] The carbon fabric may be defined as a textile material composed of interlaced carbon fibre strands, arranged in a weave pattern. The fibres may be, for instance, high-strength continuous carbon fibres woven into bidirectional (e.g., plain, twill, or satin weave) or multidirectional fabrics.

[0073]

[0051] The polyethylene-based composition and the carbon-based material are combined, forming the embedding composite, in a manner such that they can impregnate the carbon fabric.

[0052] By becoming impregnated with the embedding composite, the carbon fabric becomes resistant to heat and better binds with a ballistic core (20). In addition, it forms a further layer of fragmentation able to be associated with a ballistic core (20).

[0074]

[0053] The impregnation may be such that the embedding composite is uniformly deposited over one of the faces of the carbon fabric, thereby uniformly covering at least such face and a predefined depth of the carbon fabric.

[0075]

[0054] Specifically, the uniform depositing of the embedding composite over one of the faces of the carbon fabric may be performed by extruding the embedding composite over the said face.

[0076]

[0055] The impregnation of the embedding composite in the carbon fabric may be such that only one face of the carbon fabric is impregnated, thereby enabling that the opposite face of the carbon fabric is not covered or impregnated with the embedding composite. By being left uncovered / not impregnated, such opposite face of the carbon fabric may be bound to other structures, such as a ceramic or steel hard surface layer, for instance by means of an adhesive.

[0077]

[0056] The impregnation of the embedding composite in the carbon fabric may, alternatively, be such that the carbon fabric is fully impregnated, thereby enabling that both faces of the carbon fabric are covered / impregnated by the embedding composite, i.e., the carbon fabric becomes fully impregnated with the embedding composite. The fully impregnated carbon fabric thereby becomes, itself, a light surface layer, when associated with a ballistic core (20), which enables protection to heat and enhanced fragmentation of projectiles, especially for projectile calibres up to.

[0078]

[0057] The thickness of the embedding composite in the carbon fabric may be of 20-40 pm, optionally 30 pm.

[0079]

[0058] The mass per unit area of the embedding composite may be of 25-75 g / m2, optionally 75 g / m2.

[0080]

[0059] The carbon-based materials may comprise one or more of the following: carbon nanotubes, graphene or carbon black.

[0081]

[0060] Carbon nanotubes (CNTs) may include cylindrical nanostructures composed of carbon atoms arranged in a hexagonal lattice, with diameters typically rangingfrom 0.4 nm to 100 nm and lengths extendingfrom 50 nm to 1 pm, and mayinclude single-walled carbon nanotubes (SWCNTs), consisting of a single graphene sheet rolled into a tube, or multi-walled carbon nanotubes (MWCNTs), composed of multiple concentric graphene cylinders.

[0082]

[0061] Graphene may be defined as a two-dimensional nanomaterial consisting of a single layer of carbon atoms arranged in a hexagonal lattice, and which may have a and lateral dimensions rangingfrom 10 nm 2 pm.

[0083]

[0062] Carbon black may include a black powder composed of fine particles of elemental carbon, which may be obtained through an incomplete combustion or thermal decomposition of hydrocarbons such as oil or gas. Carbon black particles may have an average size of 10 nm to 500 nm, optionally 10-50 nm.

[0084]

[0063] The mass per unit area of the carbon fabric may also be referred to as the areal density of the carbon fabric. The mass per unit area of the carbon fabric may be of at least 100 g / m2, optionally 100-300 g / m2, optionally of 150-250 g / m2, optionally of 200 g / m2, thereby providing a mass to be impregnated with the embedding composite.

[0085]

[0064] The carbon fabric may be formed by a first plurality of threads arranged in a first direction and a second plurality of threads arranged in a second direction, the angle between the first and second directions being between 45° and 90°, optionally 90°, thereby forming a fabric which is impregnated with the embedding composite.

[0086]

[0065] The carbon fabric may also comprise a third plurality of threads arranged in a third direction with the first and second pluralities of threads, the angle between the first and second directions being between substantially of 50-90°, optionally 90°, and the angle between the third and second directions being substantially of 40-50°, optionally 45°, thereby forming a denser fabric to be is impregnated with the embedding composite.

[0087]

[0066] The polyethylene-based composition may comprise ultra-high-molecular-weight polyethylene (UHMWPE).

[0088]

[0067] The thermosetting polymer may be based on an epoxy, acrylic, silicone, vinyl ester, polyurethane or a combination thereof.

[0089]

[0068] The carbon fabric is a woven carbon fabric or a non-woven carbon fabric.

[0090]

[0069] The present disclosure also includes a ballistic armour (10) comprising the composite layer (11, 12) of the present disclosure and a ballistic core (20). Theballistic core (20) forms an energy-absorbing layer of the ballistic armour (10) which dissipates and distributes the kinetic energy of an incoming projectile, desirably after initial impact and fragmentation.

[0091]

[0070] It may, for instance, be made from polyethylene (e.g., ultra-high-molecular-weight polyethylene - UHMWPE), fibreglass, or aramid fibres (e.g., Kevlar®), absorbing and distributing the residual kinetic energy of a fragmented projectile.

[0092]

[0071] The ballistic core (20) and the composite layer (11, 12) are bound by means of the embedding composite, providing a reliable and durable binding, the composite layer (11, 12) operating as a fragmentation and heat resistant barrier.

[0093]

[0072] Bindingthe ballistic core (20) and composite layer (11, 12) may be performed by melting adhesion of the two layers through the embedding composite. A face of the composite layer (11, 12) impregnated with the embedding composite is provided on top and in contact with a face of the ballistic core (20), and the ensemble is submitted to heat and pressure, thereby performing a melting adhesion between ballistic core (20) and composite layer (11 , 12) by means of the embedding composite.

[0094]

[0073] The composite layer (11, 12) may be such that only one face of the carbon fabric is impregnated. In such case, the ballistic armour (10) may further comprise a hard surface ballistic layer (30), such that the composite layer (11 , 12) is provided between the hard surface ballistic layer (30) and the ballistic core (20).

[0095]

[0074] The impregnated face of the carbon fabric faces the ballistic core (20) and an adhesive is provided on the opposite surface, binding it to the hard surface ballistic layer (30).

[0096]

[0075] One of the faces of the composite layer (11, 12) is, thus, left not impregnated such that it may adhere to the adhesive, allowingthe binding / connection to the hard surface ballistic layer (30).

[0097]

[0076] The hard surface ballistic layer (30) may a ceramic (e.g., alumina, silicon carbide, or boron carbide) or steel based surface, operating as a surface layer to disrupt, fragment, and deform incoming projectiles, thereby reducing their penetration capability.

[0098]

[0077]

[0078] The ballistic armour (10) may further comprise a second composite layer (11, 12) according to the present disclosure. In such case, the second composite layer (11, 12) is also bound by means of its embedding composite to a face of the ballistic core (20) opposite to the face in which the first composite layer (11, 12) is provided. The first composite layer (11, 12) consists of the layer which either is provided between the ballistic core (20) and the hard surface ballistic layer (30) or which operates itself as surface layer. The second composite layer (11, 12) thereby provides an enhanced finishing to a face of the ballistic core (20) which would otherwise be left uncovered.

[0099]

[0079] The present disclosure also includes a ballistic protection apparatus, such as a vest, jacket, waistcoat, helmet, orfixed shielding, the apparatus comprising the ballistic armour (10) of the present disclosure. For instance, the ballistic armour (10) of the present disclosure may be provided within a wearable object: a vest, jacket, waistcoat, or a vehicular protection panel of a mobile body, in a vehicle, satellite, aircraft, drone, train, bus, ship, vessel or fixed shielding, enabling it to be bulletproof.

[0100]

[0080] The present disclosure further comprises the use of the composite layer (11 , 12) of the present disclosure as a layer of a ballistic armour (10). The ballistic armour (10) may optionally comprise a ballistic core (20), and the composite layer (11, 12) may be bound to such core by means of the embedding composite.

[0101]

[0081] The present disclosure further includes a method for producing a composite layer for a ballistic armour (200).

[0102]

[0082] The composite layer (11, 12) for a ballistic armour (10) of the present disclosure may be obtained through such method.

[0103]

[0083] The method comprises

[0104] providing a carbon fabric (210),

[0105] providing an embedding composite (220), the embedding composite comprising a polyethylene-based composition and at least one carbonbased material,

[0106] impregnating the carbon fabric with the embedding composite such that at least one face of the carbon fabric is impregnated (230).

[0084] The carbon fabric is a textile material composed of interlaced carbon fibre strands, arranged in a weave pattern. The fibres may be, for instance, high-strength continuous carbon fibres woven into bidirectional (e.g., plain, twill, or satin weave) or multidirectional fabrics.

[0107]

[0085] The polyethylene-based composition and the carbon-based material are combined, forming the embedding composite, in a manner such that they can impregnate the carbon fabric. By becoming impregnated with the embedding composite, the carbon fabric becomes resistant to heat and better binds with a ballistic core (20). In addition, it forms a further layer of fragmentation able to be associated with a ballistic core (20).

[0108]

[0086] The impregnation (230) may be performed by uniformly depositing the embedding composite over one of the faces of the carbon fabric.

[0109]

[0087] The uniform depositing of the embedding composite over one of the faces of the carbon fabric may be performed by extruding the embedding composite over the said face.

[0110]

[0088] The mixture of the polyethylene-based composition and the carbon-based material may be performed in the extrusion procedure of the embedding composite. For instance, they may be provided by two different openings, and combined and extruded by means of a worm drive.

[0111]

[0089] The impregnation (230) of the embedding composite in the carbon fabric may be such that only one face of the carbon fabric is impregnated. For instance, the quantity of embedding composite and properties of the carbon fabric, such as its thickness or areal density, may be adapted such that only part of the carbon fabric is impregnated, particularly one face of the fabric, up to a certain thickness lower than the full thickness of the carbon fabric.

[0112]

[0090] Alternatively, the impregnation (230) of the embedding composite in the carbon fabric may be such that the carbon fabric is fully impregnated. In such case, for instance, the quantity of embedding composite and properties of the carbon fabric, such as its thickness or areal density, may be adapted such that only part of the carbon fabric becomes fully impregnated, particularly both faces of the fabric.

[0113]

[0091] Specifically, the impregnation (230) is such that the thickness of the embedding composite in the carbon fabric is of 20-40 pm, optionally 30 pm.

[0092] The carbon-based materials may comprise one or more of the following: carbon nanotubes, graphene or carbon black.

[0114]

[0093] The mass per unit area of the provided carbon fabric may be of at least 100 g / m2, optionally 100-300 g / m2, optionally of 150-250 g / m2, optionally of 200 g / m2.

[0115]

[0094] The carbon fabric may be formed by a first plurality of threads arranged in a first direction interwoven with a second plurality of threads arranged in a second direction, the angle between the first and second directions being between 45° and 90°, optionally 90°.

[0116]

[0095] The carbon fabric may further comprise a third plurality of threads arranged in a third direction interwoven with first and second pluralities of threads, the angle between the first and second directions being between substantially of 50-90°, optionally 90°, and the angle between the third and second directions being substantially of 40-50°, optionally 45°.

[0117]

[0096] The present disclosure further includes a method for producing a ballistic armour (300).

[0118]

[0097] The ballistic armour (10) of the present disclosure may be obtained through such method.

[0119]

[0098] The method comprises

[0120] providing a composite layer (11, 12) according to the present disclosure or performing a method for producing a composite layer (11, 12) according to the present disclosure, in any of the cases obtaining a composite layer (310),

[0121] providing a ballistic core (320),

[0122] binding the ballistic core and the composite layer by means of the embedding composite (330).

[0123]

[0099] Binding the ballistic core and composite layer (330) may be performed by melting adhesion of the two layers through the embedding composite. A face of the composite layer (11, 12) impregnated with the embedding composite is provided on top and in contact with a face of the ballistic core (20), and the ensemble is submitted to heat and pressure, thereby performing a melting adhesion between ballistic core (20) and composite layer (11, 12) by means of the embedding composite.

[0100] Binding the ballistic core and the composite layer by means of the embedding composite (330), through melting adhesion of the ensemble formed by the composite layer (11, 12) and the ballistic core (20) by melting of the embedding composite may be performed by submitting the ensemble to two or more levels of heat and pressure.

[0124]

[0101] The two or more levels of heat and pressure may include i) submitting the ensemble to a preset pressure P1 and a preset temperature T1 during a t1 time interval, ii) subsequently submitting the ensemble to a preset pressure P2 and a preset temperature T2 during a t2 time interval, wherein P2 > Pl and T2 > Tl.

[0125]

[0102] The preset temperature T1 may consist of a temperature gradient ATI = Tl — TO and the preset temperature T2 may consist of a temperature gradient AT2 = T2 — Tl.

[0126]

[0103] After such heating and pressure process, the ensemble may be cooled by means of one or more levels of cooling.

[0127]

[0104] The one or more levels of heat and pressure may include i) submitting the ensemble to a preset pressure P3 and a preset temperature T3 during a t3 time interval wherein P2 > P3 and T2 > T3.

[0128]

[0105] The preset temperature T3 may consist of a temperature gradient AT3 = T2 - T3.

[0129]

[0106] The composite layer (11, 12) may be such that only one face of the carbon fabric is impregnated or the method for producing a composite layer (11, 12) may be such that the deposition of the embedding composite only impregnates one of the faces of the carbon fabric. In such case, the method further comprises providing a hard surface ballistic layer (30),

[0130] the composite layer (11, 12) being provided on top of the ballistic core (20) and the hard surface ballistic layer (30) being provided on top of the composite layer (11, 12), such that the impregnated face of the carbon fabric faces the ballistic core (20), wherein an adhesive is provided on the surface of the composite layer (11, 12) opposite to the ballistic core (20), facingthe hard surface ballistic layer (30), thereby binding such opposite face to the hard surface ballistic layer (30).

[0107] One of the faces of the composite layer (11, 12) is, thus, left not impregnated such that it may adhere to the adhesive, allowin the binding / connection to the hard surface ballistic layer (30).

[0131]

[0108] The hard surface ballistic layer (30) may be a ceramic (e.g., alumina, silicon carbide, or boron carbide) or steel based surface, operating as a surface layer to disrupt, fragment, and deform incoming projectiles, thereby reducing their penetration capability.

[0132]

[0109] The method may further comprise

[0133] providing a second composite layer (11, 12) according to the present disclosure or obtained by means of a method for producing a composite layer (11, 12) according to any the present disclosure,

[0134] binding, by means of the embedding composite of the second composite layer (11, 12), the second composite layer (11 , 12) to a face of the ballistic core (20) opposite to the face in which the first composite layer (11 , 12) is provided.

[0135]

[0110] The first composite layer (11, 12) consists of the layer which either was provided between the ballistic core (20) and the hard surface ballistic layer (30) or which operates itself as surface layer. The second composite layer (11, 12) thereby provides an enhanced finishing to a face of the ballistic core (20) which would otherwise be left uncovered.

[0136] EXAMPLES

[0137]

[0111] An example of the composite layer (11, 12) for a ballistic armour (10) of the present disclosure, Example 1 , comprises carbon woven fabric with fibres at 0° and fibres at 90°, and having a mass per unit area of 200 g / m2. Polyethylene of the embedding composite has a mass per unit area of 50 g / m2reinforced with 1.5 % mass of carbon nanotubes and, when impregnating the carbon woven fabric, partially impregnates up to a thickness of 30 pm.

[0138]

[0112] An example of the ballistic armour (10) of the present disclosure, Example 2, comprises a first composite layer (11, 12) accordingto Example 1 bound by melting adhesion to a first face of ballistic core (20) of polyethylene with a mass per unit area of 20 kg / m2and a thickness of 20 mm.

[0113] It further includes a second composite layer (11, 12) according to Example 1 bound by melting adhesion to a second face of the referred ballistic core (20).

[0139]

[0114] The first composite layer (11 , 12) is further bound to a ceramic or steel hard surface ballistic layer (30) by means of an epoxy or polyurethane-based composition.

[0140]

[0115] Another example of the composite layer (11, 12) for a ballistic armour (10) of the present disclosure, Example 3, comprises carbon woven fabric with fibres at 0° and fibres at 90°, and having a mass per unit area of 200 g / m2. Polyethylene of the embedding composite has a mass per unit area of 100 g / m2reinforced with 1.5 % mass of carbon nanotubes and, when impregnating the carbon woven fabric, fully impregnates up to a thickness of 60 pm.

[0141]

[0116] An example of the ballistic armour (10) of the present disclosure, Example 4, comprises a first composite layer (11, 12) accordingto Example 2 bound by melting adhesion to a first face of ballistic core (20) of polyethylene with a mass per unit area of 20 kg / m2and a thickness of 20 mm.

[0142]

[0117] It further includes a second composite layer (11, 12) accordingto Example 3 bound by melting adhesion to a second face of the referred ballistic core (20).

[0143]

[0118] As previously referred, the two or more levels of heat and pressure may include i) submittingthe ensemble to a preset pressure P1 and a preset temperature T1 during a t1 time interval, ii) subsequently submitting the ensemble to a preset pressure P2 and a preset temperature T2 during a t2 time interval, wherein P2 > Pl and T2 > Tl.

[0144]

[0119] The preset temperature T1 may consist of a temperature gradient ATI = Tl — TO and the preset temperature T2 may consist of a temperature gradient AT2 = T2 — Tl.

[0145]

[0120] P1 may be within a range of 35-45 bar, optionally 40 bar.

[0146]

[0121] P2 may be within a range of 85-95 bar, optionally 90 bar.

[0147]

[0122] P3 may be within a range of 85-95 bar, optionally 90 bar.

[0148]

[0123] T1 may be within a range of 90-110 °C, optionally 100 °C.

[0149]

[0124] T2 may be within a range of 120-150 °C, optionally 135 °C.

[0150]

[0125] T3 may be within a range of 30-40 °C, optionally 40 °C.

[0151]

[0126] The intervals may be within a range of 10-20 minutes, optionally 15 minutes.

[0127] The interval t2 may be within a range of 5-15 minutes, optionally 10 minutes.

[0152]

[0128] The intervalt3 may be within a range of 15-25 minutes, optionally 20 minutes.

[0153]

[0129] The method for producing a composite layer (11, 12) or the method for producing a ballistic armour (10) of the present disclosure may be provided by means of any of the embodiments of the composite layer (11,12) and / or of the ballistic armour of the present disclosure, as herein described.

[0154]

[0130] As will be clear to one skilled in the art, the present disclosure should not be limited to the embodiments presented herein, and a number of changes are possible which remain within the scope of the present disclosure.

[0155]

[0131] Of course, the disclosed embodiments are combinable, in the different possible forms, being herein avoided the repetition all such combinations.

Claims

CLAIMS1. A ballistic armour (10) comprising a composite layer (11 , 12), a ballistic core (20) and a hard surface ballistic layer (30), whereinthe composite layer (11, 12) comprises a carbon fabric impregnated with an embedding composite comprising a polyethylene-based composition or a thermosetting polymer and at least one carbon-based material, the impregnation of the embedding composite in the carbon fabric being such that at least one face of the carbon fabric is impregnated,wherein the composite layer (11, 12) is provided between the hard surface ballistic layer (30) and the ballistic core (20), an impregnated face of the carbon fabric facing the ballistic core (20) and an adhesive being provided on the opposite surface of the composite layer (11, 12), thereby binding such opposite face to the hard surface ballistic layer (30), andthe ballistic core (20) and the composite layer (11, 12) being bound by means of the embedding composite.

2. A ballistic armour (10) accordingto the previous claim, wherein the impregnation is performed by uniformly depositing the embedding composite over one of the faces of the carbon fabric.

3. A ballistic armour (10) according to the previous claim, wherein the uniform depositing of the embedding composite over one of the faces of the carbon fabric is performed by extruding the embedding composite over the said face.

4. A ballistic armour (10) according to any of the preceding claims, wherein the impregnation of the embedding composite in the carbon fabric is such that only one face of the carbon fabric is impregnated.

5. A composite layer according to any of the preceding claims wherein the ballistic core (20) comprises polyethylene, such as ultra-high-molecular-weight polyethylene (UHMWPE) and the embedding composite is a polyethylene-basedcomposition or the ballistic core (20) comprises aramid fibres and the embedding composite is a thermosetting polymer.

6. A ballistic armour (10) according to any of the preceding claims wherein the carbon-based materials comprise one or more of the following: carbon nanotubes, graphene or carbon black.

7. A ballistic armour (10) according to any of the preceding claims wherein the hard surface ballistic layer (30) is a ceramic or steel based surface.

8. A ballistic armour (10) according to any of the preceding claims wherein the thermosetting polymer is based on an epoxy, acrylic, silicone, vinyl ester, polyurethane or a combination thereof.

9. A ballistic protection apparatus, such as a vest, jacket, waistcoat, helmet, or fixed shielding, the apparatus comprising the ballistic armour (10) of any of the preceding claims.

10. A mobile body, such as a vehicle, satellite, aircraft, drone, train, bus, ship or vessel, the apparatus comprising the ballistic armour (10) of any of the claims 1-8.

11. A method for producing ballistic armour (200), the method comprising providing a carbon fabric (210),providing an embedding composite (220), the embedding composite comprising a polyethylene-based composition and at least one carbonbased material,impregnating the carbon fabric with the embedding composite such that at least one face of the carbon fabric is impregnated (230), thereby obtaining a composite layer,providing a ballistic core (320),binding the ballistic core (320) and the composite layer by means of the embedding composite (330),providing a hard surface ballistic layer (30),the composite layer (11, 12) being provided on top of the ballistic core (20) and the hard surface ballistic layer (30) being provided on top of the composite layer (11, 12), such that the impregnated face of the carbon fabric faces the ballistic core (20),wherein an adhesive is provided on the surface of the composite layer (11, 12) opposite to the ballistic core (20), facing the hard surface ballistic layer (30), thereby binding such opposite face to the hard surface ballistic layer (30).

12. A method for producing a ballistic armour (200) according to the previous claim, wherein the impregnation (230) is performed by uniformly depositing the embedding composite over one of the faces of the carbon fabric.

13. A method for producing a ballistic armour (200)accordingto the previous claim, the uniform depositing of the embedding composite over one of the faces of the carbon fabric being performed by extruding the embedding composite over the said face.

14. A method for producing a ballistic armour (200) accordingto the previous claim, the mixture of the polyethylene-based composition and the carbon-based material being performed in the extrusion procedure of the embedding composite, optionally the mixture of the polyethylene-based composition and the carbon-based material being performed by means of a worm drive.

15. A method accordingto any of the claims 11-14, wherein the impregnation (230) of the embedding composite in the carbon fabric is such that only one face of the carbon fabric is impregnated.

16. A drone comprising:a fuselage defining an internal volume for housing a plurality of components including electronic components and a propulsion system;at least one wing or lifting surface coupled to the fuselage; andan external skin covering at least a portion of the fuselage and the at least one wing or lifting surface,wherein the external skin is formed from the ballistic armour (10) of any of the claims 1-8.

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