Light-weight semi-rigid composite anti-ballistic systems with engineered compliance and rate-sensitive impact response

Abstract

Composite anti-ballistic systems having multiple nested sub-laminates manufactured from layers of unidirectional monofilaments made from engineering fibers with anti-ballistic properties embedded in polymer matrix materials and interfacial materials engineered for controlled compliance, deformation, energy release and rate sensitive behavior.

1 . An antiballistic composite comprising:
 (a) multiple sub-laminate layers; and   (b) viscoelastic dilatory material distributed as interlayers between said sub-laminate layers;   wherein said viscoelastic dilatory material converts from soft compliant material to stiff interlayers when said composite is subjected to impact.   
     
     
         2 . The composite of  claim 1 , wherein said viscoelastic dilatory material comprises a rate-sensitive high-rate stiffening polymer or a polymer foam. 
     
     
         3 . The composite of  claim 1 , wherein said viscoelastic dilatory material bonds each of said multiple sub-laminate layers together into a single panel. 
     
     
         4 . The composite of  claim 1 , wherein said interlayers are about 1-10 microns in thickness. 
     
     
         5 . The composite of  claim 1  comprising at least ten sub-laminate layers. 
     
     
         6 . The composite of  claim 1 , wherein each sub-laminate layer comprises at least one unidirectional tape comprising parallel monofilaments embedded in a resin. 
     
     
         7 . The composite of  claim 6 , wherein said monofilaments have diameters less than about 20 microns and wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to about nine times the monofilament major diameter. 
     
     
         8 . The composite of  claim 6 , wherein said monofilaments have modulus greater than 1.0×10 6  psi and failure strength greater than greater than 1.0×10 5  psi. 
     
     
         9 . The composite of  claim 6  comprising two unidirectional tapes oriented as a cross-ply, wherein the parallel monofilaments present in one tape are 90° relative to the parallel monofilaments present in the other tape. 
     
     
         10 . The composite of  claim 6 , wherein said tapes total four in a ply group, and wherein the parallel monofilaments within each of said four tapes have relative orientation of 0°/45°/90°/−45°. 
     
     
         11 . The composite of  claim 6 , wherein said tapes total nine in a ply group, and wherein the parallel monofilaments within each of said nine tapes have a relative orientation of 0°/22.5°/45°/67°/90°/−67°/−45°/−22.5°/0°. 
     
     
         12 . The composite of  claim 6 , wherein said monofilaments are extruded or pultruded. 
     
     
         13 . The composite of  claim 6 , wherein said resin comprises from 1% to 30% of the total areal weight of said tape. 
     
     
         14 . An antiballistic device comprising at least one antiballistic composite, said antiballistic composite comprising:
 (a) multiple sub-laminate layers; and   (b) viscoelastic dilatory material distributed as interlayers between said sub-laminate layers;   wherein said viscoelastic dilatory material converts from soft compliant material to stiff interlayers when said composite is subjected to impact.   
     
     
         15 . The device of  claim 14 , wherein each sub-laminate layer comprises at least one unidirectional tape comprising parallel monofilaments embedded in a resin. 
     
     
         16 . The device of  claim 14  comprising multiple antiballistic composites nested into a plate system. 
     
     
         17 . The device of  claim 14  further comprising a ceramic or metallic component. 
     
     
         18 . The device of  claim 14 , wherein said viscoelastic dilatory material comprises a rate-sensitive high-rate stiffening polymer or a polymer foam. 
     
     
         19 . The device of  claim 14 , wherein said device is worn to provide anti-penetration, load spreading, impact management and shock management to the wearer. 
     
     
         20 . The device of  claim 19 , wherein said device is a vest.