High performance same fiber composite hybrids by varying resin content only

Abstract

Multi-panel ballistic resistant articles formed from woven and/or non-woven fibrous panels, each panel including varying quantities of a polymeric composition based on the total weight of the fibers and the polymeric composition. The hybrid structures provide excellent ballistic penetration resistance while maintaining a low weight. The ballistic resistant articles may be strategically positioned to dial in different levels of desired ballistic resistance for various applications.

What is claimed is: 
     
         1 . A ballistic resistant material comprising:
 a first panel and a second panel, each comprising a plurality of fibrous layers, said plurality of fibrous layers being consolidated; each of the fibrous layers comprising a plurality of fibers, said fibers in each of said fibrous layers being the same in each panel and having a tenacity of 7 g/denier or more and a tensile modulus of 150 g/denier or more; each of said fibers having a surface, wherein the surfaces of the fibers of said first panel are coated with a polymeric matrix composition; and wherein the second panel comprises fibers that are not coated with a polymeric matrix composition.   
     
     
         2 . The ballistic resistant material of  claim 1  wherein both the first panel and the second panel comprise a plurality of non-woven fibrous layers. 
     
     
         3 . The ballistic resistant material of  claim 1  wherein the second panel is polymeric matrix-free, wherein the second panel consists of fibers that are not coated with a polymeric matrix composition, and wherein the first panel and the second panel are juxtaposed with each other in a non-bonded array. 
     
     
         4 . The ballistic resistant material of  claim 1  further comprising at least one rigid plate attached to an outer surface of the first panel, said rigid plate comprising a ceramic, glass, a metal-filled composite, a ceramic-filled composite, a glass-filled composite, a cermet, high hardness steel, an armor aluminum alloy, titanium or a combination thereof. 
     
     
         5 . The ballistic resistant material of  claim 1  wherein the first panel and the second panel are juxtaposed with each other in a non-bonded array. 
     
     
         6 . The ballistic resistant material of  claim 1  wherein the material consists of the first panel and the second panel, wherein the first panel and the second panel are juxtaposed with each other in a non-bonded array, and wherein the second panel consists of fibers that are not coated with a polymeric matrix composition. 
     
     
         7 . A hard armor article comprising the ballistic resistant material of  claim 1 , wherein the article is a helmet or a vehicle panel. 
     
     
         8 . A ballistic resistant material comprising, in order:
 a) a first panel comprising a plurality of fibrous layers, said plurality of fibrous layers being consolidated; each of the fibrous layers comprising a plurality of fibers, said fibers having a tenacity of 7 g/denier or more and a tensile modulus of 150 g/denier or more; each of said fibers having a surface, and the surfaces of said fibers being coated with a polymeric matrix composition; and   b) a second panel attached to the first panel, which second panel is different than the first panel, and which second panel comprises a plurality of fibrous layers, said plurality of fibrous layers being consolidated; each of the fibrous layers comprising a plurality of fibers, said fibers having a tenacity of 7 g/denier or more and a tensile modulus of 150 g/denier or more; each of said fibers having a surface, and the surfaces of said fibers being coated with a polymeric matrix composition; and   said first panel containing a greater percentage by weight of the polymeric matrix composition in the first panel, based on the total weight of the first panel, than a percentage by weight of the polymeric matrix composition in said second panel, based on the total weight of the second panel; and   c) one or more additional panels attached to said second panel, wherein at least one of said additional panels comprises fibers that are not coated with a polymeric matrix composition; wherein said one or more additional panels comprises a plurality of fibers having a tenacity of 7 g/denier or more and a tensile modulus of 150 g/denier or more;   wherein said first panel is positioned closer to a potential ballistic threat relative to the second panel.   
     
     
         9 . The ballistic resistant material of  claim 8  wherein all of the panels are interconnected to form a series of interconnected ballistic resistant panels, and wherein each consecutive panel in the series contains a lower percentage by weight of the polymeric matrix composition than the previous panel in the series to which it is connected, based on the total weight of each panel, and wherein said ballistic resistant material has an areal density of from about 0.25 lb/ft 2  (1.22 kg/m 2 ) to about 2.0 lb/ft 2  (9.76 kg/m 2 ). 
     
     
         10 . The ballistic resistant material of  claim 8  wherein at least one of said additional panels consists of fibers that are not coated with a polymeric matrix composition, wherein all of said panels are juxtaposed with each other in a non-bonded array. 
     
     
         11 . The ballistic resistant material of  claim 8  comprising a series of three interconnected panels, the panels having respective polymeric matrix composition quantities, in order, of 20%, 10% and 0% by weight of the combined weight of its fibers and polymeric matrix composition. 
     
     
         12 . The ballistic resistant material of  claim 8  further comprising at least one rigid plate attached to an outer surface of the first panel, said rigid plate comprising a ceramic, glass, a metal-filled composite, a ceramic-filled composite, a glass-filled composite, a cermet, high hardness steel, an armor aluminum alloy, titanium or a combination thereof. 
     
     
         13 . The ballistic resistant material of  claim 8  wherein more than one additional panel is present, wherein at least one of said additional panels comprises fibers that are not coated with a polymeric matrix composition. 
     
     
         14 . The ballistic resistant material of  claim 13  wherein at least one of said additional panels consists of fibers that are not coated with a polymeric matrix composition, wherein all of said panels are juxtaposed with each other in a non-bonded array, and wherein said ballistic resistant material has an areal density of from about 0.25 lb/ft 2  (1.22 kg/m 2 ) to about 2.0 lb/ft 2  (9.76 kg/m 2 ). 
     
     
         15 . The ballistic resistant material of  claim 13  wherein more than one additional panel comprises fibers that are not coated with a polymeric matrix composition. 
     
     
         16 . The ballistic resistant material of  claim 13  wherein more than one additional panel consists of fibers that are not coated with a polymeric matrix composition, wherein all of said panels are juxtaposed with each other in a non-bonded array, and wherein said ballistic resistant material has an areal density of from about 0.25 lb/ft 2  (1.22 kg/m 2 ) to about 2.0 lb/ft 2  (9.76 kg/m 2 ). 
     
     
         17 . The ballistic resistant material of  claim 13  further comprising one or more additional panels attached to said first panel, wherein at least one of said additional panels comprises fibers that are not coated with a polymeric matrix composition; wherein said one or more additional panels comprises a plurality of fibers having a tenacity of 7 g/denier or more and a tensile modulus of 150 g/denier or more, and wherein all of said panels are juxtaposed with each other in a non-bonded array. 
     
     
         18 . The ballistic resistant material of  claim 17  wherein at least one additional panel consisting of fibers that are not coated with a polymeric matrix composition is attached to the first panel and at least one additional panel consisting of fibers that are not coated with a polymeric matrix composition is attached to the second panel, wherein all of said panels are juxtaposed with each other in a non-bonded array, and wherein said ballistic resistant material has an areal density of from about 0.25 lb/ft 2  (1.22 kg/m 2 ) to about 2.0 lb/ft 2  (9.76 kg/m 2 ). 
     
     
         19 . A ballistic resistant material comprising:
 a first panel comprising a plurality of fibrous layers, said plurality of fibrous layers being consolidated; each of the fibrous layers comprising a plurality of fibers, said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; each of said fibers having a surface, and the surfaces of said fibers being coated with a polymeric composition; and   a second panel attached to the first panel, which second panel is different than the first panel, and which second panel comprises a plurality of fibrous layers, said plurality of fibrous layers being consolidated; each of the fibrous layers comprising a plurality of fibers, said fibers having a tenacity of about 7 g/denier or more and a tensile modulus of about 150 g/denier or more; each of said fibers having a surface, and the surfaces of said fibers optionally being coated with a polymeric composition;   wherein the first panel and the second panel are juxtaposed with each other in a non-bonded array; and   wherein when the surfaces of the fibers of the second panel are coated with a polymeric composition, said first panel contains a greater percentage by weight of the polymeric composition in the first panel, based on the total weight of the first panel, than a percentage by weight of the polymeric composition in said second panel, based on the total weight of the second panel.   
     
     
         20 . The ballistic resistant material of  claim 19  wherein both the first panel and the second panel consist of a plurality of non-woven fibrous layers, wherein the fibers of the second panel are coated with a polymeric composition and wherein the polymeric composition consists of from about 7% to about 20% by weight of the second panel.