Hard-ballistic article and process to manufacture said article

Abstract

A hard-ballistic article and a method to manufacture the article are provided. The hard ballistic article includes a hybrid panel, wherein the hybrid panel includes a) a first package of a plurality of consolidated cross-plies, wherein each consolidated cross-ply contains at least two layers of unidirectional aligned aramid fibers, wherein the aramid fibers are provided with a first matrix material, wherein the first matrix material includes a first polymer, wherein the first package exhibits a surface facing to the direction of a ballistic attack and a surface facing away from the direction of the ballistic attack, and (b) a second package containing a plurality of woven fabric layers, wherein the woven fabric layers include aramid fibers provided with a second matrix material, wherein the second matrix material is different from the first matrix material, wherein the second matrix material comprises a second polymer, wherein the second polymer is different from the first polymer, wherein the first package is bonded with its surface facing away from the direction of the ballistic attack with the second package.

1 . A hard-ballistic article comprising a hybrid panel, wherein the hybrid panel comprises
 a) a first package of a plurality of consolidated cross-plies, wherein each consolidated cross-ply contains at least two layers of unidirectional aligned aramid fibers, wherein the aramid fibers are provided with a first matrix material, wherein the first matrix material comprises a first polymer, wherein the first package has surface facing to a direction of a ballistic attack and a surface facing away from the direction of the ballistic attack, and   b) a second package containing a plurality of woven fabric layers, wherein the woven fabric layers comprise aramid fibers provided with a second matrix material, wherein the second matrix material is different from the first matrix material, wherein the second matrix material comprises a second polymer, wherein the second polymer is different from the first polymer, and   wherein the first package is bonded, at the surface of the first package facing away from the direction of the ballistic attack, with the second package.   
     
     
         2 . The hard-ballistic article according to  claim 1 , wherein a metallic or ceramic strike face is bonded to the surface of the first package facing to the direction of the ballistic attack. 
     
     
         3 . The hard-ballistic article according to  claim 1 , wherein the plurality of consolidated cross-plies means a number n of consolidated cross-plies, and n ranges from 1 to 50. 
     
     
         4 . The hard-ballistic article according to  claim 1 , wherein each consolidated cross-ply comprises 2 to 10 layers of unidirectional aligned aramid fibers. 
     
     
         5 . The hard-ballistic article according to  claim 1 , wherein a concentration of the first polymer in each layer of the unidirectional aligned aramid fibers ranges from 2 to 50 wt.-% with respect to a weight of the aramid fibers plus a weight of the first polymer without moisture. 
     
     
         6 . The hard-ballistic article according to  claim 1 , wherein an areal density of each layer of the unidirectional aligned aramid fibers including the first polymer ranges from 10 to 250 g/m 2 . 
     
     
         7 . The hard-ballistic article according to  claim 1 , wherein the first polymer is a styrene butadiene random copolymer. 
     
     
         8 . The hard-ballistic article according to  claim 7 , wherein the styrene butadiene random copolymer is a carboxylated styrene butadiene random copolymer. 
     
     
         9 . The hard-ballistic article according to  claim 1 , wherein the first matrix material comprises the first polymer and a tackifier. 
     
     
         10 . The hard-ballistic article according to  claim 1 , wherein the plurality of the woven fabric layers means a number m of woven fabric layers, and m ranges from 1 to 30. 
     
     
         11 . The hard-ballistic article according to  claim 1 , wherein the second polymer is a polychloroprene. 
     
     
         12 . The hard-ballistic article according to  claim 1 , wherein a concentration of the second polymer in each of the woven fabric layers of aramid fibers ranges from 2 to 32 wt.-% with respect to a weight of the aramid fibers in the woven fabric layer plus a weight of the second polymer. 
     
     
         13 . The hard-ballistic article according to  claim 1 , wherein an areal density of each woven fabric layer of aramid fibers including the second polymer ranges from 100 to 1000 g/m 2 . 
     
     
         14 . The hard-ballistic article according to  claim 1 , wherein the first package is bonded, at the surface of the first package facing away from the direction of the ballistic attack, with the second package by a first package/second package—bonding layer. 
     
     
         15 . The hard-ballistic article according to  claim 14 , wherein the first package/second package—bonding layer is a solidified mixed melt comprising a solid mixture of the first matrix material with the second matrix material. 
     
     
         16 . The hard-ballistic article according to  claim 2 , wherein the first package is bonded, at the surface facing the direction of the ballistic attack, with the metallic or ceramic strike face by a first package/metallic or ceramic strike face—bonding layer. 
     
     
         17 . The hard-ballistic article according to  claim 16 , wherein the first package/metallic or ceramic strike face—bonding layer is a single layer of an adhesive material or a multilayer. 
     
     
         18 . The hard-ballistic article according to  claim 1 , wherein the hard-ballistic article comprises 5 to 40 consolidated cross-plies and 2 to 18 woven fabric layers. 
     
     
         19 . The hard-ballistic article according to  claim 1 , wherein the hard ballistic article comprises a plurality of consolidated cross-plies n and a plurality of woven fabric layers m in a ratio n:m, wherein n:m is in a range from (27 to 33):(12 to 16). 
     
     
         20 . The hard-ballistic article according to  claim 1 , wherein the hard ballistic article comprises a weight of consolidated cross-plies w 1  given in wt.-% and a weight of woven fabric layers w 2  given in wt.-% in a ratio w 1 :w 2 , wherein w 1 :w 2  is in a range from (40 to 70):(30 to 60). 
     
     
         21 . Process to manufacture the hard-ballistic article of  claim 1 , comprising the steps
 i) preparing a plurality of consolidated cross-plies, wherein each consolidated cross-ply contains at least two layers of unidirectional aligned aramid fibers, wherein the aramid fibers are provided with a first matrix material, wherein the first matrix material comprises a first polymer,   ii) preparing a plurality of woven fabric layers, wherein the woven fabric layers comprise fibers provided with a second matrix material, wherein the second matrix material is different from the first matrix material, wherein the second matrix material comprises a second polymer, wherein the second polymer is different from the first polymer,   iii) stacking the plurality of woven fabric layers prepared in step ii) resulting in a stack of the plurality of woven fabric layers,   iv) stacking the plurality of consolidated cross-plies prepared in step i) on top of the of the stack of the plurality of woven fabric layers resulting in step iii) resulting in a stacked panel,   v) transferring the stacked panel resulting in step iv) into a press, heating the press to a constant temperature in the range from 100 to 250° C., pressing the stacked panel at the constant temperature at a constant pressure in the range from 5 to 150 bar for a time in a range of 1 to 100 minutes,   vi) cooling down the closed press to room temperature, and then opening the press to obtain a hybrid panel, wherein the hybrid panel comprises
 a first package containing a plurality of consolidated cross-plies, and having an outer surface, and 
 a second package containing a plurality of woven fabric layers and 
   optionally vii) binding the hybrid panel obtained in step vi) with the outer surface of the first package to a metallic or ceramic strike face.