Ballistic composite containing a thermoplastic overlay

Abstract

Ballistic composite articles comprising a fabric section, an overlay section disposed on the strikeface of the composite article and comprising a thermoplastic resin, and optionally an adhesive layer disposed between the fabric section and the overlay section are described. The ballistic composite articles can provide comparable or improved protection against projectile threats relative to conventional ballistic composites consisting only of a same-type fabric section having comparable area density, as evidenced by comparable V50 values and/lower backface deformation values when tested under the same conditions.

What is claimed is: 
     
         1 . A ballistic composite article having a strikeface and a backface, the ballistic composite article comprising:
 a) a fabric section comprising two or more fibrous fabric layers;   b) an overlay section comprising one or more layers, the overlay section being disposed on the strikeface and comprising a thermoplastic resin, wherein the weight percent of the overlay section relative to the composite article is between about 1% and about 50%; and   c) an optional first adhesive layer disposed between the fabric section and the overlay section;   whereby the composite article, when tested according to MIL-STD-662-F using a 16 grain right circular cylinder fragment-simulating projectile, has a V50 value comparable to or greater than that of an article consisting only of a same-type fabric section having an area density that is about the same as the area density of the composite article.   
     
     
         2 . The composite article of  claim 1 , wherein the overlay section is additionally disposed on the backface of the composite article, and optionally on at least a portion of at least one edge of the composite article, with the proviso that the majority of the overlay section is disposed on the strikeface. 
     
     
         3 . The composite article of  claim 1 , wherein the thermoplastic resin comprises polycarbonate, a thermoplastic elastomeric polyester having poly(1,4-butylene terephthalate) and poly(alkylene ether)glycol blocks, polybutylene terephthalate, a polyacetal, a blend of polyamide and an ethylene/α,β-unsaturated C3-C8 carboxylic acid copolymer partially neutralized with metal ions, or combinations thereof. 
     
     
         4 . The composite article of  claim 1 , wherein the weight percent of the overlay section is between about 1% and about 40%. 
     
     
         5 . The composite article of  claim 1 , wherein the first adhesive layer is present and comprises a plant-based glue, a solvent-type glue, a synthetic monomer glue, a synthetic polymer glue, an epoxy resin, a polyurethane, or combinations thereof. 
     
     
         6 . The composite article of  claim 1 , wherein one or more of the fibrous fabric layers comprises a woven fabric. 
     
     
         7 . The composite article of  claim 1 , wherein one or more of the fibrous fabric layers comprises a non-woven fabric. 
     
     
         8 . The composite article of  claim 7 , wherein the non-woven fabric comprises a unidirectionally oriented tape structure. 
     
     
         9 . The composite article of  claim 1 , wherein the fabric layers comprise a polymer selected from the group consisting of aramid, ultra-high molecular weight polyethylene, ultra-high molecular weight polypropylene, polyvinyl alcohol, polyazole, polybenzoxazole, polybenzothiazole, and combinations or blends thereof. 
     
     
         10 . The composite article of  claim 1 , wherein the fabric section further comprises a polymeric resin disposed between at least two of the fibrous fabric layers, and the polymeric resin and the overlay section comprise the same thermoplastic resin. 
     
     
         11 . The composite article of  claim 1 , wherein the areal density is between about 2.5 lbs/ft 2  and 1.0 lbs/ft 2 . 
     
     
         12 . A panel comprising the composite article of  claim 11 . 
     
     
         13 . A helmet comprising the composite article of  claim 11 . 
     
     
         14 . A ballistic composite article having a strikeface and a backface, the ballistic composite article comprising:
 a) a fabric section comprising two or more fibrous fabric layers;   b) an overlay section comprising one or more layers, the overlay section being disposed on the strikeface and comprising a thermoplastic resin, wherein the weight percent of the overlay section relative to the composite article is between about 1% and about 50%; and   c) an optional first adhesive layer disposed between the fabric section and the overlay section;   whereby the composite article, when tested according to HP White HPW-TP-0401.01B using a 9 mm Full Metal Jacket projectile, has a back face deformation value lower than that of an article consisting only of a same-type fabric section having an areal density about the same as the areal density of the composite article.   
     
     
         15 . The composite article of  claim 14 , wherein the weight percent of the overlay section is between about 1% and about 40%, and wherein the thermoplastic resin comprises polycarbonate, a thermoplastic elastomeric polyester having poly(1,4-butylene terephthalate) and poly(alkylene ether)glycol blocks, polybutylene terephthalate, a polyacetal, a blend of polyamide and an ethylene/α,β-unsaturated C3-C8 carboxylic acid copolymer partially neutralized with metal ions, or combinations thereof.