JP6945548B2 - ブリスターのない複合材料の成型 - Google Patents
ブリスターのない複合材料の成型 Download PDFInfo
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- JP6945548B2 JP6945548B2 JP2018553875A JP2018553875A JP6945548B2 JP 6945548 B2 JP6945548 B2 JP 6945548B2 JP 2018553875 A JP2018553875 A JP 2018553875A JP 2018553875 A JP2018553875 A JP 2018553875A JP 6945548 B2 JP6945548 B2 JP 6945548B2
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- ply
- woven
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- fibers
- binder
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
- B32B38/1808—Handling of layers or the laminate characterised by the laying up of the layers
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Description
本出願は、その開示全体が参照として本明細書に援用される、2016年4月15日出願の同時係属中の米国特許仮出願第62/322,841号の利益を主張する。
本開示は、欠陥のない繊維複合材料を形成するための改良されたプロセスに関する。より具体的には、本開示は、ブリスター形成を積極的に監視又は制御する必要なく、ブリスターのない繊維複合材を形成するためのプロセス、及びそれにより製造されたブリスターのない複合材料に関する。
弾道抵抗性ベスト、ヘルメット、車両パネル及び軍用装備の構造部材などの弾道抵抗性物品は、典型的には、高強度繊維を含む複合材アーマーから作製される。複合材アーマーを製造するために従来使用されている高強度繊維としては、ポリエチレン繊維、特に超高分子量ポリエチレン繊維、及びアラミド繊維、特にパラ−アラミド繊維が挙げられる。いくつかの用途では、繊維は、繊維が機械的に互いに連結された織布に形成される。他の用途では、繊維は、繊維がポリマー結合剤材料のコーティングなどで共に接着された、不織布に形成される。織布及び/又は不織布から形成された、様々な弾道抵抗性物品構造物が知られている。例えば、これらの全てが同一所有者のHoneywell International Inc.社によって所有されている、米国特許第4,403,012号、同第4,457,985号、同第4,613,535号、同第4,623,574号、同第4,650,710号、同第4,737,402号、同第4,748,064号、同第5,552,208号、同第5,587,230号、同第6,642,159号、同第6,841,492号及び同第6,846,758号は、超高分子量ポリエチレン繊維から形成された弾道抵抗性複合材について記載している。これらの複合材は、銃弾、シェル、榴散弾などの発射体からの高速衝撃による貫通に対して、異なる度合の耐性を示す。
a)複数の繊維及び/又は複数のテープを含む第1のプライを提供するステップであって、第1のプライが、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、第1のプライ内に存在し、それによって第1のプライが空隙体積を有する、ステップと、
b)第1のプライ上に第2のプライを適用するステップであって、第2のプライが、複数の繊維及び/又は複数のテープを含み、第2のプライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、第2のプライ内に存在し、それによって第2のプライが空隙体積を有する、ステップと、
c)任意選択的に、第1のプライ及び/又は第2のプライ上に1つ以上の追加プライを適用するステップであって、各追加プライが、複数の繊維及び/又は複数のテープを含み、各追加プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、各追加プライ内に存在し、それによって追加プライの各々が空隙体積を有する、ステップと、
d)第1のプライ、第2のプライ、及び任意の追加プライを、各プライ中の粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全てのプライを一体化して一体型複合材を形成するステップであって、一体型複合材が、圧密化ステップの前に、各個々のプライの合計された空隙体積未満である、総空隙体積を有する、ステップと、を含む、方法である。
a)複数の繊維及び/又は複数のテープを含み、約80g/m2未満の繊維面密度を有する第1の繊維状プライを提供するステップであって、第1の繊維状プライが、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、第1の繊維状プライ内に存在し、それによって第1の繊維状プライが空隙体積を有する、ステップと、
b)第1の繊維状プライの表面に少なくとも1つの熱可塑性オーバレイを適用するステップであって、少なくとも1つの熱可塑性オーバレイが、その表面を部分的にのみ覆い、少なくとも1つの熱可塑性オーバレイが、ポリマー結合剤の融点未満の融点を有する、ステップと、
c)少なくとも1つの熱可塑性オーバレイ上に第2の繊維状プライを適用するステップであって、第2の繊維状プライが、複数の繊維及び/又は複数のテープを含み、約80g/m2未満の繊維面密度を有し、第2の繊維状プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、状第2の繊維状プライ内に存在し、それによって第2の繊維状プライが、空隙体積を有する、ステップと、
d)任意選択的に、1つ以上の中間の熱可塑性オーバレイを介して、任意選択的に、第1の繊維状プライ及び/又は第2の繊維状プライ上に1つ以上の追加繊維状プライを適用するステップであって、各追加繊維状プライが、複数の繊維及び/又は複数のテープを含み、各々が約80g/m2未満の繊維面密度を有し、各追加繊維状プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、各追加繊維状プライ内に存在し、それによって追加プライの各々が、空隙体積を有し、熱可塑性オーバレイの各々が、状ポリマー結合剤の各々の融点未満の融点を有する、ステップと、
e)第1の繊維状プライ、第2の繊維状プライ、及び任意の追加繊維状プライを、各繊維状プライ中の粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全ての繊維状プライを一体化して一体型複合材を形成するステップであって、一体型複合材が、圧密化ステップの前に、各個々の繊維状プライの合計された空隙体積未満である、総空隙体積を有する、ステップと、を含む、方法である。
HOOC−−Z−−COOH
によって表され、式中、Zが、アジピン酸、セバシン酸、オクタデカン二酸、ピメリン酸、スベリン酸、アゼライン酸、ドデカン二酸、及びグルタル酸などの、少なくとも2個の炭素原子を含有する二価脂肪族ラジカルを表す。ジカルボン酸は、脂肪酸、又はイソフタル酸及びテレフタル酸などの芳香族酸であってもよい。ポリアミドを作製するための好適なジアミンは、次の式
H2N(CH2)nNH2
を有するものを含み、式中、nが、1〜16の整数値を有し、トリメチレンジアミン、テトラメチレンジアミン、ペンタメチレンジアミン、ヘキサメチレンジアミン、オクタメチレンジアミン、デカメチレンジアミン、ドデカメチレンジアミン、ヘキサデカメチレンジアミン、p−フェニレンジアミン、4,4’−ジアミノジフェニルエーテル、4,4’−ジアミノジフェニルスルホン、4,4’−ジアミノジフェニルメタンなどの芳香族ジアミン、2,2−ジメチルペンタメチレンジアミン、2,2,4−トリメチルヘキサメチレンジアミン、及び2,4,4トリメチルペンタメチレンジアミンなどのアルキル化ジアミン、並びにジアミノジシクロヘキシルメタンなどの脂環式ジアミン、並びに他の化合物などの化合物を含む。他の有用なジアミンしては、ヘプタメチレンジアミン、ノナメチレンジアミンなどが挙げられる。
本発明は以下の態様を含む。
[1]
複数の繊維状プライを含む、ブリスターのない弾道抵抗性複合材であって、前記繊維状プライの各々が、単回溶融熱履歴を有する不連続の非液体分散ポリマー結合剤で少なくとも部分的にコーティングされ、前記複数の繊維状プライが、一体型複合材として一体化され、前記複合材が、0%〜最大5%の空隙体積を含む、弾道抵抗性複合材。
[2]
各繊維状プライが、表面積を有し、各プライの前記表面積の50%未満が前記ポリマー結合剤によって覆われている、[1]に記載のブリスターのない弾道抵抗性複合材。
[3]
前記複合材が、0%の空隙体積を有する、[1]に記載のブリスターのない弾道抵抗性複合材。
[4]
各繊維状プライが、80g/m 2 未満の繊維面密度を有する、[1]に記載のブリスターのない弾道抵抗性複合材。
[5]
弾道抵抗性複合材を形成する方法であって、
a)複数の繊維及び/又は複数のテープを含む第1のプライを提供するステップであって、前記第1のプライが、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、前記第1のプライ内に存在し、それによって前記第1のプライが空隙体積を有する、ステップと、
b)前記第1のプライ上に第2のプライを適用するステップであって、前記第2のプライが、複数の繊維及び/又は複数のテープを含み、前記第2のプライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、前記第2のプライ内に存在し、それによって前記第2のプライが空隙体積を有する、ステップと、
c)任意選択的に、前記第1のプライ及び/又は前記第2のプライ上に1つ以上の追加プライを適用するステップであって、各追加プライが、複数の繊維及び/又は複数のテープを含み、各追加プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、各追加プライ内に存在し、それによって前記追加プライの各々が空隙体積を有する、ステップと、
d)前記第1のプライ、第2のプライ、及び任意の追加プライを、各プライ中の前記粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全てのプライを一体化して一体型複合材を形成するステップであって、前記一体型複合材が、前記圧密化ステップの前に、各個々のプライの合計された空隙体積未満である、総空隙体積を有する、ステップと、を含む、方法。
[6]
前記圧密化ステップの前の各個々のプライの合計された空隙体積が、20%よりも大きく、前記圧密化ステップの後の前記一体型複合材の前記総空隙体積が、0%〜最大約10%である、[5]に記載の方法。
[7]
各プライ中の前記粒子状ポリマー結合剤が、ステップd)で十分かつ完全に溶融される、[5]に記載の方法。
[8]
各プライ中の前記粒子状ポリマー結合剤が、ステップd)で部分的にのみ溶融され、前記プライのうちの少なくとも1つの前記繊維/テープのうちの少なくともいくつかが、ポリマー結合剤の盛り上がった不連続のパッチによって部分的に覆われている表面を有し、前記ポリマー結合剤の盛り上がった不連続のパッチが、前記繊維/テープ表面に結合されかつそこから伸長している、[5]に記載の方法。
[9]
[5]に記載のプロセスによって製造された、ブリスターのない弾道抵抗性複合材であって、各プライの前記粒子状ポリマー結合剤が、十分かつ完全に溶融され、前記一体型複合材内に空隙が全く存在しない、ブリスターのない弾道抵抗性複合材。
[10]
弾道抵抗性複合材を形成する方法であって、
a)複数の繊維及び/又は複数のテープを含み、約80g/m 2 未満の繊維面密度を有する第1の繊維状プライを提供するステップであって、前記第1の繊維状プライが、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、前記第1の繊維状プライ内に存在し、それによって前記第1の繊維状プライが空隙体積を有する、ステップと、
b)前記第1の繊維状プライの表面に少なくとも1つの熱可塑性オーバレイを適用するステップであって、前記少なくとも1つの熱可塑性オーバレイが、前記表面を部分的にのみ覆い、前記少なくとも1つの熱可塑性オーバレイが、前記ポリマー結合剤の融点未満の融点を有する、ステップと、
c)前記少なくとも1つの熱可塑性オーバレイ上に第2の繊維状プライを適用するステップであって、前記第2の繊維状プライが、複数の繊維及び/又は複数のテープを含み、約80g/m 2 未満の繊維面密度を有し、前記第2の繊維状プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、前記第2の繊維状プライ内に存在し、それによって前記第2の繊維状プライが、空隙体積を有する、ステップと、
d)任意選択的に、1つ以上の中間の熱可塑性オーバレイを介して、任意選択的に、前記第1の繊維状プライ及び/又は前記第2の繊維状プライ上に1つ以上の追加繊維状プライを適用するステップであって、各追加繊維状プライが、複数の繊維及び/又は複数のテープを含み、各々が約80g/m 2 未満の繊維面密度を有し、各追加繊維状プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で少なくとも部分的にコーティングされ、1つ以上の間隙が、各追加繊維状プライ内に存在し、それによって前記追加プライの各々が、空隙体積を有し、前記熱可塑性オーバレイの各々が、前記ポリマー結合剤の各々の融点未満の融点を有する、ステップと、
e)前記第1の繊維状プライ、第2の繊維状プライ、及び任意の追加繊維状プライを、各繊維状プライ中の前記粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全ての前記繊維状プライを一体化して一体型複合材を形成するステップであって、前記一体型複合材が、前記圧密化ステップの前に、各個々の繊維状プライの合計された空隙体積未満である、総空隙体積を有する、ステップと、を含む、方法。
Claims (6)
- 複数の繊維状プライを含む、ブリスターのない弾道抵抗性複合材であって、前記繊維状プライの各々が不織であり、複数の一方向に配向された繊維を含み、前記繊維状プライの各々が、ポリマー結合剤で部分的にコーティングされ、前記複数の繊維状プライが、一体型複合材として一体化され、前記一体型複合材が、0%〜最大4%の空隙体積を含み、前記ポリマー結合剤が各繊維状プライの繊維の上及び間にあり、前記ポリマー結合剤が前記一体型複合材の隣接する繊維状プライの上及び間にあり、各繊維状プライは表面積を有し、各繊維状プライの表面積の50%未満が前記ポリマー結合剤によって覆われ、各繊維状プライが80g/m 2 未満の繊維面密度を有する、弾道抵抗性複合材。
- 弾道抵抗性複合材を形成する方法であって、
a)複数の一方向に配向された繊維及び/又は複数の一方向に配向されたテープを含む第1の不織プライを提供するステップであって、前記第1の不織プライが、乾燥した、溶剤を含まない粒子状ポリマー結合剤で部分的にコーティングされ、1つ以上の間隙が、前記第1の不織プライ内に存在し、それによって前記第1の不織プライが空隙体積を有する、ステップと、
b)前記第1の不織プライ上に第2の不織プライを適用するステップであって、前記第2の不織プライが、複数の一方向に配向された繊維及び/又は複数の一方向に配向されたテープを含み、前記第2の不織プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で部分的にコーティングされ、1つ以上の間隙が、前記第2の不織プライ内に存在し、それによって前記第2の不織プライが空隙体積を有する、ステップと、
c)任意選択的に、前記第1の不織プライ及び/又は前記第2の不織プライ上に1つ以上の追加不織プライを適用するステップであって、各追加不織プライが、複数の一方向に配向された繊維及び/又は複数の一方向に配向されたテープを含み、各追加不織プライが、任意選択的に、乾燥した、溶剤を含まない粒子状ポリマー結合剤で部分的にコーティングされ、1つ以上の間隙が、各追加不織プライ内に存在し、それによって前記追加不織プライの各々が空隙体積を有する、ステップと、
d)前記第1の不織プライ、第2の不織プライ、及び任意の追加不織プライを、各不織プライ中の前記粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全ての不織プライを一体化して一体型複合材を形成するステップであって、前記一体型複合材が、前記圧密化ステップの前に、各個々の不織プライの合計された空隙体積未満である、総空隙体積を有する、ステップと、
を含み、前記複合材が、0%〜最大4%の空隙体積を含み、各不織プライは表面積を有し、各不織プライの表面積の50%未満が前記ポリマー結合剤によって覆われ、各繊維状プライが80g/m 2 未満の繊維面密度を有する、方法。 - 請求項2に記載の方法であって、
前記第1の不織プライが40g/m 2 から80g/m2未満の繊維面密度を有し、前記第2の不織プライが40g/m 2 から80g/m2未満の繊維面密度を有し、
前記方法がさらに、
前記第1の不織プライの表面上に少なくとも1つの熱可塑性オーバレイを適用するステップであって、前記少なくとも1つの熱可塑性オーバレイが、前記第1の不織プライの前記表面を部分的にのみ覆い、前記少なくとも1つの熱可塑性オーバレイが、前記第1の不織プライの前記ポリマー結合剤の融点未満の融点を有する、ステップと、
前記第1の不織プライ、前記第2の不織プライ、前記任意の追加不織プライ及び前記少なくとも1つの熱可塑性オーバレイを、各不織プライ中の前記粒子状ポリマー結合剤を少なくとも部分的に溶融するのに十分な条件下で熱及び圧力を用いて圧密化し、それによって全ての前記不織プライ及び前記少なくとも1つの熱可塑性オーバレイを一体化して一体型複合材を形成するステップであって、前記一体型複合材が、前記圧密化ステップの前に、各個々の不織プライの合計された空隙体積未満である、総空隙体積を有する、ステップと、
を含み、
前記複合材が、0%〜最大4%の空隙体積を含み、各不織プライは表面積を有し、各不織プライの表面積の50%未満が前記ポリマー結合剤によって覆われる、方法。 - 複数の繊維状プライを含む、ブリスターのない弾道抵抗性複合材であって、前記繊維状プライの各々が、不織であり、及びポリマー結合剤のパッチで部分的にコーティングされ、前記複数の繊維状プライが、一体型複合材として一体化され、前記各繊維状プライは複数の一方向に配向された繊維を含み、一方向に配向された繊維は超高分子量ポリエチレン繊維を含有し、前記ポリマー結合剤は、超低密度ポリエチレン(VLDPE)、低密度ポリエチレン(LDPE)、線状低密度ポリエチレン(LLDPE)、中密度ポリエチレン(MDPE)、高密度ポリエチレン(HDPE)、ポリ(メチレン)、メタロセン−低密度ポリエチレン(m−LDPE)、メタロセン−線状低密度ポリエチレン(m−LLDPE)、メタロセン−中密度ポリエチレン(m−MDPE)、環状オレフィンコポリマー(COCs)、エチレンビニルアセテート(EVA)、又はエチレンアクリル酸(EAA)を含有し、一体型複合材中のポリマー結合剤の総重量が2重量%〜20重量%であり、一体型複合材が0%〜最大1.5%の空隙体積を含み、各繊維状プライが80g/m2未満の繊維面密度を有する、弾道抵抗性複合材。
- 請求項1に記載のブリスターのない弾道抵抗性複合材であって、前記結合剤が異なる融点を有する少なくとも2つの異なる結合剤のブレンドを含み、前記ブレンドが第1の結合剤及び第2の結合剤を含み、第1の結合剤が第2の結合剤とは異なる融点を有し、少なくとも一つの前記結合剤がメタロセン−低密度ポリエチレン(m−LDPE)、メタロセン−線状低密度ポリエチレン(m−LLDPE)、及びメタロセン−中密度ポリエチレン(m−MDPE)からなる群から選択される、弾道抵抗性複合材。
- 請求項2に記載の方法であって、圧密化が、50℃〜175℃の範囲の温度で、かつ5psig(0.034MPa)〜2500psig(17MPa)の範囲の圧力で、0.01秒〜24時間の継続時間で行われ、前記複合材の各プライの表面積の2%〜20%が前記ポリマー結合剤によって覆われ、圧密化工程が二重ベルトプレスで行われる、方法。
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- 2017-04-05 MX MX2018012518A patent/MX2018012518A/es unknown
- 2017-04-05 JP JP2018553875A patent/JP6945548B2/ja active Active
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BR112018071190B1 (pt) | 2023-03-28 |
CA3020694A1 (en) | 2017-10-19 |
EP3442787A4 (en) | 2019-12-18 |
CA3020694C (en) | 2021-08-03 |
CN117207607A (zh) | 2023-12-12 |
AR108136A1 (es) | 2018-07-18 |
JP2019513590A (ja) | 2019-05-30 |
US20170297295A1 (en) | 2017-10-19 |
MX2018012518A (es) | 2019-07-08 |
CN109195786A (zh) | 2019-01-11 |
EP3442787A1 (en) | 2019-02-20 |
BR112018071190A2 (pt) | 2019-02-12 |
KR20190003565A (ko) | 2019-01-09 |
EP3442787B1 (en) | 2022-06-08 |
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