Fiber composites having strength and flexibility, systems, and methods thereof

Patent metadata

Field	Value
Publication number	US-2023152061-A1
Application number	US-202117797694-A
Country	US
Kind code	A1
Filing date	Feb 1, 2021
Priority date	Feb 6, 2020
Publication date	May 18, 2023
Grant date	—

Abstract

Systems and techniques to provide a flexible, lightweight material that is also effective at protecting a body from ballistic threats are described. An example composite material described herein is fiber-based, and it includes one or more first regions where the fiber composite material is consolidated, and one or more second regions where the fiber composite material is unconsolidated. Example methods of manufacturing the composite material disclosed herein include using a specialized tool with a heated platen press or an autoclave. The tool may include one or more protrusions and/or cavities that contact a precursor composite material to transform the precursor material into a partially consolidated fiber composite material, which is suitable for use as body armor, among other potential applications for the manufactured composite material.

First claim

1 - 13 . (canceled)

14 . A fiber composite material comprising:
an array of spaced first regions where the fiber composite material is consolidated, an individual first region in the array comprising unidirectional fibers embedded in a matrix; and one or more second regions where the fiber composite material is unconsolidated, the one or more second regions comprising a composite laminate, each layer of the composite laminate comprising the unidirectional fibers embedded in the matrix.

15 . The fiber composite material of claim 14 , wherein the individual first region is a polygon.

16 . The fiber composite material of claim 14 , wherein first fibers of a first layer of the composite laminate are oriented at an angle relative to second fibers of a second layer of the composite laminate, the second layer being adjacent to the first layer.

17 . The fiber composite material of claim 14 , wherein the fiber composite material comprises at least one of:
ultra-high-molecular-weight polyethylene (UHMWPE) fibers; or a ceramic matrix composite.

18 . The fiber composite material of claim 14 , wherein the array includes:
a first subset of the spaced first regions arranged in a first pattern; and a second subset of the spaced first regions arranged in a second pattern, the second pattern different than the first pattern.

19 . The fiber composite material of claim 14 , wherein at least one of:
the spaced first regions are uniformly-spaced; or the spaced first regions have a common geometric shape.

20 . The fiber composite material of claim 14 , wherein the fiber composite material is at least one of:
a body armor plate; or a layer of a multi-layer composite plate usable as body armor.

21 - 33 . (canceled)

34 . A fiber composite material comprising:
one or more first regions of fibers embedded in a first matrix; and one or more second regions of at least one of:
the fibers being devoid of the first matrix; or
the fibers embedded in a second matrix that is different than the first matrix.

35 . The fiber composite material of claim 34 , further comprising one or more third regions of the fibers embedded in a mixture of the first matrix and the second matrix, the one or more third regions being interposed between the one or more first regions and the one or more second regions.

36 - 40 . (canceled)

41 . A multi-layer composite plate comprising:
an outermost layer made of at least one of a ceramic, a metal, or a polymer; and an innermost layer made of a fiber composite material comprising:
one or more first regions; and
one or more second regions, wherein the one or more second regions have one or more second material properties different from one or more first material properties of the one or more first regions.

42 . The multi-layer composite plate of claim 41 , wherein the innermost layer comprises a partially consolidated fiber composite material having the one or more first regions where the fiber composite material is consolidated and one or more second regions where the fiber composite material is unconsolidated.

43 . The multi-layer composite plate of claim 41 , wherein:
the one or more first regions of the fiber composite material comprise fibers embedded in a matrix; and the one or more second regions of the fiber composite material comprise the fibers devoid of the matrix.

44 . The multi-layer composite plate of claim 41 , wherein:
the one or more first regions of the fiber composite material comprise fibers embedded in a first matrix; and the one or more second regions of the fiber composite material comprise the fibers embedded in a second matrix different than the first matrix.

45 . The multi-layer composite plate of claim 41 , wherein:
the one or more first regions of the fiber composite material comprise fibers embedded in a matrix, wherein the fibers account for a first percentage of the fiber composite material within the one or more first regions; and the one or more second regions of the fiber composite material comprise the fibers embedded in the matrix, wherein the fibers account for a second percentage of the fiber composite material within the one or more second regions, the second percentage different than the first percentage.

46 . The multi-layer composite plate of claim 41 , wherein:
an individual first region of the one or more first regions comprises unidirectional fibers embedded in a matrix; and the one or more second regions comprise a composite laminate, each layer of the composite laminate comprising the unidirectional fibers embedded in the matrix.

47 . The multi-layer composite plate of claim 46 , wherein first fibers of a first layer of the composite laminate are oriented at an angle relative to second fibers of a second layer of the composite laminate, the second layer being adjacent to the first layer.

48 . The multi-layer composite plate of claim 41 , wherein an individual first region of the one or more first regions is a polygon.

49 . The multi-layer composite plate of claim 41 , wherein the fiber composite material comprises at least one of:
ultra-high-molecular-weight polyethylene (UHMWPE) fibers; or a ceramic matrix composite.

50 . The multi-layer composite plate of claim 41 , wherein at least one of:
the one or more first regions are uniformly-spaced; or the one or more first regions have a common geometric shape.

51 . The multi-layer composite plate of claim 41 , wherein the multi-layer composite plate is body armor.

Assignees

• Univ Washington

Inventors

• Ghods Sean
• Arola Dwayne
• Suarez Matthew

Classifications

• B32B2307/558

  Impact strength, toughness · CPC title

• F41H5/0464

  the additional layers being only fibre- or fabric-reinforced layers · CPC title

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title

• B32B5/263

  next to one or more woven fabric layers · CPC title

• B29K2995/0082

  Flexural strength; Flexion stiffness · CPC title