Studies on the Fabrication and Stab Resistance Characterization of Novel Thermoplastic-Kevlar Composites

Kevlar has demonstrated the ability to protect well against ballistic threats but has low resistance to puncture. Correctional Kevlar has shown good resistance to puncture. However, the fabric is expensive, difficult to manufacture because of its tight weave construction, and has limited protection against ballistic threats. In an effort to produce materials that are less bulky, more flexible, and resistant to puncture, thermoplastic-Kevlar (TP-Kevlar) composites have been examined. Kevlar fabric was impregnated with thermoplastic film using a hot press to produce the composites. Static and dynamic puncture resistant properties of the TP-Kevlar composites were investigated using a National Institute of Justice (NIJ Standard 0115.00) Stab Tower. The TP-films used in this study were polyethylene, Surlyn, and co extruded-Surlyn, which is a co extrusion of Surlyn and polyethylene. Response of the polyethylene (PE)-Kevlar composites, Surlyn-Kevlar composites, and co extruded (COEX)-Kevlar composites to spike and knife threats under static and dynamic conditions were compared with that of neat Kevlar. The infusion of thermoplastic films into the Kevlar fabric was shown to dramatically increase puncture resistance during quasi-static and dynamic testing with spikes. The TP-film type also made a difference when examining the resistance on a comparative basis of the TP-Kevlar targets. The TP-Kevlar composite targets showed more resistance to quasi-static spike testing than quasi-static knife testing. Weapon comparisons revealed that the TP-Kevlar composite targets had more resistance to dynamic knife testing than dynamic spike testing.