Self-Reinforced Rigid Plastics for Body Armor Applications

Maxdem has developed novel self-reinforced thermoplastic polyphenylenes, designated Poly-X (TM) resins, which possess unique properties, especially ultrahigh strength and modulus. Previous evaluations (SBIR Contract DAAH01-94--C-R040) demonstrated the ballistic performance of these polymers to be superior to that of current plastic materials, including polycarbonate and acrylic. Consideration of the Poly-X(TM) materials' ballistic performance and failure modes suggest that they can yield new body armors with unparalleled properties, possibly either constructed of the Poly-X(TM) materials alone or, more likely, in conjunction with fiber-reinforced backings like Spectra-Shield(TM). For instance, compared to rigid metal, ceramic or cermet strike-face materials, Poly-X(TM) inserts would offer much lower weight, equivalent or improved performance, greater design flexibility and producibility (due to their thermoplastic processability), and potentially lower cost. During the proposed Phase I program, we will prepare several Poly-X(TM) sample configurations and Simula will test them against "worst- case" 7.62-mm ball ammunition threats as an initial demonstration of the effectiveness of these materials and to help to identify the most promising design concepts for utilizing them. Phase II efforts will focus on further optimization of the materials and material combinations for maximal ballistic performance and construction of a prototype boody armor based on the new material system(s).