Novel Flame and Impact Resistant Foam Core

Flame resistant lightweight, foam cored composites are needed for many Air Force applications including aircraft structures and portable personnel protective barriers. FMI proposes to fulfill this need by development of an innovative composite structurethat will incorporate fire resistant resin and foam with Kevlar ballistic fabric. This approach is based upon individual materials and production techniques that are well understood by previous FMI development efforts. A (FR) phenolic foam core will beused to reduce weight but at the same time provide fire and impact resistance. A compression molding process will be used to combine all of the components into one foam cored sandwich composite. The outside of the composite will have the (FR) resinimpregnated fiberglass, which will provide some structural, flame resistant, and ballistic properties. The (FR) foamed core will provide further flame resistant properties while also adding some impact resistance. The backside of the core will beprotected with (FR)resin impregnated Kevlar,which will continue to provide flame resistance, but most importantly prevent bullet penetration from a Threat Level II. This process will yield a lightweight, foamed core protective barrier at a low cost. Alow cost process to produce lightweight flame resistant foamed core composite with improved impact resistance that will be of interest in the fabrication of both military and commercial products. Products such as firewalls for transport vehicles andaircraft, and portable personnel protective barriers.