The present invention contemplates a method for forming a composite structure including a plurality of rigid layers and one or more reformable epoxy resin layers. The resulting composite is molded to form a non-planar composite structure.

A rigid ballistic-resistant composite includes large denier per filament (dpf) yarns. The yarns are held in place by a resin to form a rigid composite panel with improved ballistic performance. The large dpf yarns may be selected from aromatic heterocyclic co-polyamide fibers, polyester-polyarylate fibers, high modulus polypropylene (HMPP) fibers, ultra high molecular weight polyethylene (UHMWPE) fibers, poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers, poly-diimidazo pyridinylene (dihydroxy) phenylene (PIPD) fibers, carbon fibers, and polyolefin fibers.

A rigid ballistic-resistant composite includes large denier per filament (dpf) yarns. The yarns are held in place by a resin to form a rigid composite panel with improved ballistic performance. The large dpf yarns may be selected from aromatic heterocyclic co-polyamide fibers, polyester-polyarylate fibers, high modulus polypropylene (HMPP) fibers, ultra high molecular weight polyethylene (UHMWPE) fibers, poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers, poly-diimidazo pyridinylene (dihydroxy) phenylene (PIPD) fibers, carbon fibers, and polyolefin fibers.

A combat helmet has a shell made from a ballistic rated material, the shell having an outer surface and an inner surface such that at least a portion of the outer surface is formed as a series of adjoining polygon shaped faceted regions that help distribute any force impacted on such regions across a relatively large portion of the shell. The faceted regions are curvedly contoured, and may extend through to the inner surface of the shell. The faceted regions may cover primarily the crown section of the helmet shell, the lower section, or both.

A combat helmet has a shell made from a ballistic rated material, the shell having an outer surface and an inner surface such that at least a portion of the outer surface is formed as a series of adjoining polygon shaped faceted regions that help distribute any force impacted on such regions across a relatively large portion of the shell. The faceted regions are curvedly contoured, and may extend through to the inner surface of the shell. The faceted regions may cover primarily the crown section of the helmet shell, the lower section, or both.

A multilayer composite includes adjacent filler layers having a filler material dispersed within a first polymeric matrix and an intervening-layer disposed between the adjacent filler layers. The intervening-layer comprises nanoplatelets embedded within a second polymeric matrix and are aligned substantially parallel to the adjacent filler layers. The intervening-layer is configured to fail upon application of a force to the multilayer composite that is greater than or equal to a predetermined force threshold.

A multilayer composite includes adjacent filler layers having a filler material dispersed within a first polymeric matrix and an intervening-layer disposed between the adjacent filler layers. The intervening-layer comprises nanoplatelets embedded within a second polymeric matrix and are aligned substantially parallel to the adjacent filler layers. The intervening-layer is configured to fail upon application of a force to the multilayer composite that is greater than or equal to a predetermined force threshold.

The invention relates to a process for producing a ballistic-resistant curved molded article said process comprising forming a stack of a plurality of composite sheets, pressing the stack comprising the composite sheets at a temperature of between 80° C. to 150° C. and a pressure of between 10 and 400 bar for at least 5 minutes to obtain a curved molded article, cooling the compacted stack to a temperature below 80° C. while maintaining the pressure above 10 bar, releasing the pressure from the cooled curved molded article; wherein the composite sheets comprise unidirectionally aligned high tenacity polyethylene fibers and a matrix comprising a polyethylene resin being a homopolymer or copolymer of ethylene having a density of between 870 to 980 kg/m.sup.3 when measured according to ISO1183 and a melt flow index of between 0.5 and 50 g/10 min when measured according to ASTM 1238B-13 at a temperature of 190° C. and a weight of 21.6 kg.

The present invention contemplates a method for forming a composite structure including a plurality of rigid layers and one or more reformable epoxy resin layers. The resulting composite is molded to form a non-planar composite structure.

A flexible, fibrous energy managing composite panel includes multiple flocked energy absorbing material (FEAM) layers separated by dividers. The FEAM layers can be single side or double side and can be fabricated from monofilament fibers having different properties (e.g., length and denier) flocked onto various substrates. The dividers can include sheets, fabrics, films, foam, spacer fabrics to separate the flock fibers in adjacent layers. The composite panels can be processed for breathability and flexibility. Other embodiments include piezoelectric FEAM layers and dividers for electronic sensing applications, and application of composite panels to body armor and the outer shells of helmets.