STRUCTURAL SHELL

Abstract

The present invention provides a structural shell comprising a basalt fibre-reinforced material, wherein the basalt fibre-reinforced material comprises a polymer material, the polymer material being capable of at least partially thermally cracking at a temperature of from 200 to 600 C.

Claims

1. A structural shell comprising a basalt fibre-reinforced material, wherein the basalt fibre-reinforced material comprises a polymer material, the polymer material being capable of at least partially thermally cracking at a temperature of from 200 to 600C.

2. The structural shell of claim 1, wherein the polymer material is a thermoplastic: material.

3. The structural shell of claim 1, wherein the polymer material comprises a polymethacrylate.

4. The structural shell of claim 3, wherein the polymer material comprises a poly(methyl methacrylate).

5. The structural shell of claim 3, wherein the polymer material is capable of at least partially melting at a temperature of from 150 to 300 C. and/or wherein the polymer material is capable of at least partially melting at a lower temperature than it is capable of at least partially thermally cracking.

6. The structural shell of claim 1, wherein the polymer material is capable of at least partially thermally cracking at a temperature of from 300 to 500 C., wherein the at least partially thermally cracked polymer material is a liquid at 20 C.

7. (canceled)

8. The structural shell of claim 1, wherein the ratio by weight of basalt fibres to polymer material is from 80:20 to 10:60.

9. The structural shell of claim 1, wherein basalt fibres are dispersed in the polymer material in a regular arrangement, wherein the basalt fibre-reinforced material comprises a plurality of layers of substantially parallel basalt fibres, wherein the average direction of the substantially parallel basalt fibres is different in adjacent layers.

10. (canceled)

11. (canceled)

12. (canceled)

13. The structural shell of claim 1, further comprising a polymer core.

14. The structural shell of claim 13, wherein the polymer core comprises a polyester.

15. The structural shell of claim 14, wherein the polyester comprises PET.

16. The structural shell of claim 13, wherein the polymer core has a melting temperature of from 200 to 300 C.

17. The structural shell of claim 1 further comprising a geleoat, wherein the gelcoat comprises unsaturated polyester resins andfor vinyl resins.

18. (canceled)

19. (canceled)

20. (canceled)

21. A hull for a marine vessel, a structural grid for a marine vessel, a deck for a marine vessel, a wind turbine blade, a ski or ski pole, or a ballistic resistant panel comprising the structural shell of claim 1, wherein in the ballistic resistant panel, the ratio by weight of polymer material to basalt fibres is from 0.35 to 0.45.

22. (canceled)

23. (canceled)

24. A marine vessel comprising at least one hull and/or at least one structural grid and/or at least one deck, wherein the at least one hull andior at least one structural grid and/or at least one deck are/is according to claim 21.

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. A method of manufacturing the structural shell of claim 1, the method comprising: providing a mould; introducing basalt fibres into the mould; contacting the basalt fibres with a mixture comprising a resin and a hardening agent at a relative pressure of 0.65 bar or less to form a structural shell; and recovering the structural shell from the mould.

30. The method of claim 29, wherein the resin comprises from 50 to 85 wt. % methyl methacrylate monomers and/or from 10 to 50 wt. % acrylic polymers.

31. The method of claim 29, wherein the hardening agent comprises an organic peroxide, wherein the mixture comprises the hardening agent in an amount of from 0.5 to 30 phr.

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. The method of claim of claims 29, wherein the method further comprises forming a gelcoat in the mould prior to the introduction of the basalt fibres into the mould.

38. The method of claim 29, wherein the method further comprises introducing a polymer core into the mould prior to contacting the basalt fibres with the mixture.

39. (canceled)

40. A method of disassembling the structural, shell of claim 1, the method comprising: providing the structural shell; heating the structural shell to a temperature of from 200 to 600 C. to at least partially thermally crack the polymer material; separating the at least partially thermally cracked polymer material from the basalt fibres; and recovering the basalt fibres and/or the at least partially thermally cracked polymer material.

41. The method of claim 40, wherein the heating is carried out in an inert atmosphere.

42. (canceled)

43. (canceled)

44. The method of claim 40, wherein the structural shell comprises a polymer core, and the method further comprises recovering the polymer core.

45. The method of claim 44, wherein prior to heating to the temperature of from 200 to 600 C., the method further comprises: heating the structural shell to a temperature of from 150 to 300 C. to at least partially melt the polymer material; separating the polymer core from the at least partially melted polymer material; and recovering the polymer core.

46. The method of claim 40, wherein the structural shell comprises a gelcoat, and the method further comprises at least partially mechanically removing the gelcoat prior to heating and/or removing the gelcoat by combustion of the gelcoat.

47. A method of disassembling the structural shell of claim 1, the method comprising: providing the structural shell; contacting the structural shell with a solvent to at least partially dissolve the polymer material; and recovering the basalt fibers and/or the polymer material.

Description

[0120] The invention will now be described in relation to the following non-limiting drawings in which:

[0121] FIG. 1 is a schematic of a marine vessel comprising a structural shell according to the present invention.

[0122] FIG. 2 is schematic of the cross section X-Y of FIG. 1.

[0123] FIG. 3 is a flow chart of a method of manufacturing the structural shell according to the present invention.

[0124] FIG. 4 is a flow chart of a method of disassembling a structural shell according to the present invention.

[0125] FIG. 5 is a flow chart of a method of disassembling a structural shell according to the present invention.

[0126] FIG. 6 is a schematic of an exploded view of the basalt fibre layer structure of a structural shell according to the present invention.

[0127] Referring to FIG. 1, there is shown a schematic of a marine vessel according to the present invention (shown generally at 1) having a hull 2 and a deck 3. FIG. 2 shows a cross-section along the line X-Y of FIG. 1. There is shown a structural shell (shown generally at 4) containing a polymer core 5 surrounded by polymer material 6 reinforced with basalt fibres 7. The basalt fibre-reinforced material 6 is coated with a gelcoat 8.

[0128] Referring to FIG. 3, there is shown a flow chart of a method of manufacturing the structural shell, hull, structural grid, deck, marine vessel, wind turbine blade or ski and and/or ski pole according to the present invention (shown generally at 9). The method comprises: 10 providing a mould; 11 introducing basalt fibres into the mould; 12 contacting the basalt fibres with a mixture comprising a resin and a hardening agent at a relative pressure of 0.65 bar or less to form a structural shell, hull, deck, marine vessel, wind turbine blade or ski and and/or ski pole; and 13 recovering the structural shell, hull, structural grid, deck, marine vessel, wind turbine blade or ski and and/or ski pole from the mould. Optionally, the method further comprises 15 forming a gelcoat in the mould prior to the introduction of the basalt fibres into the mould. Optionally, the method further comprises 16 introducing a polymer core into the mould prior to contacting the basalt fibres with the mixture.

[0129] Referring to FIG. 4, there is shown a flow chart of a method of disassembling a structural shell, hull, structural grid, deck, marine vessel, wind turbine blade or ski and and/or ski pole according to the present invention (shown generally at 17). The method comprises: 18 providing the structural shell, structural grid, hull, deck, marine vessel, wind turbine blade or ski and and/or ski pole; 19 heating the structural shell, hull, structural grid, deck, marine vessel, wind turbine blade or ski and and/or ski pole to a temperature of from 200 to 600 C. to at least partially thermally crack the polymer material; 20 separating the at least partially thermally cracked polymer material from the basalt fibres; and 21 recovering the basalt fibres and/or the at least partially thermally cracked polymer material. Optionally, the structural shell comprises a polymer core, and the method further comprises 22 recovering the polymer core. Optionally, the structural shell comprises a gelcoat, and the method further comprises 23 at least partially mechanically removing the gelcoat prior to heating and/or removing the gelcoat by combustion of the gelcoat.

[0130] Referring to FIG. 5, there is shown a flow chart of a method of disassembling a structural shell, hull, structural grid, deck, marine vessel, wind turbine blade or ski and and/or ski pole according to the present invention (shown generally at 30). The method comprises 31 providing the structural shell, hull, deck, structural grid, marine vessel, wind turbine blade, ski or ski pole (or other object described herein); 32 contacting the structural shell, hull, deck, structural grid, marine vessel, wind turbine blade, ski or ski pole (or other object described herein) with a solvent to at least partially dissolve the polymer material; and 33 recovering the basalt fibers and/or the polymer material.

[0131] Referring to FIG. 6, there is shown a schematic of an exploded view the basalt fibre layer structure of a structural shell according to the present invention (shown generally at 24). There is shown a plurality of layers of substantially parallel basalt fibres 7, wherein the average direction of the substantially parallel basalt fibres 7 in each layer is about 45 or about 90 relative to the average direction of the substantially parallel basalt fibres 7 in adjacent layers.

[0132] The invention will now be described in relation to the following non-limiting examples.

EXAMPLE 1

[0133] A basalt-fibre reinforced material as described herein was manufactured according to the methods described herein. The material had a monolithic structure. That is, the material consisted of a single piece of basalt fibre-reinforced material. The manufactured material was a 1 m1 m panel.

Step 1:

[0134] The weaves (layers) of basalt fibres were laid up in the following three layers: [0135] Layer 1: 600 TRI (600 g/m.sup.2 tri-axial weave) [0136] Layer 2: 550 UNI (550 g/m.sup.2 uni-directional weave) [0137] Layer 3: 600 TRI (600 g/m.sup.2 tri-axial weave)

Step 2:

[0138] A wooden table was wrapped as an envelope to secure a full vacuum seal around. The layer structure of step 1 was introduced into the envelope. The plastic wrap was sealed with tack tape in order seal off the bag completely. The layer structure of step 1 was in this envelope, ready to be infused. Peel ply was added on top of the layers (in order to release the vacuum bag from the composite easily and to create a better end finish) and on top of that a mesh was added to help the resin flow more gradually. At one end of the vacuum table (at the end of each part of the envelope) there was a spiral tube, which helps the resin flow over the width of the panel more gradually.

[0139] A vacuum pump was installed to a vacuum container (for capturing resin overflow). The bag was tested to be airtight by building up a relative pressure of 1.0 bar. Once a relative pressure of 1.0 bar was reached, the valves were closed and the vacuum pump was stopped for a so-called drop test (to measure eventual air leakage).

[0140] After completing the above steps, 3000 g of Elium from Arkema was mixed with 85 g of benzoyl peroxide hardening agent (Perkadox GB-50X from Nouryon) in a bucket. Once mixed, the bucket with the Eliume/Perkadox GB-50X resin was connected to the vacuum bag and the vacuum pump was started again. This created a flow of resin due to the negative relative pressure over the entire panel.

[0141] This step was carried out at room temperature.

Step 3:

[0142] The resin was kept under the reduced pressure for approximately 90 minutes. The composite was then left overnight in the vacuum bag and the vacuum bag was removed the morning after to recover the basalt fibre-reinforced material.

[0143] The monolithic basalt fibre-reinforced material was capable of being recycled by the methods described herein.

EXAMPLE 2

[0144] A monolithic basalt-fibre reinforced material was manufactured as described in Example 1. However, the layer structure of step 1 was different. In this example, the weaves (layers) of basalt fibres were laid up in the following four layers: [0145] Layer 1: 550UNI (550 g/m.sup.2 uni-directional weave) [0146] Layer 2: 300 BI (300 g/m.sup.2 bi-axial weave) [0147] Layer 3: 300 BI (300 g/m.sup.2 bi-axial weave) [0148] Layer 4: 550UNI (550 g/m.sup.2 uni-directional weave; oriented at 90 from layer 1)

[0149] The monolithic basalt fibre-reinforced material was capable of being recycled by the methods described herein.

EXAMPLE 3

[0150] A sandwich-structure basalt-fibre reinforced material was manufactured as described in Example 1. However, the layer structure of step 1 was different. In this example, the weaves (layers) of basalt fibres were laid up in the following four layers, with a PET foam core in the centre: [0151] Layer 1: 550UNI (550 g/m.sup.2 uni-directional weave) [0152] Layer 2: 300 BI (300 g/m.sup.2 bi-axial weave) [0153] Layer 3: PET foam core (thickness: 20 mm) [0154] Layer 4: 300 BI (300 g/m.sup.2 bi-axial weave) [0155] Layer 5: 550UNI (550 g/m.sup.2 uni-directional weave)

[0156] The sandwich-structure material was a 1 m0.10 m panel. The sandwich-structure basalt fibre-reinforced material was capable of being recycled by the methods described herein.

[0157] When the PET core is present, it is crucial that the resins flows through the injection holes in the PET core to create a strong bond at both ends of the sandwich.

EXAMPLE 4

[0158] Panels comprising the basalt-fibre reinforced material described herein were prepared according to the following method steps: [0159] 1. Prior to work: Prepare lamination room at room temperature between 18 and 24 C. Max humidity 45%; [0160] 2. Degrease and clean lamination table; [0161] 3. Wax lamination table with mould release wax; [0162] 4. Apply first layer of peel ply, ends glued with aerosol adhesive; [0163] 5. Marking layers setup with masking tape; [0164] 6. Lay-up fibre weaves according to Table 1; [0165] 7. Cover lay-up with peel ply and glue ends with aerosol adhesive; [0166] 8. Set-up tacky tape on flat surface on lamination table; [0167] 9. Add mesh flow media and keep flat on surface with masking tape; [0168] 10. Install 310 mm spiral, positioned with masking tape. 1 suction point on cloth, 1 vacuum point in the middle of the lay-up and the last one at the end on mesh flow media; [0169] 11. Install vacuum points in centre of spirals; [0170] 12. Set-up vacuum pack on the tacky tape. Envelop the lamination table when table has porosity; [0171] 13. Install 10 mm infusion hoses on vacuum points and seal the connections with tacky tape; [0172] 14. Drop test vacuum test prior to infusion. Pressure 0.80/1.00 bar. Drop allowance 0.5 bar/20 min; [0173] 15. Mix 2.7% of Perkadox GB50 with the Elium (10 kg Elium=270 g Perkadox GB50); [0174] 16. De-gas Elium/Perkadox mixture for 7-10 min; [0175] 17. Put de-gassed, mixed bucket of resin, levelled under the lamination table; [0176] 18. Put infusion hoses in bucket resin (eventually taped on a solid bar to keep hoses in position); [0177] 19. Open valve#2 slowly to have all resins in the tubes and no air. Close the valve before the resin enters the fibres; [0178] 20. Start infusion opening valve #1; [0179] 21. When resin flows 3 cm behind vacuum point #2, open valve point #2 by 25%-50% and open full when resins are visually over the panel; [0180] 22. Close vacuum point #1 when catalyst starts working and panel increases temperature of 35 C. [0181] 23. Keep vacuum on till resin fully cures; [0182] 24. Wait till panel temperature drops to room temperature; [0183] 25. De-mould.

TABLE-US-00001 TABLE 1 layer structure Layer Weave Lay up () Surface (m.sup.2) 1 UNI 550 1 2 UNI 550 90 1 3 UNI 550 1 4 UNI 550 90 1 5 UNI 550 1 6 UNI 550 90 1 7 UNI 550 1 8 UNI 550 90 1 9 UNI 550 1 10 UNI 550 90 1 11 UNI 550 1 12 UNI 550 90 1 13 UNI 550 1 14 UNI 550 90 1 15 UNI 550 1 16 UNI 550 90 1 17 UNI 550 1 18 UNI 550 90 1 19 UNI 550 1 20 UNI 550 90 1 21 UNI 550 1 22 UNI 550 90 1 23 UNI 550 1 24 UNI 550 90 1 25 UNI 550 1 26 UNI 550 90 1 27 UNI 550 1 28 UNI 550 90 1 29 UNI 550 1 30 UNI 550 90 1 31 UNI 550 1 32 UNI 550 90 1

[0184] The total weave and panel area was therefore 32 m.sup.2.

[0185] Three different pressures were used to manufacture three panels, respectively, each having the 32-layer structure of Table 1: 0.80, 0.85 and 0.90 bar. The total weight of each component for each panel are shown in Table 2.

TABLE-US-00002 TABLE 2 weights of components in panel Pressure (bar): 0.80 0.85 0.90 Fibres (kg): 17.60 17.60 17.60 Resin (kg): 7.57 7.39 7.22 Perkadox (kg): 0.204 0.200 0.195 Total panel weight (kg): 25.37 25.19 25.01

[0186] This shows that the more negative the pressure applied, the lower the resin:fibre ratio in the panel.

[0187] The same method was also used to prepare panels of roughly half the area. The layer structure is shown in Table 3.

TABLE-US-00003 TABLE 3 layer structure Layer Weave Lay up () Surface (m.sup.2) 1 UNI 550 0.54 2 UNI 550 90 0.54 3 UNI 550 0.54 4 UNI 550 90 0.54 5 UNI 550 0.54 6 UNI 550 90 0.54 7 UNI 550 0.54 8 UNI 550 90 0.54 9 UNI 550 0.54 10 UNI 550 90 0.54 11 UNI 550 0.54 12 UNI 550 90 0.54 13 UNI 550 0.54 14 UNI 550 90 0.54 15 UNI 550 0.54 16 UNI 550 90 0.54 17 UNI 550 0.54 18 UNI 550 90 0.54 19 UNI 550 0.54 20 UNI 550 90 0.54 21 UNI 550 0.54 22 UNI 550 90 0.54 23 UNI 550 0.54 24 UNI 550 90 0.54 25 UNI 550 0.54 26 UNI 550 90 0.54 27 UNI 550 0.54 28 UNI 550 90 0.54 29 UNI 550 0.54 30 UNI 550 90 0.54 31 UNI 550 0.54 32 UNI 550 90 0.54

[0188] The total weave and panel area was therefore 17.28 m.sup.2.

[0189] The same three different pressures were used to manufacture three panels having the 32-layer structure of Table 3, i.e. 0.80, 0.85 and 0.90 bar. The total weight of each component for each panel are shown in Table 4.

TABLE-US-00004 TABLE 4 weights of components in panel Pressure (bar): 0.80 0.85 0.90 Fibres (kg): 9.50 9.50 9.50 Resin (kg): 3.90 3.75 4.15 Resin:fibre ratio: 41.05% 39.47% 43.68% Total panel weight (kg): 13.40 13.25 13.65 Panel thickness (mm): 12.75 12.35 12.80

[0190] The panels were subjected to armour protection ballistic resistance testing (NIJ-STD-0108.01 levels III and IIIA) and passed.

EXAMPLE 5

[0191] Panels comprising the basalt-fibre reinforced material described herein were prepared according to the following method steps: [0192] 1. Prior to work: Prepare lamination room at room temperature between 18 and 24 C. Max humidity 45%; [0193] 2. Degrease and clean lamination table; [0194] 3. Wax lamination table with mould release wax; [0195] 4. Apply first layer of peel ply, ends glued with aerosol adhesive; [0196] 5. Marking layers setup with masking tape; [0197] 6. Lay-up fibre weaves according to Table 5; [0198] 7. Cover lay-up with peel ply and glue ends with aerosol adhesive; [0199] 8. Set-up tacky tape on flat surface on lamination table; [0200] 9. Add mesh flow media and keep flat on surface with masking tape; [0201] 10. Install 310 mm spiral, positioned with masking tape. 1 suction point on cloth, 1 vacuum point in the middle of the lay-up and the last one at the end on mesh flow media; [0202] 11. Install vacuum points in centre of spirals; [0203] 12. Install pressure gauge; [0204] 13. Set-up vacuum pack on the tacky tape. Envelop the lamination table when table has porosity; [0205] 14. Install 10 mm infusion hoses on vacuum points and seal the connections with tacky tape; [0206] 15. Drop test vacuum test prior to infusion. Pressure 1.00 bar. Drop allowance 0.5 bar/20 min; [0207] 16. Mix 2.7% of Perkadox GB50 with the Elium (10 kg Elium=270 g Perkadox GB50); [0208] 17. De-gas Elium/Perkadox mixture for 7-10 min; [0209] 18. Put de-gassed, mixed bucket of resin, levelled under the lamination table; [0210] 19. Put infusion hoses in bucket resin (eventually taped on a solid bar to keep hoses in position); [0211] 20. Start infusion opening valve #1; [0212] 21. When resin flows 3 cm behind vacuum point #2, open valve point #2; [0213] 22. At full infusion, close vacuum point #2; [0214] 23. Close vacuum point #1 when catalyst starts working and panel increases temperature of 35 C. [0215] 24. Keep vacuum on till resin fully cures; [0216] 25. Wait till panel temperature drops to room temperature; [0217] 26. De-mould.

TABLE-US-00005 TABLE 5 layer structure Layer Weave Lay up () Surface (m.sup.2) 1 UNI 550 1 2 UNI 550 90 1 3 UNI 550 1 4 UNI 550 90 1 5 UNI 550 1 6 UNI 550 90 1 7 UNI 550 1 8 UNI 550 90 1 9 UNI 550 1 10 UNI 550 90 1 11 UNI 550 1 12 UNI 550 90 1 13 UNI 550 1 14 UNI 550 90 1 15 UNI 550 1 16 UNI 550 90 1 17 UNI 550 1 18 UNI 550 90 1 19 UNI 550 1 20 UNI 550 90 1 21 UNI 550 1 22 UNI 550 90 1 23 UNI 550 1 24 UNI 550 90 1 25 UNI 550 1 26 UNI 550 90 1 27 UNI 550 1 28 UNI 550 90 1 29 UNI 550 1 30 UNI 550 90 1 31 UNI 550 1 32 UNI 550 90 1

[0218] The total weave and panel area was therefore 32 m.sup.2. The total panel weight was 24.83 kg, made up of 17.60 kg fibres, 7.04 kg resin and 0.19 kg Perkadox.

[0219] A panel having a quasi-isotropic lay-up was also manufactured according to the above procedure having a layer structure according to Table 6.

TABLE-US-00006 TABLE 6 layer structure Surface (m.sup.2) - Surface (m.sup.2) - Layer Weave Lay up () UNI BI 1 UNI 550 1 2 BI 300 1 3 UNI 550 90 1 4 BI 300 1 5 UNI 550 1 6 BI 300 1 7 UNI 550 90 1 8 BI 300 1 9 UNI 550 1 10 BI 300 1 11 UNI 550 90 1 12 BI 300 1 13 UNI 550 1 14 BI 300 1 15 UNI 550 90 1 16 BI 300 1 17 UNI 550 1 18 BI 300 1 19 UNI 550 90 1 20 BI 300 1 21 UNI 550 1 22 BI 300 1 23 UNI 550 90 1 24 BI 300 1 25 UNI 550 1 26 BI 300 1 27 UNI 550 90 1 28 BI 300 1 29 UNI 550 1 30 BI 300 1 31 UNI 550 90 1 32 BI 300 1 33 UNI 550 1 34 BI 300 1 35 UNI 550 90 1 36 BI 300 1 37 UNI 550 1 38 BI 300 1 39 UNI 550 90 1 40 BI 300 1 41 UNI 550 1 42 BI 300 1 43 UNI 550 90 1

[0220] The total panel area was therefore 43 m.sup.2, having 22 m.sup.2 UNI and 21 m.sup.2 BI. The total panel weight was 25.96 kg, made up of 18.40 kg fibres (12.10 kg UNI and 6.30 kg BI), 7.36 kg resin and 0.20 kg Perkadox.

[0221] Smaller panels having the same layer structures were also manufactured according to the above procedure, the layer structures being defined in Tables 7 and 8.

TABLE-US-00007 TABLE 7 layer structure Layer Weave Lay up () Surface (m.sup.2) 1 UNI 550 0.81 2 UNI 550 90 0.81 3 UNI 550 0.81 4 UNI 550 90 0.81 5 UNI 550 0.81 6 UNI 550 90 0.81 7 UNI 550 0.81 8 UNI 550 90 0.81 9 UNI 550 0.81 10 UNI 550 90 0.81 11 UNI 550 0.81 12 UNI 550 90 0.81 13 UNI 550 0.81 14 UNI 550 90 0.81 15 UNI 550 0.81 16 UNI 550 90 0.81 17 UNI 550 0.81 18 UNI 550 90 0.81 19 UNI 550 0.81 20 UNI 550 90 0.81 21 UNI 550 0.81 22 UNI 550 90 0.81 23 UNI 550 0.81 24 UNI 550 90 0.81 25 UNI 550 0.81 26 UNI 550 90 0.81 27 UNI 550 0.81 28 UNI 550 90 0.81 29 UNI 550 0.81 30 UNI 550 90 0.81 31 UNI 550 0.81 32 UNI 550 90 0.81

[0222] The total weave and panel area was therefore 25.92 m.sup.2. The total panel weight was 18.90 kg, made up of 14.26 kg fibres and 4.64 kg resin. The resin to fibre ratio was therefore 32.54% and the panel thickness was 12.12 mm.

TABLE-US-00008 TABLE 8 layer structure Surface (m.sup.2) - Surface (m.sup.2) - Layer Weave Lay up () UNI BI 1 UNI 550 0.81 2 BI 300 0.81 3 UNI 550 90 0.81 4 BI 300 0.81 5 UNI 550 0.81 6 BI 300 0.81 7 UNI 550 90 0.81 8 BI 300 0.81 9 UNI 550 0.81 10 BI 300 0.81 11 UNI 550 90 0.81 12 BI 300 0.81 13 UNI 550 0.81 14 BI 300 0.81 15 UNI 550 90 0.81 16 BI 300 0.81 17 UNI 550 0.81 18 BI 300 0.81 19 UNI 550 90 0.81 20 BI 300 0.81 21 UNI 550 0.81 22 BI 300 0.81 23 UNI 550 90 0.81 24 BI 300 0.81 25 UNI 550 0.81 26 BI 300 0.81 27 UNI 550 90 0.81 28 BI 300 0.81 29 UNI 550 0.81 30 BI 300 0.81 31 UNI 550 90 0.81 32 BI 300 0.81 33 UNI 550 0.81 34 BI 300 0.81 35 UNI 550 90 0.81 36 BI 300 0.81 37 UNI 550 0.81 38 BI 300 0.81 39 UNI 550 90 0.81 40 BI 300 0.81 41 UNI 550 0.81 42 BI 300 0.81 43 UNI 550 90 0.81

[0223] The total weave and panel area was therefore 34.83 m.sup.2, having 17.82 m.sup.2 UNI and 17.01 m.sup.2 BI. The total panel weight was 20.70 kg, made up of 14.90 kg fibres and 5.80 kg resin. The resin to fibre ratio was therefore 38.93% and the panel thickness was 13.20 mm.

[0224] The panels were subjected to armour protection ballistic resistance testing (NU-STD-0108.01 levels III and IIIA) and passed.

[0225] The foregoing detailed description has been provided by way of explanation and illustration, and is not intended to limit the scope of the appended claims. Many variations in the presently preferred embodiments illustrated herein will be apparent to one of ordinary skill in the art and remain within the scope of the appended claims and their equivalents.