3D Woven Preform Thermoplastic Composite Ballistic Panels
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Solution Overview
Problem
Current ballistic panels manufactured by press curing of phenolic polyvinyl butyral (PVB) Aramid two-dimensional (2D) woven pre-impregnated preforms are heavy due to the need for thick panels to meet threat compliance standards, which is a limitation in terms of weight and efficiency.
Innovation Solution
A compression resin transfer molding process using a three-dimensional woven fabric preform infused with a thermoplastic resin, such as polymethyl methacrylate, which is compressed and cured to form a lightweight, monolithic composite material with enhanced penetration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick panels are used to meet threat compliance standards, then penetration resistance is improved, but weight increases
Solution Approach 1:
The patent employs a composite material system consisting of a three-dimensional woven preform (made of aramid, carbon, or glass fibers) combined with a thermoplastic resin matrix. This composite structure achieves superior penetration resistance at reduced thickness compared to traditional 2D woven prepregs, thereby reducing panel weight while maintaining ballistic protection performance
Solution Approach 2:
The patent transitions from traditional two-dimensional woven preforms to three-dimensional woven preforms with z-directional interlocking. This dimensional enhancement creates through-thickness fiber connectivity that significantly improves penetration resistance, allowing thinner panels to achieve the same protective performance, thus reducing weight
2Strength
If traditional 2D woven prepregs are used, then manufacturing process is simple, but penetration resistance is insufficient
Solution Approach 1:
The patent uses pre-formed three-dimensional woven preforms that are manufactured separately before being placed in the mold cavity. This preliminary preparation allows the complex 3D structure to be created using specialized weaving machinery, while the final composite manufacturing process remains relatively simple through resin transfer molding and compression curing
Solution Approach 2:
The patent introduces a thermoplastic resin as an intermediary material that infiltrates the three-dimensional woven preform structure. This resin acts as a binding medium that consolidates the preform, transfers loads effectively, and achieves the desired penetration resistance without requiring complex manufacturing steps
3Strength
If thick panels are manufactured, then penetration resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent utilizes thermoplastic resins that can be processed at relatively low temperatures compared to thermoset resins. The compression molding process parameters (temperature, pressure, time) can be optimized to achieve complete resin infiltration and consolidation, reducing manufacturing costs while producing thinner, more efficient panels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in lightweight ballistic panels capable of resisting penetration from high-velocity rounds while meeting compliance standards, offering improved energy dissipation and reduced manufacturing costs compared to traditional methods.
Implementation Method 1
introducing a resin into the mold so that the resin penetrates into the preform
Implementation Method 2
compressing the mold to push the resin into the preform, after introducing the resin into the mold. In various embodiments, the compressing the mold causes the resin to evenly distribute through the preform
Implementation Method 3
curing the resin in the preform to form a monolithic composite material
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
A system of manufacturing a ballistic material is disclosed herein. The system includes a preform (108) including a three-dimensional woven fabric, a mold including a cavity (102a), the cavity (102a) configured to receive the preform (108), and a port (110) formed through the mold and into the cavity (102a), wherein the port (110) is configured to introduce a resin (112) into the cavity (102a), the resin (112) filling the cavity (102a) and penetrating into the preform (108).