Aramid Fiber Composite Ballistic Resistance via High Pressure Molding
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Solution Overview
Problem
Current ballistic resistant products, particularly those made from aramid fibers, face challenges in effectively resisting high energy rifle bullets, as they lack sufficient resistance and weight efficiency.
Innovation Solution
A method involving the use of high tenacity aramid fibers coated with a thermoplastic polyurethane resin and molded under high pressure (at least 1500 psi) to create a composite material with enhanced ballistic resistance, utilizing multiple layers oriented at specific angles for improved structural integrity and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional aramid fiber products are used, then excellent basic properties are achieved, but resistance to high energy rifle bullets is insufficient
Solution Approach 1:
The patent applies composite materials by combining aramid fibers with a thermoplastic polyurethane matrix to create a hybrid composite structure. This composite approach leverages the high strength and stiffness of aramid fibers alongside the toughness and energy-absorbing capabilities of the polyurethane matrix, achieving superior ballistic resistance to high energy rifle bullets that neither material could achieve alone.
Solution Approach 2:
The patent utilizes parameter changes by controlling the molecular weight, composition, and processing conditions of the thermoplastic polyurethane resin. By optimizing these parameters, the composite achieves enhanced ballistic performance while maintaining processability and structural integrity under high-velocity impact conditions.
2Reliability
If more layers are added to improve protection, then ballistic resistance increases, but weight increases
Solution Approach 1:
The composite material structure allows for reduced layer count while maintaining or improving ballistic resistance. The thermoplastic polyurethane matrix provides additional protective functionality and structural integrity, enabling fewer layers to achieve the same or better protection level compared to traditional aramid-only constructions, thereby reducing overall weight.
Solution Approach 2:
The patent applies local quality by creating regions of enhanced protection where the thermoplastic polyurethane matrix is strategically positioned and distributed within the composite structure. This localized reinforcement provides targeted protection against high energy impacts without uniformly increasing weight across the entire product.
3Reliability
If high pressure molding is applied, then ballistic resistance improves, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes by optimizing the thermoplastic polyurethane resin properties and molding parameters to achieve effective ballistic performance. By carefully controlling temperature, pressure, and time parameters during molding, the process achieves high-quality composite formation with improved ballistic resistance while managing manufacturing complexity through systematic parameter optimization.
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 method significantly enhances the ballistic resistance of the composite material to high energy rifle bullets, offering improved protection with potentially reduced weight and layer count compared to traditional methods, while maintaining mechanical strength.
Implementation Method 1
coating the fibrous layer with a thermoplastic polyurethane resin
Implementation Method 2
molding the fibrous layer at a pressure of at least about 1,500 psi (10.3 MPa)
Data Source
AI summary
A method of making a ballistic resistant composite material having improved resistance to high energy rifle bullets and the like. The method comprises providing at least one fibrous layer comprising a network of high tenacity aramid fibers. The fibrous layer is coated with a thermoplastic polyurethane resin. The coated fibrous layer is molded at a pressure of at least about 1,500 psi (10.3 MPa). Preferably, a plurality of fibrous layers are employed, each of which is formed from to unidirectionally oriented aramid fibers in a thermoplastic polyurethane resin matrix. Adjacent fibrous layers are preferably oriented at 90° with respect to each other.