Ballistic Resistant Composite With Powder Coated Surface
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Solution Overview
Problem
Current ballistic resistant articles with composite layers and polymer films on their surfaces do not adequately protect against both bullet and fragment ammunition at the same areal density, as evidenced by lower v50-values compared to the desired standards.
Innovation Solution
A ballistic resistant article comprising consolidated composites with layers of high-strength fibers (≥800 mN/tex) impregnated with a matrix material and a powder-coated surface formed by partly molten and solidified powder particles, which provides enhanced penetration resistance and stability against abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer film is applied on the surface of composite layers, then the article achieves basic ballistic resistance, but the v50-value against both bullet and fragment ammunition is insufficient at the same areal density
Solution Approach 1:
The invention applies a powder coating layer composed of thermoplastic polymer particles onto the fiber composite layers. This creates a multi-layer composite structure where the powder coating forms a distinct protective surface layer with different properties than the underlying fiber composite, achieving superior ballistic resistance against both bullet and fragment ammunition
Solution Approach 2:
The powder coating process involves heating the thermoplastic powder to its melting point and then rapidly cooling it to form a solidified surface layer. This phase change transformation creates a dense, cross-linked polymer surface that significantly enhances the v50-value while maintaining areal density
2Ease of manufacture
If conventional polymer film coating is used, then manufacturing is relatively simple, but the article shows fiber bundling and reduced stability against abrasion
Solution Approach 1:
The thermoplastic powder coating undergoes phase transition from solid particles to molten state during heating, then rapidly solidifies upon cooling. This phase change creates a cross-linked, interpenetrating network that bonds the powder particles to each other and to the fiber composite, preventing fiber bundling and providing excellent abrasion resistance
Solution Approach 2:
The invention replaces the conventional polymer film lamination process with a powder coating and thermal processing system. Instead of applying and bonding a separate film layer mechanically, the thermoplastic powder is applied and then activated through heating to form a integrated surface layer that is chemically and mechanically bonded to the substrate
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 described solution achieves higher v50-values against both bullet and fragment ammunition at the same areal density compared to conventional articles, with improved stability and reduced fiber bundling, even at slightly lower areal densities, demonstrating enhanced ballistic protection and durability.
Implementation Method 1
at least the front surface of each consolidated composite is powder coated with partly molten and solidified powder particles
Implementation Method 2
at least the front surface of each consolidated composite is powder coated with partly molten and solidified powder particles
Data Source
AI summary
A ballistic resistant article is provided along with a process to manufacture the article. The ballistic resistant articles includes at least one consolidated composite, wherein the at least one consolidated composite includes at least two layers, each layer includes a network of fibers, the fibers have a strength of at least 800 mN/tex (1100 MPa) according to ASTM D 7269-07, the fibers in each layer are impregnated with a matrix material, and each consolidated composite has a front surface and a rear surface. In the ballistic article, at least the front surface of each consolidated composite is powder coated with partly molten and solidified powder particles to form a powder coated surface.