Ballistic Material Sheet Mechanical Fusion
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Solution Overview
Problem
Existing multilayered material sheets for ballistic resistance have limitations in achieving optimal anti-ballistic performance, particularly in energy absorbance (Eabs) values, due to insufficient improvement in mechanical properties and increased use of bonding agents.
Innovation Solution
A material sheet comprising multiple thin monolayers of drawn unidirectional polymer fibers with a strength greater than 1.2 GPa, where the monolayers are mechanically fused under high pressure below the fibers' melting temperature, minimizing bonding agents and maximizing interfacial sites, resulting in improved anti-ballistic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayered material sheets are used to improve anti-ballistic performance, then energy absorbance increases, but bonding agent content increases and mechanical properties deteriorate
Solution Approach 1:
The patent changes the bonding mechanism from chemical bonding agents to physical mechanical fusion through high pressure compression. By applying pressures of 100-500 MPa, the fibers are fused together through plastic deformation and cold welding, eliminating the need for bonding agents while maintaining layer adhesion and improving anti-ballistic performance.
Solution Approach 2:
The patent removes bonding agents entirely from the material sheet composition. By extracting this harmful substance and replacing its function with mechanical fusion, the patent achieves both reduced bonding agent content (0-5 wt%) and improved mechanical properties while maintaining reliable anti-ballistic protection.
2Stability of the object's composition
If bonding agents are used to bond fiber layers, then layer adhesion improves, but mechanical properties in fiber direction deteriorate
Solution Approach 1:
The patent replaces the chemical bonding system with a mechanical bonding system. High pressure compression (100-500 MPa) induces plastic deformation at fiber contact points and creates cold welds between adjacent fibers, achieving layer adhesion through mechanical interlocking and metallic bonding rather than chemical adhesives.
Solution Approach 2:
The patent changes the bonding mechanism from chemical to physical-mechanical by applying extreme pressure. This parameter change transforms the bonding interface from adhesive-based to fusion-based, preserving fiber strength while achieving reliable layer adhesion through cold welding and plastic deformation.
3Quantity of substance
If high pressure is applied to fuse fibers, then bonding agent content reduces, but fiber strength may deteriorate
Solution Approach 1:
The patent optimizes the pressure parameter to a specific range (100-500 MPa) that is sufficient to induce fiber fusion and eliminate bonding agents but remains below the threshold that would cause fiber breakage or excessive deformation. This precise parameter control allows mechanical fusion without compromising fiber strength.
Solution Approach 2:
The patent applies high pressure for a brief duration sufficient to achieve fiber fusion and bonding agent elimination, then quickly releases the pressure. This rapid compression-decompression cycle prevents prolonged stress exposure that could deteriorate fiber strength while achieving the desired fusion effect.
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 approach significantly enhances anti-ballistic performance by increasing the number of interfacial sites and reducing bonding agent content, leading to better energy absorbance and cost-effectiveness while maintaining mechanical strength.
Implementation Method 1
the at least one monolayer has a thickness of less than 100 μm and the material sheet comprises a bonding agent of less than 13 wt % relative to the total weight of the material sheet
Implementation Method 2
EP 0116845 A2 discloses a process for the production of polyethylene articles, including multilayered material sheets, which involves the application of pressure and temperatures of between 100° C. to 160° C. to a network of fibers for sufficient time such that adjacent fibers adhere
Implementation Method 3
The application of evaluated pressure and/or time is applied to deform the fibers to substantially eliminate voids and thereby produce a film-like article
Implementation Method 4
The anti-ballistic performance is further improved through the combination of a thin monolayer with a relatively low level of bonding agent compared to the prior art, whether added, or formed in situ by partial melting or preferably by mechanical fusing of the drawn ultra high molecular weight polymer fibers
Data Source
AI summary
Material sheets are provided which include at least one monolayer, wherein the at least one monolayer has a plurality of drawn unidirectional polymer fibers having a strength of greater than 1.2 GPa and a thickness of less than 100 μm, and wherein the material sheet includes a bonding agent of less than 13 wt % relative to the total weight of the material sheet.