Ballistic Tape Composite Layering for Impact Resistance
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Solution Overview
Problem
Current ballistic-resistant materials lack a combination of high ballistic performance, construction stability, and controlled deformation properties, particularly at extreme temperatures, and are heavy and difficult to process.
Innovation Solution
A composite ballistic-resistant article comprising a compressed stack of sheets with a HDPE-based layer and an elastomer-based layer, where the HDPE-based layer contains at least 60 wt.% HDPE and the elastomer-based layer contains at least 60 wt.% thermoplastic elastomer, providing improved impact resistance and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a ballistic-resistant article comprises only thermoplastic elastomer as matrix, then it shows good construction stability, but it exhibits poor structural integrity at extreme temperatures and poor peel resistance
Solution Approach 1:
The patent employs a composite matrix system combining thermoplastic elastomer and HDPE in specific layers. The thermoplastic elastomer layer provides construction stability and flexibility, while the HDPE layer contributes structural integrity and temperature resistance. This composite approach allows the article to simultaneously achieve good construction stability and reliable structural integrity at extreme temperatures, which neither material could provide alone.
2Reliability
If a ballistic-resistant article comprises only HDPE as matrix, then it shows good structural integrity, but it exhibits poor impact resistance and poor processing properties
Solution Approach 1:
The patent creates a layered composite structure where HDPE-based layers provide structural integrity and the thermoplastic elastomer-based layers provide superior impact resistance through their elastic properties. The combination allows the article to maintain structural integrity while significantly improving impact resistance compared to HDPE alone. Additionally, the thermoplastic elastomer component enhances processing properties such as peel resistance and ease of drilling or cutting.
3Stability of the object's composition
If the matrix content in thermoplastic elastomer layer is increased, then it shows improved construction stability, but it reduces ballistic performance at equal weight
Solution Approach 1:
The patent applies local quality by differentiating matrix content and composition across different layers. The thermoplastic elastomer-based layer contains 0.2-8 wt.% matrix material optimized for construction stability and flexibility, while the HDPE-based layer contains 5-20 wt.% matrix material optimized for structural integrity and ballistic performance. This localized optimization allows each layer to contribute its specific strengths without compromising overall ballistic performance at equal weight.
4Weight of moving object
If the article is designed to be light-weight, then it shows reduced weight, but it compromises ballistic performance and construction stability
Solution Approach 1:
The patent utilizes a light-weight composite material system combining thermoplastic elastomer and HDPE in a layered structure. This composite approach achieves superior strength-to-weight and stiffness-to-weight ratios compared to conventional single-material systems. The thermoplastic elastomer provides flexibility and impact absorption at low weight, while the HDPE layers provide structural support and ballistic protection, enabling the article to maintain high ballistic performance and construction stability at reduced weight.
Data Source
AI summary
The invention pertains to a ballistic-resistant moulded article comprising a compressed stack of sheets comprising reinforcing tapes having a tensile strength of at least 1.0 GPa, a tensile modulus of at least 40 GPa, and a tensile energy-to-break of at least 15 J/g, the direction of the tapes within the compressed stack being not unidirectional, wherein the stack comprises a first layer comprising sheets comprising reinforcing tapes and a high-density polyethylene (HDPE) as matrix material and a fur- ther layer comprising sheets comprising reinforcing tapes and a thermoplastic elastomer as matrix material, wherein the further layer comprises 0.2-8 wt.% matrix material. It has been found that the combination of a layer comprising HDPE as matrix with a layer comprising a thermoplastic elastomer as matrix results in an article which combines high impact re- sistance with improved constructional integrity of the article and reduced dynamic and static back face deformation upon im- pact.