Ballistic Resistant Articles Using High Aspect Ratio Tape Stacks
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Solution Overview
Problem
Existing ballistic-resistant materials face challenges in achieving high ballistic performance while maintaining low areal weight and stable delamination properties, with existing solutions either compromising on performance or weight when reducing matrix content.
Innovation Solution
A ballistic-resistant moulded article comprising a compressed stack of sheets with reinforcing elongate bodies, specifically tapes with a width-to-thickness ratio of at least 10:1 and a linear density of at least 5000 dtex, combined with 0.2-8 wt.% of an organic matrix material, where the tapes are oriented in multiple directions to enhance strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the content of matrix material is decreased to reduce areal weight, then areal weight is reduced, but delamination properties and peel strength deteriorate
Solution Approach 1:
The patent changes the physical parameters of the reinforcing elements by specifying a width-to-thickness ratio of at least 10:1 and linear density of at least 5000 dtex. These parameter changes allow the use of only 0.2-8 wt.% matrix material while maintaining adequate delamination resistance, as the optimized geometry and density of the tapes provide sufficient structural integrity with minimal matrix binding material.
Solution Approach 2:
The patent creates a composite structure combining reinforcing tapes with specific geometric parameters and an organic matrix material in controlled amounts (0.2-8 wt.%). This composite approach allows the tape geometry to carry the primary load while the minimal matrix content provides just enough binding to prevent delamination, achieving both weight reduction and reliability maintenance.
2Strength
If the content of matrix material is decreased to improve ballistic performance, then ballistic performance is improved, but delamination properties deteriorate
Solution Approach 1:
The patent specifies precise parameter ranges for the reinforcing tapes (width-to-thickness ratio ≥10:1, linear density ≥5000 dtex) that enable superior ballistic performance with minimal matrix material (0.2-8 wt.%). The optimized tape parameters provide enhanced strength-to-weight ratio while the geometry ensures adequate inter-laminar bonding without excessive matrix content.
Solution Approach 2:
The patent uses tape replicas or copies with specific geometric characteristics (width, thickness, linear density relationships) that replicate the optimal performance properties. These standardized tape configurations ensure consistent ballistic performance and delamination resistance across the composite structure with minimal matrix material.
3Ease of manufacture
If unidirectional fiber orientation is used to simplify manufacturing, then manufacturing complexity is reduced, but delamination properties and structural stability deteriorate
Solution Approach 1:
The patent segments the reinforcing structure into multiple tape layers with different orientations within the compressed stack. This segmentation approach creates a multi-directional reinforcement system that improves delamination resistance and structural stability while maintaining manufacturing simplicity through the use of discrete, pre-formed tapes that can be stacked and compressed using standard composite manufacturing processes.
Data Source
AI summary
The invention pertains to a ballistic-resistant moulded article comprising a compressed stack of sheets comprising reinforcing elongate bodies and an organic matrix material, the direction of the elongate bodies within the compressed stack being not unidirectionally, wherein the elongate bodies are tapes with a width of at least 2 mm and a width to thickness ratio of at least 10:1 with the stack comprising 0.2-8 wt. % of an organic matrix material. A method for manufacturing the ballistic-resistant moulded article is also claimed.