Large-DPF Ballistic Composites for Lower-Cost Armor Panels
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Solution Overview
Problem
Current ballistic-resistant composite armor systems are expensive due to the use of finer denier per filament (dpf) yarns, which are costly to produce and limit the development of rigid armor with improved ballistic performance.
Innovation Solution
The use of large denier per filament (dpf) yarns in rigid or semi-rigid ballistic-resistant composites, where the 'Composite-Armor dpf factor' is calculated to optimize ballistic performance, incorporating high-performance fibers like aramid, UHMWPE, and polyester polyarylate, with a resin system to enhance energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If finer denier per filament (dpf) yarns are used to achieve better ballistic performance, then ballistic protection is improved, but material cost increases significantly
Solution Approach 1:
The patent changes the dpf parameter from traditional fine dpf (1.5-5.4) to large dpf (greater than 5.4, including 10, 15, 20, or more). This parameter inversion resolves the contradiction by demonstrating that larger dpf values can achieve equivalent or superior ballistic performance (V50) while using lower cost input yarns, thereby reducing material costs without sacrificing ballistic protection
Solution Approach 2:
The patent creates composite armor systems combining large dpf high-performance yarns (aramid, UHMWPE, HMPP, polyester) with thermoplastic and thermoset resin systems. This composite approach allows the use of more cost-effective yarn configurations while maintaining structural integrity and ballistic performance through the synergistic interaction between fibers and resin matrix
2Reliability
If higher tensile strength and initial modulus yarns are used to improve ballistic performance, then V50 performance increases, but input yarn cost increases
Solution Approach 1:
The patent modifies the dpf parameter to large values (greater than 5.4) while maintaining appropriate tensile strength and modulus through fiber selection and yarn construction. This allows achieving required V50 performance without needing the most expensive high-modulus fine dpf yarns, as the large dpf configuration provides sufficient mechanical properties at lower cost
3Reliability
If more filaments are used in yarn construction to improve energy dissipation, then ballistic performance improves, but yarn cost and complexity increase
Solution Approach 1:
The patent inverts the traditional approach by using fewer, larger dpf filaments instead of many fine filaments. This inversion demonstrates that large dpf yarns (with fewer filaments per yarn) can provide equivalent or superior energy dissipation capabilities through more efficient stress distribution and fiber-matrix interaction, thereby reducing yarn construction complexity
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
This approach results in lighter, more cost-effective ballistic panels with improved V50 performance, enabling better ballistic protection at lower material costs and expanding market applications for large dpf high-performance yarns.
Implementation Method 1
incorporating high-performance fibers like aramid, UHMWPE, and polyester polyarylate, with a resin system to enhance energy dissipation
Data Source
AI summary
According to some embodiments, there is provided a ballistic-resistant composite including a plurality of large denier per filament (dpf) yarns. The large dpf yarns may have a “Composite-Armor dpf factor” (CA•dpf) of greater than or equal to 6.9.