Rigid ballistic composites having large denier per filament yarns
Find Innovative SolutionsGenerate Solutions
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 organic fibers like aramid, UHMWPE, and polyester-polyarylate fibers with CA·dpf greater than 6.9, to create lighter, cost-effective armor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If finer or smaller dpf yarns are used to achieve better ballistic performance, then ballistic performance is improved, but cost increases significantly
Solution Approach 1:
The patent changes the dpf parameter from traditional fine dpf values (1.5-5.4) to large dpf values (greater than 5.4, preferably greater than 10), fundamentally altering the yarn structure while maintaining ballistic performance through optimized fiber arrangement and resin impregnation
Solution Approach 2:
The patent replaces expensive fine dpf high-performance yarns with cheaper large dpf yarns made from standard high-performance fibers (aramid, UHMWPE, PBO), significantly reducing material cost while achieving equivalent or superior ballistic performance through the composite structure
2Reliability
If finer or smaller dpf yarns are used to achieve better ballistic performance, then ballistic performance is improved, but weight increases
Solution Approach 1:
The patent changes the dpf parameter to large values, reducing the number of filaments needed per yarn while increasing individual filament diameter, which optimizes the balance between strength and weight in the composite armor structure
Solution Approach 2:
The patent creates a composite structure combining large dpf high-performance yarns with thermoplastic or thermoset resin matrices, optimizing the weight-performance ratio through synergistic material combination and structured assembly
3Ease of manufacture
If large dpf yarns are used to reduce cost and weight, then cost and weight are improved, but ballistic performance may be compromised
Solution Approach 1:
The patent creates a composite structure where large dpf yarns are impregnated with resin and arranged in specific configurations (woven, non-woven, laminated), achieving ballistic performance equivalent to or exceeding fine dpf systems through optimized composite architecture
Solution Approach 2:
The patent optimizes local properties of the composite structure, including resin distribution, yarn spacing, and layer orientation, to ensure uniform stress distribution and energy dissipation throughout the armor panel, maintaining ballistic performance despite using larger dpf values
Data Source
AI summary
A rigid ballistic-resistant composite includes large denier per filament (dpf) yarns. The yarns are held in place by a resin to form a rigid composite panel with improved ballistic performance. The large dpf yarns may be selected from aromatic heterocyclic co-polyamide fibers, polyester-polyarylate fibers, high modulus polypropylene (HMPP) fibers, ultra high molecular weight polyethylene (UHMWPE) fibers, poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers, poly-diimidazo pyridinylene (dihydroxy) phenylene (PIPD) fibers, carbon fibers, and polyolefin fibers.