Rigid Ballistic Composite Panels Using Large-DPF Yarns

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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 composite armor systems, where the 'Composite-Armor dpf factor' is calculated to optimize ballistic performance, reduces production costs and enhances ballistic resistance without increasing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If finer or smaller dpf yarns are used to achieve better ballistic performance, then ballistic resistance is improved, but production cost increases significantly

Engineering Contradiction:

Improveballistic resistanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the dpf parameter from traditional fine values (1.5-5.4) to larger values (greater than 5.4, preferably greater than 10), fundamentally altering the yarn structure to achieve both cost reduction and maintained ballistic performance. This parameter inversion resolves the contradiction by showing that larger dpf yarns can provide equivalent or superior ballistic resistance at lower production costs.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structures combining large dpf yarns with thermoplastic and thermoset resin systems to achieve ballistic resistance. The composite approach allows the use of more economical large dpf yarns while maintaining protective performance through the synergistic combination of fiber and resin materials.

Inventive Principle:

Principle #40Composite materials

2Reliability

If finer or smaller dpf yarns are used to improve ballistic performance, then energy dissipation efficiency is improved, but product cost increases

Engineering Contradiction:

Improveenergy dissipation efficiencyVSAvoidproduct cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the dpf parameter to larger values while maintaining energy dissipation efficiency through optimized yarn construction and resin integration. The larger dpf yarns provide sufficient energy dissipation capability at lower costs, resolving the contradiction between performance and manufacturing expense.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The composite material system combines large dpf yarns with engineered resin matrices to achieve effective energy dissipation. The resin system complements the fiber structure to ensure adequate energy absorption and distribution, maintaining protective performance while reducing overall product cost.

Inventive Principle:

Principle #40Composite materials

3Reliability

If high performance yarns with higher tensile strength and modulus are used to improve ballistic performance, then ballistic resistance is improved, but input yarn cost increases significantly

Engineering Contradiction:

Improveballistic resistanceVSAvoidinput yarn cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes from using expensive high-performance yarns with enhanced tensile strength and modulus to large dpf yarns that achieve ballistic resistance through different mechanisms. The parameter shift from fine/high-strength yarns to large dpf yarns reduces input material cost while maintaining protective performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material construction where large dpf yarns are integrated with resin systems to achieve the required ballistic resistance. This composite approach provides an alternative to relying solely on expensive high-strength yarns, reducing input yarn cost while maintaining reliability.

Inventive Principle:

Principle #40Composite materials

4Reliability

If traditional fine dpf yarns are used to achieve superior ballistic performance, then weight-to-performance ratio is optimized, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveballistic performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the dpf parameter to larger values, simplifying the manufacturing process while maintaining ballistic performance. Large dpf yarns are easier to handle, process, and integrate into composite structures, reducing manufacturing complexity compared to fine dpf yarns.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11536540B2Rigid ballistic composites having large denier per filament yarns

Publication Date: 2022.12.27 BARRDAY

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.