Rigid ballistic composites having large denier per filament yarns
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.
1. A rigid ballistic-resistant composite, comprising:
a) a plurality of yarns arranged into a fabric, the yarns having a “Composite-Armor dpf factor” (CA·dpf factor ) selected to provide improved ballistic performance; and
b) a resin in contact with the fabric to form a rigid composite panel in which the yarns of the fabric are held in place by the resin,
wherein CA·dfp factor is determined according to the following equation:
CA
·
dpf
factor
=
dpf
yarn
(
1
(
S
.
G
.
yarn
)
3
)
=
dpf
yarn
×
(
S
.
G
.
yarn
)
3
,
wherein dpf yarn is a denier per filament of the yarns,
wherein S.G. yarn is a specific gravity of the yarns, and
wherein the yarns have a CA·dpf factor of less than 85, and consist of ultra high molecular weight polyethylene (UHMWPE) fibers having a CA·dfp factor of greater than 10.04.
2. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise UHMWPE fibers with a dpf yarn between 11 and 30.55.
3. The rigid ballistic-resistant composite of claim 2 , wherein the UHMWPE fibers have a dpf yarn of about 30.55.
4. The rigid ballistic-resistant composite of claim 1 , wherein the yarns consist of UHMWPE fibers having a dpf yarn of greater than 30.55.
5. The rigid ballistic-resistant composite of claim 1 , wherein the resin is a thermosetting resin.
6. The rigid ballistic-resistant composite of claim 1 , wherein the resin is a thermoplastic resin.
7. The rigid ballistic-resistant composite of claim 1 , wherein the resin is selected from the group consisting of:
polyesters;
polypropylenes;
polyurethanes;
polyethers;
polybutadiene;
polyacrylate;
copolymers of ethylene;
polycarbonates;
ionomers;
ethylene acrylic acid (EAA) copolymers;
phenolics;
vinyl esters;
PVB phenolics;
natural rubbers;
synthetic rubbers;
polyethylene; and
styrene-butadiene rubbers.
8. A protective material comprising the rigid ballistic-resistant composite as claimed in claim 1 , wherein the protective material is selected from the group consisting of:
personal armor plates;
personal armor shields;
commercial vehicle armor;
military vehicle armor;
lightweight aircraft armor;
ship armor;
helmets; and
structural armor.
9. A rigid ballistic-resistant composite, comprising:
a) a resin; and
b) a plurality of yarns held in place by the resin,
wherein the yarns have a “Composite-Armor dpf factor” (CA·dpf factor ) determined according to
CA
·
dpf
factor
=
dpf
yarn
(
1
(
S
.
G
.
yarn
)
3
)
=
dpf
yarn
×
(
S
.
G
.
yarn
)
3
,
wherein dpf yarn is a denier per filament of the yarns,
wherein S.G. yarn is a specific gravity of the yarns, and
wherein the yarns comprise ultra high molecular weight polyethylene (UHMWPE) fibers having a CA·dpf factor of greater than 10.04.