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·dpf factor is determined according to the following equation:
CA
·
dp
f
factor
=
d
p
f
y
a
r
n
(
1
(
S
.
G
.
yarn
)
3
)
=
d
p
f
y
a
r
n
×
(
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 are selected from the group consisting of:
polyester-polyarylate fibers having a CA·dpf factor of greater than 13.72; and
high modulus polypropylene (HMPP) fibers having a CA·dpf factor of greater than 6.03.
2. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise polyester-polyarylate fibers having a CA·dpf factor of greater than 13.72.
3. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise HMPP fibers having a CA·dpf factor of greater than 4.74 based on measured density of the yarns.
4. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise HMPP fibers having a CA·dpf factor of greater than 6.03.
5. The rigid ballistic-resistant composite of claim 1 , wherein the yarns have a CA·dpf factor between 16 and 42.
6. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise polyester-polyarylate fibers with a dpf yarn of between 5 and 10.20.
7. The rigid ballistic-resistant composite of claim 6 , wherein the polyester-polyarylate fibers have a dpf yarn of about 10.20.
8. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise HMPP fibers with a dpf yarn of greater than 12.5.
9. The rigid ballistic-resistant composite of claim 8 , wherein the HMPP fibers have a dpf yarn of between 19.0 and 37.00.
10. The rigid ballistic-resistant composite of claim 8 , wherein the HMPP fibers have a dpf yarn of about 37.00.
11. The rigid ballistic-resistant composite of claim 1 , wherein the yarns are selected from the group consisting of:
polyester-polyarylate fibers having a dpf yarn of greater than 10.20; and
HMPP fibers having a dpf yarn of greater than 37.00.
12. The rigid ballistic-resistant composite of claim 1 , wherein the resin is a thermosetting resin.
13. The rigid ballistic-resistant composite of claim 1 , wherein the resin is a thermoplastic resin.
14. 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.
15. The rigid ballistic-resistant composite of claim 1 , wherein the yarns comprise organic high-performance fibers.
16. 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.
17. 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
·
dp
f
factor
=
d
p
f
y
a
r
n
(
1
(
S
.
G
.
yarn
)
3
)
=
d
p
f
y
a
r
n
×
(
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 at least one of:
polyester-polyarylate fibers having a CA·dpf factor of greater than 13.72; and
high modulus polypropylene (HMPP) fibers having a CA·dpf factor of greater than 6.03.