posted 11-15-2002 22:56               

Here is some rather shocking stuff from an armor manufacturer, BSST, who had the stones to RECALL all of their Zylon based products, the info has been available since 07-20-2001. This is about the time that Toyobo published the PDF we have previously referenced.
Note that BSST ACTUALLY WALKs THE WALK,
"An open and in-depth information issue was always part of the BSST philosophy" Unlike the ethical midgets at Second Chance, Armor Holdings, Safariland, and numerous other American Manufacturers.
BSST published the test results and reason for the recall. THEY DID THE RIGHT THING.
******************************************* http://www.bsstgmbh.de/BSSTV20/html/english/eS010702.htm
An open and in-depth information issue was always part of the BSST philosophy. A body armor manufacturer is one link of the 'warranty chain', containing the fiber manufacturer, processing companies like weaving mills, garment manufacturers, dealers and of course the customer.
BSST wants to comment on the occurences of the last days and weeks dealing with the subject "Zylon" and we think it is our duty to pass on the information and results to our customers.

Facts and questions:

Due to the requests dealing with the warranty issue, Toyobo started accelerated aging tests with the ZylonŽ fiber. The test results can be reviewed in the article, dated 07-18-2001.

Facts
Without any valuation of the test results, the following facts can be recorded:
After 10 days at 80°C and 80% relative humidity, the strength loss of the ZylonŽ fiber is 20%
After 10 days at 60°C and 80% relative humidity, the strength loss of the ZylonŽ fiber is 10%
After 10 days at 40°C and 80% relative humidity, almost no strength loss of the ZylonŽ fiber was recorded
The ZylonŽ fiber is sensitive to certain environmental conditions and according to Toyobo, the strenght loss
is a result of hydrolysis, this means reaction of the fiber with water.
Based on the two and a half years history with the ZylonŽ fiber, Toyobo estimates a strength loss of
less than 5% for 10 years at room temperature.
As a result, it is impossible for Toyobo to guarantee 10 years.

Questions
With this theoretical backround knowledge the following questions arise, dealing with the practical use of ZylonŽ fiber for body armor:
What does 20%, 10%, 5% or even 1% strenght loss of the fiber means for the ballistic performance
(e.g. V50 value) of body armor ?
Is it possible to reach or even exceed the test conditions mentioned above, during the daily use of the body armor ?
Storage of body armor for 10 years at room temperature does not meet reality.
What will be the strength loss for 10 years at real operational conditions ?
Is the use of ZylonŽ fiber for body armor justifiable, when it is impossible for the fiber manufacturer to make the warranty,
which is demanded by the technical guideline?

Consequences

We rated body armor with ballistic packages made of ZylonŽ as the revolution in ballistic body protection. Light, thin, flexible but nevertheless outstanding ballistic performance. But at the moment it looks like ZylonŽ, corresponding to the current stage of technical development, can not meet the demands. The requirements for ballistic body protection are extremly high and leave no room for compromises. As a result of the above mentioned questions, BSST takes the necessary steps:
BSST has access to V50 test results, which show direct relation between strength loss
and decrease of ballistic performance.
BSST agrees that the test conditions can be reached during daily use of body armor, even for a limited period of time.
BSST valuates the exclusive storage of body armor at room temperature as not realistic.
Therefore a definitive statement concerning the real strength loss for 10 years is not possible.
Since the fiber manufacturer makes no warranty, it would be irresponsible for BSST to make any appropriate warranty.

Conclusion

Statements about the long-term characteristics of ZylonŽ fiber are based on theoretical considerations and can not be confirmed or disproved due to missing practical values. As a result, BSST will not use ZylonŽ fiber of the current stage of development for ballistic packages of body armor.

BSST management, Nellingen 07-20-2001

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DSM put on hold the market introduction of ZylonŽ-UD http://www.bsstgmbh.de/BSSTV20/html/english/eS010701.htm
The worldwide only manufacturer of ZylonŽ-UD (also known as ZylonŽ Shield), has stopped the production and distribution of ZylonŽ-UD.
Companies, processing this product, were told to take back body armor produced up to now.
In order to evaluate the long-term characteristics of materials, so called aging tests are performed. During this tests, the material is exposed to increased temperature and humidity conditions, for a certain time period. In the scope of this tests, DSM got serious indications of accelerated aging of ZylonŽ-UD, which become apparent by a significant loss of strength. According to DSM, the use of ZylonŽ-UD in bullet resistant vests may not be justified, because the required warranty can not be granted. DSM took the necessary steps and put on hold the market introduction of ZylonŽ-UD. If this fast loss of strength also applies to ZylonŽ fabric, is currently subject of intensive tests.

Result of the accelerated aging test of ZYLON AS (Reference: Toyobo) According to Toyobo, manufacturer of the ZylonŽ fiber, the DSM test results can not be confirmed. It is assumed, that the effect is caused by ZylonŽ-UD and not by the ZylonŽ fiber itself. The figure shows the results of the accelerated aging test of the ZylonŽ fiber. During a time period of 100 days (horizontal axis), the change of strength (vertical axis) was determined and plotted into the figure as measuring data. 80% relative humidity and 3 different temperatures were chosen for the test. The lower line shows the course at 80°C and after 10 days the loss of strength is about 20%. The line above shows the course at 60°C and after 10 days the loss of strength is about 10%. At 40°C, almost no loss of strength was recorded during the period of the test. As a result of this tests, the actual loss of strength under realistic conditions can only be estimated. Based on the two and a half years history in the production of ZylonŽ fiber, Toyobo is able to estimate less than 5% strength loss for 10 years at room temperature. According to Toyobo, it is not possible for them to guarantee 10 years (demanded by the german technical guideline for body armor, dated October 2000) based on the result.

Recall
As a result, the ballistic packages Definite-1 and Definite-2 are no longer available. In the scope of the recall, customers already wearing BSST body armor, containing one of this ballistic packages are informed at the moment.

We will keep you informed.

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Decrease in performance of ZylonŽ greater than expected http://www.bsstgmbh.de/BSSTV20/html/english/eS011102.htm
The latest results of the aging test with ZylonŽ are causing great concern. Toyobo, the producer of the ZylonŽ fiber just released an update on the progress of their aging test. After a test period of 150 days at 40°C and 80% relativ humidity, the ZylonŽ fiber shows a loss in performance of more than 15%. That the decrease in performance of the ZylonŽ fiber is greater than expected at the beginning of the aging test, was already obvious in our report, dated 08-29-01 (German language only). But back than it was assumed, that the decrease in performance follows a straight line the logarithmic plot. The graph on the right shows very impressiv, that the drop in performance does not follow the straight line, this means the consequences of the accelerated aging of the ZylonŽ fiber are worse than theoretically expected.

The effect is still unsolved
According to Toyobo, the mechanism that causes the drop in performance is not clear at this time. Customers of Toyobo should take this information into account when designing a product made of ZylonŽ, when this product is expected to be used in such conditions for a long time.

ZylonŽ in body armor
Environmental conditions and the use of ZylonŽ in body armor was an issue in our report, dated 08-29-01 (German language only). By the way, on the updated website of Toyobo, body armor is no longer listed as an field of application for ZylonŽ. Anyway, the decision of the BSST management not to use ZylonŽ in ballistic packages any more, was confirmed again.

Results of the aging test with ZylonŽ (Source: Toyobo)

posted 11-15-2002 23:40               

[Edited to include date stamp from original publication-Mad Dog]

posted 11-16-2002 00:25               

11-30-2001
Decrease in performance of ZylonŽ greater than expected
The latest results of the aging test with ZylonŽ are causing great concern.
Toyobo, the producer of the ZylonŽ fiber just released an update on the progress of their aging test.

10-02-2001
New ballistic data on ZylonŽ-UD and ZylonŽ fabric.
Concerning the aging issue of ZylonŽ, DSM High Performance Fibers provided us with new ballistic data on ZylonŽ-UD and ZylonŽ fabric

07-20-2001 Company statement
After information became public concerning possible safety defects of body armor containing ZylonŽ-UD or ZylonŽ fabric, BSST decided to recall already delivered vests as a precaution.

07-19-2001 Recall
After the recall of BSST body armor models Definite-1 and Definite-2, containing ZylonŽ-UD, the model iXZ, made of ZylonŽ fabric, were also recalled.

07-18-2001 DSM put on hold the market introduction of ZylonŽ-UD
The worldwide sole manufacturer of ZylonŽ-UD (also known as ZylonŽ Shield), has stopped the production and distribution of ZylonŽ-UD

07-09-2001 Technical problems with ZylonŽ
We were informed by our fiber supplier, that technical problems with the new ZylonŽ fiber occured. As a result, all BSST ballistic packages which contain ZylonŽ fibers are not available at the moment.

***************************************

In short, TOYOBO began notifiying their users by early July of 2001 that there were severe aging and degradation problems with Zylon. BSST acknowledged this publicly on JULY 9, 2001

Precautionary recalls began by BSST on JULY 19, 2001. ONLY TEN DAYS LATER!

By October 2, BSST showed that V50 losses due to degradation from huimidity were signifigant, and by November 30 had shown conclusively that the losses were logarithmic, rather than linear. In other words, very bad indeed.

Is it even imaginable that TOYOBO forgot to
inform their largest American OEM users of these problems?

Is it even imaginable that men like Second Chance's Richard Davis and Ed Bachner (VP of technology)didn't grasp the signifigance of the data that Toyobo almost certainly presented to them in July of 2001?

SO WHY ARE THEY STILL MARKETING ZYLON VESTS MORE THAN A YEAR LATER?????

And another thing...
Why won't they answer our phone calls??
Why won't they respond to our emails??

Denial.
Its not just a river in Egypt anymore.
Now, its the preferred beverage of Zylonistas everywhere.

posted 11-16-2002 00:56               

any thought to sending an article about this to some trade pubs, or anything?

posted 11-16-2002 02:42               

In the meantime, send links for this to EVERYONE on your mail lists!

posted 11-17-2002 00:43               

What will it take for someone, somewhere in law enforcement or the judicial arena to instigate a Grand Jury investigation into the fraud being perpetrated by the armor companies?

Won't someone out there please step up to the plate and at least file a class action suit against the Zylonistas?

posted 11-27-2003 22:25               

Evidently, the ones using the laminates are still claiming "it isn't a fiber problem, it's a construction problem".
Unfortunately for Toyobo, they seem to endorsing this mindset. Big mistake.

As you can see, extensive testing in Europe has already shown that the laminates tested take a dump too, just a little slower than the woven material.

posted 12-30-2003 07:31            

Could this be the building of a government mandated recall list? Or will this information possibily be used to assist the government in an effort to ballistically "spot check" degradation levels of worn armor?