Anti-Ballistic Laminate Manufacturing Method
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Solution Overview
Problem
Current anti-ballistic protection systems are either heavy and expensive or flimsy and ineffective, lacking efficient and scalable methods for manufacturing lightweight, flexible laminates suitable for mass production in residential and commercial applications.
Innovation Solution
A method for producing continuous lengths of flexible ballistic-resistant laminates by bonding individual sheets of lightweight anti-ballistic materials, such as Kevlar, Dyneema, and graphene, using various bonding processes like stitching, gluing, and welding, to create multi-layered structures that can be rolled and configured for enhanced protection without excessive weight or volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional anti-ballistic materials (ceramics, metal plates) are used, then protection effectiveness is improved, but weight and volume increase significantly
Solution Approach 1:
The patent employs composite material structures combining multiple layers of different materials (ceramic particles, polymer matrices, fibrous reinforcements) to achieve effective ballistic protection while reducing overall weight. The composite approach allows optimization of each layer's function - ceramic for hard protection, polymer for flexibility and energy absorption, creating a lightweight yet protective system
2Weight of moving object
If lightweight materials are used to reduce weight, then weight is reduced, but protection effectiveness decreases and materials become flimsy
Solution Approach 1:
Lightweight polymers and fibrous materials are combined with ceramic particles to create composite structures that maintain protection effectiveness while reducing weight. The polymer matrix provides flexibility and energy absorption, while embedded ceramic particles provide hard protection, achieving both lightweight and protective properties simultaneously
Solution Approach 2:
Different regions of the anti-ballistic structure use different material compositions and densities optimized for their specific functions. Impact-facing layers use harder materials for initial contact, while inner layers use softer materials for energy dissipation, creating localized optimization that maintains overall protection while reducing total weight
3Reliability
If rigid structures are used to provide protection, then protection effectiveness is improved, but flexibility and ease of deployment are reduced
Solution Approach 1:
The patent utilizes flexible polymer matrices and thin-film composite structures that can bend and conform to different shapes while maintaining their protective integrity. These flexible composite films provide ballistic protection without the rigidity of traditional solid plates, enabling deployment in various configurations and locations
4Reliability
If complex multi-layer structures are used to improve protection, then protection effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple functional layers (ceramic dispersion, fibrous reinforcement, polymer matrix) are combined into integrated composite structures that can be manufactured as single units. The manufacturing process merges material deposition, bonding, and curing steps to create multi-functional protective layers without requiring separate assembly operations for each layer
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the efficient mass production of lightweight, flexible laminates that effectively prevent ballistic objects and shrapnel penetration, offering a balance between protection and weight, suitable for various anti-ballistic products like bulletproof systems and barriers.
Implementation Method 1
using said bonding process to bond said first sheet of material to said one or more additional sheets of material together to form said continuous length of flexible ballistic resistant laminate
Data Source
AI summary
Laminates and their process of manufacture, with the laminates made with anti-ballistic materials, such as woven and unwoven fabrics. The laminates are provided with different structures, materials, bondings, and other features, and example methods of manufacturing those laminates efficiently and in mass quantities. The method of production is a process of laminating individual flexible sheets including anti-ballistic material (which may be of woven or unwoven cloth or thin solid sheets or foils comprised of one or more light-weight anti-ballistic materials) into a flexible laminate for use to protect people or spaces from ballistic objects such as bullets and shrapnel from weapons and other moderate to high-kinetic energy objects