Ballistic Composite Foam Coating Eliminates Stitching
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Solution Overview
Problem
Current ballistic protection materials are rigid, uncomfortable, and costly due to stitching, require multiple materials, and have suboptimal ballistic resistance/weight ratios, with some materials failing under high temperatures and lacking oil and water repellency.
Innovation Solution
A composite material with a ballistic fabric substrate coated with a polymer layer of acrylic and polyurethane resin foam, applied via foaming, which increases ballistic resistance without excessive weight, eliminating the need for stitching and anti-trauma elements, and allowing for simpler, more cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stitches are used to hold fabric layers together, then resistance against deformation due to impact increases, but the packet becomes rigid and uncomfortable for the wearer
Solution Approach 1:
The patent removes stitches entirely from the ballistic protection system. Instead of using mechanical stitching to hold layers together, the invention relies on the inherent friction and interlocking between the textured fabric surfaces and the foam layers, eliminating the need for rigid stitching while maintaining structural integrity.
Solution Approach 2:
The patent uses thin foam layers (3-10mm) with specific density (40-80 kg/m³) that provide both protection and flexibility. These foam films conform to the wearer's body contours, providing comfort while maintaining the necessary protective characteristics against impact deformation.
2Strength
If multiple types of materials are used to achieve desired performance, then ballistic resistance improves, but the method of preparing the packet becomes more complex
Solution Approach 1:
The patent employs a standardized multi-layer construction where each layer type (textile fabric, foam, optional anti-trauma layer) serves multiple functions. The textile layers provide both ballistic resistance and structural integrity, while the foam layers simultaneously provide cushioning, layer bonding, and trauma reduction, reducing the need for specialized components.
Solution Approach 2:
The patent uses consistent fabric construction across all textile layers with uniform thread count, weave pattern, and material composition. This homogeneity simplifies the manufacturing process by allowing standardized cutting, layering, and assembly procedures while maintaining consistent ballistic performance throughout the packet.
3Object-affected harmful factors
If anti-trauma reinforcement layers are added to reduce trauma, then trauma limitation improves, but the packet becomes stiffer and less comfortable
Solution Approach 1:
The patent applies anti-trauma foam layers selectively only in specific regions where trauma risk is highest, such as the front and back panels of ballistic vests, while omitting them from side panels or areas requiring maximum flexibility. This localized application provides trauma protection where needed while preserving comfort and range of motion in other areas.
Solution Approach 2:
The patent varies the foam density and thickness parameters to optimize the balance between trauma reduction and comfort. By using lower density foams (40-80 kg/m³) with controlled thickness (3-10mm), the system provides adequate cushioning against impact trauma while maintaining sufficient flexibility for wearer comfort and movement.
4Strength
If unidirectional materials are used for ballistic fabric, then ballistic resistance is achieved, but the material cannot be subjected to usual finishing treatments for oil and water repellency
Solution Approach 1:
The patent creates a composite structure combining the unidirectional ballistic fabric with foam layers and optional thermoplastic bonding layers. This composite construction allows the ballistic fabric to maintain its superior one-directional strength characteristics while the foam and bonding layers provide the necessary surface properties for finishing treatments, enabling oil and water repellency without compromising ballistic performance.
5Strength
If more layers are added to increase ballistic resistance, then protection level improves, but the overall weight of the article increases
Solution Approach 1:
The patent optimizes the weight-to-protection ratio by carefully selecting and adjusting parameters including foam density (40-80 kg/m³), foam thickness (3-10mm per layer), fabric thread count, and layer consolidation. These parameter optimizations allow achieving required ballistic resistance levels with minimized material quantities and overall weight.
Solution Approach 2:
The patent uses a moderate number of layers (typically 3-5 layers total including textile and foam) rather than excessive layering, relying on the high effectiveness of each individual layer through optimized material selection and construction. This partial action approach achieves sufficient protection without the weight penalty of over-engineering with excessive layers.
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
The composite material achieves a superior ballistic resistance/weight ratio, resulting in lighter, more comfortable, and cost-effective ballistic protection articles with reduced material usage and improved performance under various conditions.
Implementation Method 1
a layer of polymer coating constituted by a foam comprising an acrylic resin and a polyurethane resin
Implementation Method 2
said polymer coating being applied on said surface at an amount ranging between 1-30 g of dry polymerised resin per square meter of substrate surface
Data Source
AI summary
The present invention regards a composite material for ballistic protection comprising a ballistic fabric substrate having at least one surface provided with a polymer coating obtainable through foaming and subsequent polymerization of a mixture comprising an acrylic resin and a polyurethane resin.The present invention further regards the method for preparing such composite material, as well as a laminated multilayer system, a packet for ballistic protection and an article for ballistic protection comprising such composite material.