Multi-Layer Ballistic Fabric Interweaving for Layer Bonding

Solution Overview

Problem

Conventional methods for securing multiple layers of woven fabrics together in ballistic applications are costly, labor-intensive, and can cause damage to the yarns or create gaps, leading to undesirable ballistic performance.

Innovation Solution

A multi-layer woven fabric is created by interweaving securing yarns with the warp and weft yarns as the fabric is formed, eliminating the need for stitching or resin, which reduces crimp and enhances ballistic performance by maintaining the integrity of the layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple layers of woven fabrics are secured together by resin, then the layers are joined, but the costs increase and compatibility issues arise

Engineering Contradiction:

Improvelayer bondingVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the fabric layers and securing function into a single integrated woven structure. Multiple fabric layers are woven together with interlayer yarns that pass through both layers, creating a unified construction that eliminates the need for separate resin bonding processes and reduces manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces interlayer yarns as intermediary elements that facilitate the connection between fabric layers. These yarns act as mediators that physically link multiple layers together through the weaving process, replacing the need for resin as a bonding intermediary.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If multiple layers of woven fabrics are stitched together, then the layers are joined, but gaps are formed and yarns are damaged

Engineering Contradiction:

Improvelayer bondingVSAvoidballistic performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges the fabric layers and securing function into a single integrated woven structure. Multiple fabric layers are woven together with interlayer yarns that pass through both layers, creating a unified construction that eliminates the need for separate resin bonding processes and reduces manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If multiple layers of woven fabrics are manufactured separately and then combined, then the layers can be assembled, but labor costs increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges the fabric layers and securing function into a single integrated woven structure. Multiple fabric layers are woven together with interlayer yarns that pass through both layers, creating a unified construction that eliminates the need for separate resin bonding processes and reduces manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11535959B2Woven multi-layer fabrics and methods of fabricating same

Publication Date: 2022.12.27 BARRDAY

AI summary

A multi-layer ballistic woven fabric, including an upper woven layer having upper warp yarns and upper weft yarns that are interwoven together to form the upper woven layer. The multi-layer ballistic woven fabric also includes a lower woven layer having lower warp yarns and lower weft yarns that are interwoven together, and a plurality of securing yarns, each securing yarn interwoven with at least some of the upper yarns and some of the lower yarns so as to secure the upper and lower woven layers together. At least one of the securing yarns is woven underneath a first lower weft yarn, then above a second upper weft yarn adjacent the first lower weft yarn, then underneath a third lower weft yarn adjacent the second upper weft yarn and then above a fourth upper weft yarn adjacent the third lower weft yarn. The multi-layer ballistic woven fabric is formed by interweaving the securing yarns with the warp yarns and weft yarns as the upper woven layer and lower woven layer are made.