Ballistic Material System With Hybrid Weave Layers
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Solution Overview
Problem
Current ballistic materials used in soft body-armor struggle to efficiently meet the performance criteria for both deformable and non-deformable threats while maintaining a lightweight and flexible design, often requiring excessive material to pass tests, which results in increased weight and reduced mobility.
Innovation Solution
A ballistic material system comprising a symmetrical hybrid structure with varying weave and denier in its layers, incorporating high-strength fibers like Kevlar®, Twaron®, and Dyneema®, and optimized water repellency levels, which reduces weight while enhancing resistance to both deformable and non-deformable projectiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional scoured and water repel treated ballistic materials are used to meet performance criteria for deformable and non-deformable threats, then protection performance is improved, but weight increases and mobility decreases
Solution Approach 1:
The patent applies different weave patterns and denier values to different layers of the ballistic material system. Specifically, it uses a combination of plain weave, twill weave, and satin weave patterns, along with varying denier (fiber thickness) across layers, to optimize local performance characteristics for stopping different types of projectiles while minimizing overall weight.
Solution Approach 2:
The patent employs a composite structure combining multiple fabric types with different properties (plain weave, twill weave, satin weave, different denier values) in a layered configuration. This composite approach allows the material system to exhibit superior ballistic performance compared to single-material constructions, achieving both weight reduction and enhanced protection.
2Reliability
If excessive ballistic material is used to pass performance tests, then protection performance is improved, but weight increases and flexibility decreases
Solution Approach 1:
The patent systematically varies key parameters including weave pattern type (plain, twill, satin), denier values (fiber thickness), and layer configuration to optimize performance. By carefully controlling these parameters, the material achieves maximum protection with minimum material quantity, thereby maintaining flexibility and mobility.
Solution Approach 2:
The ballistic material system is divided into multiple functional layers, each with specific weave patterns and denier values optimized for different aspects of ballistic protection. This segmentation allows each layer to contribute specifically to stopping different types of threats, achieving comprehensive protection with reduced total material weight.
3Ease of manufacture
If uniform weave and denier are used throughout the ballistic material, then manufacturing is simplified, but performance efficiency decreases
Solution Approach 1:
Different layers of the ballistic material system utilize different weave patterns (plain, twill, satin) and denier values optimized for specific performance requirements. This local differentiation of material properties maximizes performance efficiency by matching material characteristics to specific protective needs at different locations within the material structure.
Data Source
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AI summary
A ballistic material system for tactical body armor comprises utilizing novel fabric structure with less than all of the fabric layers having the same level of scoured and water repel treated finish. This improved structure can be symmetrical or unsymmetrical, and can include water repel treated finish level in the range of 0% to 99%.