Ballistic Laminate Using Intersecting Non-Ballistic Threads for Stability
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Solution Overview
Problem
Existing ballistic protection textiles face challenges in achieving high performance while reducing weight, maintaining flexibility, and ensuring stability, as unidirectional and multidirectional laminates often require additional stabilization methods that increase weight and do not contribute to ballistic characteristics.
Innovation Solution
A ballistic laminate structure comprising a first textile element with non-ballistic weft threads and ballistic warp threads, and a second textile element with ballistic weft threads and non-ballistic warp threads, where the ratio of ballistic to non-ballistic threads is between 5 and 120, combined using adhesive polymers or stitching, to create a stable and lightweight fabric with enhanced ballistic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If non-ballistic threads with count higher than 50 dtex are used to stabilise unidirectional ballistic threads, then the fabric stability is improved, but the weight increases and the threads create undulations that reduce ballistic performance and abrasion resistance
Solution Approach 1:
The patent changes the critical parameter of thread count from conventional high counts (>50 dtex) to low counts (5-120 dtex), specifically using 70 dtex non-ballistic threads. This parameter change enables the non-ballistic threads to provide stabilization without creating harmful undulations, reducing weight while maintaining fabric stability and ballistic performance
Solution Approach 2:
The patent applies different thread counts to different functional requirements: non-ballistic threads with 70 dtex are used specifically for stabilization at intersection points, while ballistic threads maintain their high strength characteristics. This local differentiation optimizes each component's contribution without compromise
2Weight of moving object
If the number of non-ballistic threads is lowered to reduce weight, then the weight is reduced, but the fabric stability becomes insufficient requiring protective films and pressure/heat treatment
Solution Approach 1:
The patent identifies the optimal parameter range for non-ballistic thread count as 5-120 dtex, with preferred embodiment at 70 dtex. This specific parameter range provides the critical insight that too few threads reduce stability while too many create undulations and increase weight. The 70 dtex specification achieves the optimal balance
Solution Approach 2:
The non-ballistic threads serve multiple functions simultaneously: they provide fabric stability, reduce undulations, contribute to abrasion resistance, and enable weight reduction. This multi-functionality eliminates the need for additional protective films and complex stabilization treatments
3Stability of the object's composition
If non-ballistic threads are used for stabilization, then the fabric stability is improved, but the non-ballistic threads do not contribute to ballistic characteristics and constitute dead weight
Solution Approach 1:
By optimizing the non-ballistic thread count to 70 dtex (within the 5-120 dtex range), the patent maximizes the stabilizing function while minimizing the mass of non-ballistic material. This parameter optimization ensures that non-ballistic threads provide maximum stabilization with minimum dead weight
Solution Approach 2:
The patent creates a composite structure where non-ballistic threads (70 dtex) and ballistic threads are combined in specific ratios. This composite approach allows each material type to perform its optimized function: non-ballistic threads for stabilization and ballistic threads for energy absorption, achieving synergistic performance
4Ease of operation
If ballistic threads with count less than 930 dtex are used, then the flexibility and comfort are improved, but the fabric requires more non-ballistic threads for stabilization which increases weight
Solution Approach 1:
The patent uses non-ballistic threads with count between 5-120 dtex (preferred 70 dtex) which provides optimal stabilization efficiency. This parameter change ensures that even when using lower count ballistic threads for flexibility, the stabilization requirement is met with minimal non-ballistic thread mass, avoiding weight increase
Data Source
AI summary
Ballistic laminate for implementing a ballistic structure comprising at least two textile layers placed one on top of the other and joined together. The layers (elements) comprise at least a first textile element, of which the ballistic warp threads, having a count higher than 40 dtex, intersect non-ballistic weft threads, having a count less than 40 dtex, and at least a second textile element, in which non-ballistic warp threads, having a count less than 40 dtex, intersect ballistic weft threads having a count higher than 40 dtex. These at least two elements are joined together using various technologies to obtain a stable structure in which the energy absorption in the face of projectiles is greater than the energy absorption for conventional warp-weft fabrics for the same weight per square meter.