Ballistic Laminate Structure with Pre-Annealed Cross-Plied Fabric
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Solution Overview
Problem
Existing ballistic materials lack sufficient dimensional stability and high performance fiber content, which affects their ability to effectively absorb and distribute impact without substantial shrinkage or loss of geometric configuration.
Innovation Solution
A ballistic laminate structure composed of pre-annealed nonwoven fabric layers with unidirectionally-oriented high performance fibers, joined at an angle using thermoplastic films or other bonding methods, to create a dimensionally stable cross-plied fabric with a high percentage of high performance fibers, such as aramid or polyolefin fibers, and optionally incorporating thermoplastic layers for enhanced stability and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If existing ballistic materials are used, then they can provide basic impact absorption, but they lack sufficient dimensional stability and shrink substantially under impact
Solution Approach 1:
The patent applies preliminary annealing treatment to the nonwoven fabric layers before lamination. This pre-annealing process pre-shrinks the high performance fibers and stabilizes the fabric structure in advance, preventing substantial shrinkage during subsequent ballistic impact. The fabric layers are pre-conditioned to their final dimensional state before being assembled into the laminate structure.
Solution Approach 2:
The patent creates a composite laminate structure consisting of multiple nonwoven fabric layers with unidirectionally-oriented high performance fibers joined together at angles (such as 0 degrees and 90 degrees). This composite construction combines layers with different fiber orientations to achieve both dimensional stability and reliable impact absorption, with each layer contributing specific directional strength properties.
2Strength
If high performance fiber content is increased, then impact distribution capability improves, but manufacturing complexity increases
Solution Approach 1:
The patent segments the high performance fiber reinforcement into multiple separate nonwoven fabric layers, each with unidirectionally-oriented fibers. These layers are then laminated together in a sequence (such as 0 degrees, 90 degrees, 0 degrees). This segmentation allows each layer to be manufactured independently with optimized fiber orientation, then assembled into a complex multi-directional structure that distributes impact forces effectively while maintaining manageable manufacturing processes for each individual 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
The solution provides a dimensionally stable and high-strength ballistic material that maintains its geometric configuration under impact, effectively absorbing and distributing force with minimal shrinkage, suitable for use in protective inserts and body armor.
Implementation Method 1
first pre-annealed nonwoven fabric layers, each comprising a loosely assembled array of unidirectionally-oriented, untwisted, high performance fibers
Implementation Method 2
the first pre-annealed fabric layer comprises high performance fibers annealed at a temperature sufficient to shrink the fabric layer in a machine direction
Implementation Method 3
The means for joining may comprise, for example, heat-activated thermoplastic films, resins, glues, open-weave scrims, stitching, ultrasonic bonding, point bonding, autogenous bonding
Implementation Method 4
ultrasonic bonding
Implementation Method 5
effectively absorbing and distributing force with minimal shrinkage
Data Source
AI summary
A ballistic laminate structure in sheet form includes first and second pre-annealed nonwoven fabric layers. Each fabric layer is constructed of a loosely assembled array of unidirectionally-oriented, untwisted, high performance fibers. The layers are joined together at an angle to form a dimensionally stable cross-plied fabric.