Ballistic Resistant Panel With Bonded Aramid Stack
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Solution Overview
Problem
Existing ballistic resistant panels are not well-suited for applications requiring multi-round capability due to significant damage from initial projectile impacts, leading to ineffective protection against subsequent projectiles, and they are difficult and costly to install in vehicle doors.
Innovation Solution
A ballistic resistant panel with a stack of aramid fibers bonded using a heated vacuum bagging process, encapsulated in a waterproof cover with an anti-wear strip, allowing for quick and easy installation in vehicle doors without specialized tools or skills, and providing enhanced multi-shot capability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing ballistic panels are made of stacked woven sheets bound by stitching, then ballistic protection is provided through fiber stretching and breaking, but the panel suffers severe damage from initial impacts and cannot effectively stop subsequent projectiles
Solution Approach 1:
The patent applies preliminary action by bonding the ballistic sheets together before impact using heat and pressure. This pre-bonding creates a unified structure where energy from subsequent impacts is distributed across the entire panel rather than being concentrated at stitch lines, enabling the panel to withstand multiple projectile strikes effectively
Solution Approach 2:
The patent merges multiple ballistic sheets into a single bonded composite structure. By combining the sheets through thermal bonding, the panel functions as an integrated system where each sheet contributes to stopping multiple projectiles, rather than treating each sheet as a separate sacrificial element
2Ease of manufacture
If ballistic panels are made with stitched woven sheets, then the stitching pattern binds sheets together, but the stitching requires industrial sewing machines and complex manufacturing processes
Solution Approach 1:
The patent replaces the mechanical stitching system with a thermal bonding system. Instead of using needles and thread to bind sheets, the invention uses heat and pressure to fuse the sheets together, eliminating the need for industrial sewing machines and complex stitching mechanisms while achieving effective panel construction
Solution Approach 2:
The patent changes the bonding parameter from mechanical (stitching) to thermal (heat bonding). This parameter change simplifies the manufacturing process by using temperature and pressure control instead of mechanical needle penetration and thread insertion, reducing equipment complexity while maintaining sheet integration
3Reliability
If ballistic sheets are exposed without protective covering, then the ballistic fibers can dissipate impact energy, but moisture and wear can degrade the cover and compromise protection
Solution Approach 1:
The patent uses a flexible protective cover made of thin film material to enclose the ballistic sheets. This cover protects the ballistic fibers from moisture and wear while remaining thin enough not to significantly compromise the ballistic performance, creating a durable sealed assembly that maintains protection over time
Solution Approach 2:
The patent applies beforehand cushioning by providing a protective cover that shields the ballistic sheets from environmental degradation before damage can occur. The cover acts as a barrier against moisture and physical wear, preserving the integrity of the ballistic material throughout its service life
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 improved ballistic performance, ease of installation, and cost-effectiveness, enabling rapid deployment in vehicle doors with enhanced protection against multiple projectiles and reduced installation time and costs.
Implementation Method 1
bonded using a heated vacuum bagging process
Implementation Method 2
bonded using a heated vacuum bagging process
Implementation Method 3
encapsulated in a waterproof cover that prevents moisture on an outer surface of the cover from reaching the plurality of ballistic sheets
Data Source
AI summary
A ballistic resistant panel can be configured to be quickly and easily installed in a vehicle door. The ballistic resistant panel can include a plurality of ballistic sheets arranged in a stack. The stack can have an outer perimeter sized to fit within a cavity of the vehicle door. The panel can include a cover disposed over the stack, and the cover can be sealed around a perimeter of the stack to form a waterproof barrier that prevents moisture from reaching and altering the performance of the ballistic sheets. At least one anti-wear strip can be adhered to an outer surface of the cover. The anti-wear strip can provide a low friction surface that protects the panel from damage caused by moving internal door components, such as moving window components that repeatedly rub against the panel.