Flexible Body Armor Filler Structure for Ballistic Protection and Flexibility
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Solution Overview
Problem
Conventional ballistic filler in flexible body armor compromises on performance attributes such as flexibility, back face deformation, mechanical fatigue resistance, and fragmentation threat resistance, often requiring a trade-off between these factors.
Innovation Solution
A ballistic filler comprising a woven fabric stitched to unidirectional laminates, with specific stitching patterns, creating regions of stitched and unstitched plies of high-strength yarns to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ballistic filler uses more plies to improve ballistic resistance, then penetration resistance improves, but weight and flexibility deteriorate
Solution Approach 1:
The patent employs composite materials by combining different types of high-strength fibers (aramid, UHMWPE, steel) in specific ply configurations. This allows achieving superior ballistic penetration resistance with reduced total ply count compared to conventional single-material fillers, thereby reducing weight while maintaining or improving protection level
Solution Approach 2:
The patent implements local quality optimization by placing specific fiber types and ply configurations in different regions of the ballistic filler assembly. High-strength steel wires are positioned in specific layers where they provide maximum effectiveness against penetration, while other regions use aramid or UHMWPE plies optimized for their specific ballistic threats, achieving superior protection with reduced overall material quantity
2Strength
If conventional ballistic filler increases ply count to improve ballistic resistance, then penetration resistance improves, but flexibility deteriorates
Solution Approach 1:
The combination of different fiber materials with complementary properties (aramid for flexibility and tensile strength, UHMWPE for high strength-to-weight ratio, steel for penetration resistance) allows achieving superior ballistic protection with fewer total plies, thereby maintaining flexibility while improving penetration resistance
Solution Approach 2:
Specific ply configurations and material selections are optimized for different regions and threat types, allowing the armor to provide high penetration resistance where needed while maintaining flexibility in other areas for wearer comfort and mobility
3Ease of operation
If conventional ballistic filler uses certain ply structures to improve flexibility, then flexibility improves, but back face deformation increases
Solution Approach 1:
The multi-material composite structure distributes impact forces across different fiber types with complementary mechanical properties. The combination of stiff (steel, aramid) and flexible (UHMWPE) materials works together to arrest projectiles while limiting back face deformation, even when flexibility is enhanced through material selection
Solution Approach 2:
The patent optimizes various parameters including ply thickness, fiber orientation, and material composition ratios to achieve the desired balance between flexibility and back face deformation control. By adjusting these parameters in the composite structure, the armor can be tuned to provide both flexibility and reduced deformation
4Object-affected harmful factors
If conventional ballistic filler optimizes for back face deformation reduction, then deformation resistance improves, but flexibility deteriorates
Solution Approach 1:
The composite structure combines materials with different mechanical characteristics to simultaneously achieve back face deformation resistance and flexibility. The stiff components (steel wires, aramid plies) provide deformation resistance while flexible components (UHMWPE plies) maintain overall flexibility, eliminating the need to trade one for the other
5Reliability
If conventional ballistic filler uses certain configurations to improve mechanical fatigue resistance, then durability improves, but ballistic performance deteriorates
Solution Approach 1:
The multi-material composite structure provides both enhanced mechanical fatigue resistance and superior ballistic performance through synergistic material properties. Steel wires provide fatigue resistance through their elastic properties, while aramid and UHMWPE plies provide ballistic protection, with each material contributing its strengths without compromising the other
6Reliability
If conventional ballistic filler optimizes for durability, then mechanical fatigue resistance improves, but fragmentation threat resistance deteriorates
Solution Approach 1:
The composite filler structure combines materials with different strengths against various threats. Steel wires and aramid plies provide mechanical fatigue resistance through their elastic and tensile properties, while the multi-layer composite structure with specific ply orientations provides enhanced resistance to fragmentation threats by distributing and arresting high-velocity fragments
Data Source
AI summary
Implementations described and claimed herein provide a ballistic filler for a flexible soft body armor and methods of manufacturing the same. In one implementation, a first portion having a first subpanel is stitched directly to a second subpanel with a stitching pattern. The first subpanel has one or more layers of woven fabric, and the second subpanel has one or more layers of unidirectional fabric. A second portion backs the first portion. The second portion has one or more layers of unstitched unidirectional fabric.