Coated multi-threat materials and methods for fabricating the same
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Solution Overview
Problem
Current multi-threat protective materials face challenges such as high scrap rates due to sheet format limitations, varying film thickness requirements, and surface layer shedding, which increase production costs and diminish protection over time.
Innovation Solution
A coated multi-threat fabric using an ethylene acrylic acid copolymer with specific properties, applied in a continuous roll process, allowing for flexible storage and variable widths, with multiple layers of high-performance fibers and polymeric coatings that enhance stab, impact, and ballistic resistance without the need for large pressing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If film impregnated fabric-based materials are used for multi-threat protection, then protective performance is improved, but manufacturing complexity and equipment requirements increase due to the need for press equipment
Solution Approach 1:
The patent replaces the mechanical pressing system with a coating system that applies polymeric material to the fabric surface. Instead of using press equipment to impregnate film into fabric, the invention uses a coating apparatus to deposit the polymeric material, which is then cured to form the protective layer. This substitution eliminates the need for complex press equipment while achieving similar protective performance.
Solution Approach 2:
The patent changes the manufacturing parameters from high-pressure/temperature pressing to controlled coating and curing parameters. The polymeric material is applied in a controlled manner and then cured under controlled conditions to achieve the desired protective properties, replacing the traditional high-pressure impregnation process.
2Reliability
If sheet format materials are produced using press equipment, then multi-threat protection is achieved, but production efficiency decreases due to high scrap rates
Solution Approach 1:
By replacing the pressing mechanism with a coating system, the patent enables continuous production of fabric rolls rather than limited sheet formats. The coating apparatus can process continuous fabric rolls, and the cured material maintains its protective properties, eliminating the need to cut and press individual sheets and reducing scrap from pattern fitting.
Solution Approach 2:
The patent applies the polymeric coating to the fabric in advance during the manufacturing process, creating a continuous roll of pre-protected fabric. This preliminary coating action allows the fabric to be stored and transported in roll form, and cut to size later without requiring re-pressing, thereby improving production efficiency and reducing scrap.
3Adaptability or versatility
If different base fabrics require different film weights, then customized protection is achieved, but inventory complexity increases requiring multiple film thicknesses
Solution Approach 1:
The patent changes the film weight parameter by controlling the coating thickness during the coating process. By adjusting the amount of polymeric material applied and the coating parameters, different weights and thicknesses can be achieved on demand without requiring separate inventory of pre-manufactured films in various thicknesses.
Solution Approach 2:
The patent makes the coating system universal by using the same polymeric material and coating apparatus to produce films of varying thicknesses and weights. The single coating system can accommodate different base fabrics and produce customized protection levels without requiring separate manufacturing lines or inventory management for multiple film specifications.
4Reliability
If abrasive additives are applied in top coating for stab protection, then stab resistance is improved, but durability decreases due to surface layer shedding
Solution Approach 1:
The patent uses a composite polymeric material that integrates abrasive particles within the bulk of the coating rather than just as a surface layer. The polymeric matrix binds the abrasive particles throughout the coating thickness, preventing shedding while maintaining stab resistance. This composite structure ensures the abrasive particles remain embedded and functional throughout the service life of the protective material.
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 enhanced resistance to multiple threats, reduces production costs, and maintains protection over time by using a flexible, continuous roll process with improved manufacturing efficiency and flexibility in fabric sizes, while maintaining or improving protective properties compared to conventional press-formed materials.
Implementation Method 1
heating of the raw coated fabric bonds the first coating layer to the first fabric layer and the second coating layer to the second fabric layer
Implementation Method 2
The polymeric material comprises an ethylene acrylic acid copolymer selected to allow the coated multi-threat fabric to be stored on a roll of a predetermined size. The ethylene acrylic acid copolymer has a melt flow index of between about 250 g/10 min and 1400 g/10 min at about 190 degrees C.
Data Source
AI summary
According to some aspects, a method of manufacturing a coated multi-threat fabric, including providing a first fabric layer having a first surface, the first fabric layer having a plurality of high performance fibers, applying a first polymeric material onto the first surface of the first fabric layer, the polymeric material having a melt flow index of between about 0.7 to 1400 g/10 min, a Shore D hardness of between about 36 and 75, and ultimate tensile strength of between about 5 and 75 MPa, spreading the first polymeric material onto the first surface of the first fabric layer so as to form a raw coated fabric having a first coating layer, and heating the raw coated fabric to bond the first coating layer to the first fabric layer, wherein the first polymeric material is selected such that the coated multi-threat fabric is flexible enough to be stored on a roll of a predetermined size. In some aspects, a coated multi-threat fabric includes at least one layer of fabric, each layer having a plurality of high performance fibers, and at least one coating of polymeric material bonded to the at least one layer of fabric, the polymeric material comprising an ethylene acrylic acid copolymer selected to allow the coated multi-threat fabric to be stored on a roll of a predetermined size.