Unidirectional Fiber Spreading for Thin Uniform Ballistic Layers
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Solution Overview
Problem
Existing unidirectionally oriented fiber structures lack uniformity, which affects their ballistic and structural properties, as they often result in thicker layers with fewer fibers in a coplanar configuration, limiting their performance in applications like body vests and structural panels.
Innovation Solution
A process involving the supply of high tenacity fibers arranged unidirectionally, coated with a liquid of viscosity between 5 to 600 centipoises, passed through a fiber spreading device, and then dried to achieve a thinner, more uniform fiber structure with increased fiber spread, resulting in a unidirectionally oriented fiber structure with a thickness of 9 to 76µm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fiber structures are used without spreading, then the structure maintains higher thickness, but uniformity and coplanar fiber arrangement are reduced
Solution Approach 1:
The patent applies a liquid coating to fibers and uses a spreading device to flatten the coated fibers from a three-dimensional random arrangement into a two-dimensional coplanar structure. This dimensional reduction spreads fibers apart laterally while maintaining their length, achieving both uniformity and reduced thickness simultaneously
Solution Approach 2:
The patent changes the physical state of the fiber structure by coating fibers with a liquid that temporarily modifies their surface properties. This liquid coating enables the fibers to be spread apart and flattened into a coplanar arrangement, and subsequent drying preserves this spread, uniform configuration
2Reliability
If fewer layers are used in the fiber structure, then the structure is thinner, but ballistic performance is reduced
Solution Approach 1:
The patent changes the architectural parameter of fiber arrangement from random to coplanar and spread apart. This configuration increase the effective surface area and number of fibers engaged per unit thickness, allowing thinner structures to achieve equivalent or superior ballistic performance by maximizing fiber utilization
Solution Approach 2:
The patent creates a composite structure by coating fibers with a liquid material that binds them together in a spread, coplanar arrangement. This composite approach allows multiple thin layers to be laminated into a unified structure with enhanced ballistic properties, as the spread configuration distributes impact forces more effectively across layers
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 process enhances the uniformity and ballistic performance of the fiber structures by reducing fiber thickness and increasing the number of layers within a given weight, leading to improved resistance against ballistic projectiles and structural integrity.
Implementation Method 1
coating the yarns with a liquid having a viscosity of from 5 to 600 centipoises
Implementation Method 2
passing the yarns through a fiber spreading device; whereby the yarns are reduced in thickness and increased in width after passing through the fiber spreading device
Implementation Method 3
drying the yarns
Data Source
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AI summary
A process for forming a unidirectionally oriented fiber structure formed of high tenacity fibers. A plurality of yarns of high tenacity fibers are supplied, with the yarns being unidirectionally oriented. The yarns are coated with a liquid having a viscosity of about 5 to about 600 centipoises and tension is applied to the yarns. The yarns are passed through a fiber spreading device and the yarns are dried. The yarns are reduced in thickness and increased in width after passing through the fiber spreading device, with the fibers forming the yarns being spread apart, thus providing a relatively thin unidirectionally oriented fiber structure.