Composite Ballistic Fabric with Multi-Directional Support
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Solution Overview
Problem
Existing ballistic resistant products made from unidirectionally oriented high tenacity fibers require complex and costly manufacturing processes, making them economically unfeasible for widespread production.
Innovation Solution
A flexible multilayered composite fabric is created by bonding a non-woven unidirectionally oriented fiber fabric with a multi-directionally oriented fiber fabric using a thermoplastic resin matrix, where the multi-directionally oriented fabric acts as a supporting layer that becomes an integral part of the composite, reducing waste and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unidirectionally oriented high tenacity fibers are used to create ballistic resistant products, then ballistic resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies composite materials by combining unidirectionally oriented high tenacity fibers with a multi-directionally oriented supporting fabric and thermoplastic resin matrix. This composite structure achieves ballistic resistance while simplifying manufacturing, as the supporting fabric provides structural integrity during processing and becomes an integral part of the final product, eliminating the need for complex handling procedures.
2Strength
If unidirectionally oriented fiber fabrics are used for ballistic protection, then ballistic performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the unidirectionally oriented fiber fabric with a multi-directionally oriented supporting fabric and thermoplastic resin into a single integrated composite structure. The supporting fabric serves dual purposes: it provides structural support during manufacturing (reducing handling complexity) and becomes an integral load-bearing component of the final product (eliminating waste and reducing costs).
Solution Approach 2:
The patent eliminates the traditional approach of discarding supporting fabrics after use. Instead, the supporting fabric is recovered as a valuable component by bonding it permanently to the unidirectional fiber fabric through the thermoplastic resin, transforming what would be waste material into an integral part of the ballistic protective structure.
3Manufacturing precision
If complex manufacturing processes are used for unidirectional fiber products, then fiber orientation precision is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-orienting the high tenacity fibers unidirectionally before they are incorporated into the composite structure. The supporting fabric is also prepared in advance with its multi-directional orientation. This pre-preparation allows for rapid assembly and consolidation without requiring complex real-time orientation control during manufacturing, thereby maintaining precision while improving productivity.
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 resulting composite material exhibits excellent ballistic properties while being more economical to produce, with the supporting multi-directionally oriented fabric enhancing the material's quality and reducing production costs.
Implementation Method 1
bonding a non-woven unidirectionally oriented fiber fabric with a multi-directionally oriented fiber fabric using a thermoplastic resin matrix
Data Source
AI summary
A multilayered composite fabric which comprises (a) a first fabric comprising non-woven unidirectionally oriented fibers in a first resin matrix, the fibers comprising high tenacity fibers, the first fabric comprising first and second surfaces; and (b) a second fabric comprising multi-directionally oriented fibers optionally in a second resin matrix, the second fabric also comprising high tenacity fibers, the second fabric having first and second surfaces, the first surface of the second fabric being bonded to the second surface of the first fabric thereby forming the composite fabric. Also described is a method of making such fabric wherein the second fabric layer is used as a support during the manufacturing process and is thereafter consolidated into a single structure with the first fabric layer.