Crimp-Imbalanced Armor Fabric for Ballistic Flexibility
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Solution Overview
Problem
Current soft fabric armor technologies face limitations in achieving both ballistic and penetration protection while maintaining flexibility, as uni-directional constructions sacrifice comfort and flexibility for increased protection, and existing crimped fabrics do not adequately explore functionally graded crimping for enhanced protection levels.
Innovation Solution
The method involves varying crimp levels within and across layers of a multi-layer fabric armor system by controlling yarn tensions and applying a temporary coating to create crimp-imbalanced yarns, allowing for functionally graded protection against ballistic and stab threats while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uni-directional constructions are used to increase protection, then ballistic protection is improved, but flexibility and comfort deteriorate
Solution Approach 1:
The patent applies different crimp levels to different yarn families (warp vs weft) within the same fabric structure. This local differentiation allows specific regions to provide ballistic protection while other regions maintain flexibility, resolving the contradiction between protection and comfort.
Solution Approach 2:
The invention creates asymmetric crimp distribution where one yarn family has higher crimp content than the other. This asymmetry enables the fabric to exhibit direction-dependent mechanical properties, providing protection in the direction of higher crimp while maintaining flexibility in the direction of lower crimp.
2Strength
If crimp interchange is increased to improve energy absorption, then ballistic protection is improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies the crimp parameter of yarns by applying temporary coatings during manufacturing, which control the crimp level and interchange behavior. This parameter change approach simplifies manufacturing by using a controllable coating process rather than complex mechanical crimping systems.
Solution Approach 2:
The temporary coating acts as an intermediary substance that facilitates controlled crimp development during manufacturing. The coating is applied to yarns before weaving and is later removed, serving as a temporary mediator to achieve the desired crimp structure without permanent manufacturing complexity.
3Strength
If functionally graded crimping is applied to enhance protection, then penetration resistance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements functionally graded crimping by applying different concentrations or types of temporary coatings to different yarn families or regions. This local quality approach enables graduated crimp levels that enhance penetration resistance while using a relatively simple coating application process.
Data Source
AI summary
Crimp-imbalanced protective fabric is accomplished by varying the levels of yarn crimp within and across a layer or layers of a multi-layer fabric armor system. The method includes developing a crimp in the yarn (utilized for producing a fiber layer) by pulling the yarn through a solution that substantially coats the yarn. The removable coating has a thickness that ensures a proper amount of crimp in the yarn. The tension in the yarn is controlled; the yarn is weaved; and a crimp is applied in the yarn. Once the crimp is applied, families of the crimped yarn are utilized as a layer or layered to produce a soft armor form.