Crimp-Imbalanced Fabrics for Ballistic and Stab Protection
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Solution Overview
Problem
Existing crimped fabric technologies face limitations in achieving simultaneous enhanced ballistic and stab penetration protection, as well as flexibility and comfort, due to antagonistic design requirements for these protection types, and lack sufficient exploration of functionally graded crimp imbalance in the through-thickness direction for improved performance attributes.
Innovation Solution
Varying crimp levels within a fabric layer and across multiple layers to create crimp imbalance gradients along the through-thickness direction, utilizing controlled yarn tensions and temporary coatings to achieve crimped fabric architectures that enhance ballistic, stab, blast, and shock protection while maintaining flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform crimp levels are used in fabric layers, then manufacturing simplicity is maintained, but protection performance against ballistic and stab threats is insufficient
Solution Approach 1:
The fabric system is divided into multiple layers, each with distinct crimp imbalance characteristics. Individual layers are designed with specific crimp ratios between orthogonal yarn families, creating a segmented structure that progressively manages impact energy from different threat types through the thickness direction.
Solution Approach 2:
Different regions of the fabric (different layers) are assigned different crimp imbalance properties tailored to specific protection needs. Surface layers may have higher crimb imbalance for ballistic protection, while deeper layers have different characteristics for stab penetration resistance, optimizing local protection quality throughout the fabric system.
2Reliability
If high crimp imbalance is used to enhance protection, then ballistic and stab protection is improved, but flexibility and comfort are reduced
Solution Approach 1:
The protection mechanism is extended from two-dimensional fabric plane to three-dimensional through-thickness direction by varying crimp imbalance across multiple layers. This dimensional transition allows protection performance to be optimized in the thickness direction while maintaining flexibility in the fabric plane, as the graded structure enables progressive energy management without requiring excessive stiffness in any single layer.
Solution Approach 2:
The fabric system functions as a composite structure with multiple layers having different crimp imbalance characteristics. This composite architecture combines layers with varying mechanical properties to achieve both high protection performance and maintained flexibility, as the graded structure allows each layer to contribute differently to overall performance while working together synergistically.
3Reliability
If conventional single-layer fabric design is used, then manufacturing simplicity is maintained, but simultaneous enhancement of ballistic and stab protection cannot be achieved
Solution Approach 1:
The fabric system is divided into multiple layers, each with distinct crimp imbalance characteristics. Individual layers are designed with specific crimp ratios between orthogonal yarn families, creating a segmented structure that progressively manages impact energy from different threat types through the thickness direction.
Solution Approach 2:
The multi-layer fabric system with graded crimp imbalance achieves multi-functionality, providing both ballistic protection and stab penetration resistance simultaneously. The graded structure enables the fabric to respond differently to various threat types (ballistic impacts, stab penetrations, blunt trauma) through the same system, making it universally effective against multiple threat categories.
Data Source
AI summary
Crimp-imbalanced fabric systems are accomplished by varying the levels of yarn crimp within a single fabric layer and across layers of a multi-layer fabric system. The method includes developing a crimp in the yarn (utilized for producing a fabric layer) by optionally pulling the yarn through a solution that substantially coats the yarn. The optionally 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 single layer or multiple layer system to increase performance attributes including enhanced energy absorption.