Unidirectional Fiber Spreading for Uniform Ballistic Composite 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 have fibers stacked on top of each other, leading to suboptimal performance in composite applications.
Innovation Solution
A process involving the supply of high tenacity fibers arranged unidirectionally, coated with a liquid of specific viscosity, subjected to tension, and passed through a fiber spreading device to increase width and reduce thickness, resulting in a more uniform and thinner fiber structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fibers are arranged in traditional unidirectional structures, then the structure maintains simplicity and ease of manufacture, but the fibers stack on top of each other resulting in non-uniform distribution and reduced ballistic performance
Solution Approach 1:
The patent transforms the traditional unidirectional fiber arrangement by introducing a lateral spreading dimension. Fibers are spread laterally across the width of the fabric, converting a one-dimensional alignment problem into a two-dimensional distribution problem. This dimensional change allows fibers to be distributed more uniformly across the fabric width while maintaining unidirectional orientation, resolving the contradiction between uniformity and structural simplicity.
Solution Approach 2:
The patent introduces dynamic tensioning during the fiber spreading process. By applying controlled tension to the fabric during manufacturing, the fibers are dynamically positioned and distributed laterally. This dynamic approach allows the fiber arrangement to be optimized for uniformity while the tensioning mechanism can be adjusted during production, maintaining ease of manufacture while achieving superior fiber distribution.
2Strength
If multiple layers of fiber structures are laminated to improve ballistic performance, then the structural strength increases, but the overall thickness and weight of the composite structure increase
Solution Approach 1:
The patent changes the key parameter of fiber distribution uniformity to maximize the ballistic effectiveness of each individual layer. By achieving optimal lateral spreading and uniform fiber distribution within each layer, the protective performance per unit weight is enhanced. This allows reduction in the number of layers required, thereby reducing overall composite weight while maintaining or improving ballistic resistance.
3Quantity of substance
If fibers are densely packed in traditional structures, then the material usage is maximized, but the non-uniform fiber distribution reduces the effectiveness of each fiber in resisting ballistic impact
Solution Approach 1:
The patent addresses the density-uniformity contradiction by utilizing the lateral dimension for fiber distribution. Instead of only longitudinal packing, fibers are spread laterally across the fabric width, creating a two-dimensional distribution pattern. This allows maintained or increased fiber density while achieving superior uniformity, as fibers are distributed evenly across the width rather than stacking in the thickness direction.
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 composite products by spreading fibers, allowing for more layers within a given weight, thereby improving the structural and ballistic resistance of the final composite product.
Implementation Method 1
coating the yarns with a liquid having a viscosity of from about 5 to about 600 centipoises
Implementation Method 2
The oriented fiber structures are typically coated or impregnated with a matrix resin
Implementation Method 3
applying tension to the yarns
Implementation Method 4
drying the yarns
Data Source
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.