Flexible Armor Panel Assembly via Conditioning and Ultrasonic Welding
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Solution Overview
Problem
Rigid ballistic panels in personal protective vests restrict freedom of movement and comfort while providing safety protection, as they do not allow for the desired flexibility and comfort required by security personnel.
Innovation Solution
A system for assembling flexible body armor panels using a break-in machine, hydraulic press machine, high frequency ultrasonic welding machine, and industrial conveyor oven machine, which includes a housing with conditioning belt assemblies and a drive assembly to condition and assemble soft-flexible armor panels that can be integrated into personal protective vests, allowing for increased flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid ballistic panels are used in personal protective vests, then protection from small arms fire is provided, but freedom of movement and comfort are restricted
Solution Approach 1:
The patent replaces rigid ballistic panels with flexible armor panels constructed from multiple layers of flexible materials including Kevlar and other high-strength fibers. These flexible panels are enclosed in a flexible cover made of materials like Cordura or TPU, allowing the armor to conform to the body's movements while maintaining ballistic protection capabilities against small arms fire and fragments.
Solution Approach 2:
The flexible armor panel employs composite material construction with multiple layers of different materials serving specific functions: ballistic layers for protection, flexible support layers for structural integrity, and waterproof/breathable membranes for environmental protection. This multi-material composite approach enables simultaneous achievement of ballistic protection and flexibility for freedom of movement.
2Ease of manufacture
If flexible armor panels are assembled using traditional methods, then assembly is simple, but manufacturing precision and quality consistency are insufficient
Solution Approach 1:
The patent implements preliminary preparation of armor panels and components with pre-defined configurations, pre-attached components, and pre-positioned elements. This preliminary action ensures that when assembly occurs, components fit together with high precision and consistency, eliminating variability introduced during manual assembly while maintaining the simplicity of the overall process.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods with automated assembly systems that use robotic manipulation, automated stitching or bonding equipment, and computer-controlled positioning. This substitution maintains ease of manufacture through automation while dramatically improving manufacturing precision and quality consistency through programmable repeatability.
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 system enables the creation of flexible body armor panels that provide high-level protection while maintaining the wearer's freedom of movement and comfort, addressing the limitations of rigid panels by enhancing the assembly process to produce more pliable and effective armor.
Implementation Method 1
high frequency ultrasonic welding machine
Implementation Method 2
hydraulic press machine
Implementation Method 3
industrial conveyor oven machine
Data Source
AI summary
A break-in machine for use in conditioning a flexible armor panel is described herein. The break-in machine includes a housing, an upper conditioning belt assembly, a lower conditioning belt assembly, and a drive assembly. The upper conditioning belt assembly includes a plurality of sprocketed conveyor rollers spaced along a longitudinal axis, and a first conditioning belt orientated around the plurality of sprocketed conveyor rollers. The lower conditioning belt assembly is positioned vertically below the upper conditioning belt assembly and includes a plurality of adjustable conveyor rollers spaced between the sprocketed conveyor rollers along the longitudinal axis, and a second conditioning belt orientated around the plurality of adjustable conveyor rollers. The drive assembly includes a motor and a drive chain coupled to each of the sprocketed conveyor rollers.