Flexible Body Armor Assembly With Cross-Plied Panels and Frame Support

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing ballistic protective equipment faces challenges in achieving a balance between lightweight construction, flexibility, and enhanced ballistic performance, particularly in resisting penetration and back face deformation, while maintaining durability and comfort.

Innovation Solution

A soft body armor assembly comprising cross-plied ultra-high molecular weight polyethylene fiber sheets and composite sheets, integrated with a frame for structural support and energy dissipation, enhances ballistic protection and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional ballistic protective equipment uses heavy materials to resist penetration, then ballistic protection is improved, but weight increases

Engineering Contradiction:

Improveballistic protectionVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs composite material structures combining ultra-high molecular weight polyethylene fiber sheets with other ballistic materials. This composite approach achieves superior ballistic protection while maintaining lightweight characteristics, as the polyethylene fibers provide high strength-to-weight ratio and energy absorption capabilities.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The armor assembly is divided into multiple subpanels, each containing specific arrangements of fiber sheets. This segmentation allows optimization of material distribution across different protection zones, placing higher density materials where penetration resistance is most critical while reducing weight in less vulnerable areas.

Inventive Principle:

Principle #1Segmentation

2Strength

If rigid materials are used to resist penetration, then ballistic protection is improved, but flexibility decreases

Engineering Contradiction:

Improvepenetration resistanceVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent utilizes flexible fiber sheet structures that can deform and absorb impact energy while maintaining protective integrity. The ultra-high molecular weight polyethylene fibers are arranged in flexible configurations that allow the armor to conform to body movements without compromising penetration resistance.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The armor structure incorporates dynamic characteristics where the fiber sheets can flex and reconfigure during impact events. The material properties and structural design enable the armor to transition from a flexible state during normal wear to a more rigid response state during ballistic impact, optimizing both flexibility and protection.

Inventive Principle:

Principle #15Dynamics

3Strength

If thick layers of ballistic material are used to reduce back face deformation, then protection is improved, but weight and bulk increase

Engineering Contradiction:

Improveback face deformation resistanceVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent implements local quality optimization by varying the density, thickness, and material composition of different layers within the armor assembly. Areas requiring higher back face deformation resistance receive enhanced material configurations, while other areas use lighter constructions, achieving overall protection without uniform weight increase.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Multi-layer composite structures combine materials with different mechanical properties to efficiently manage impact energy. The ultra-high molecular weight polyethylene fiber sheets work in conjunction with other ballistic materials to distribute and dissipate impact forces, reducing back face deformation without requiring excessive thickness or weight.

Inventive Principle:

Principle #40Composite materials

4Strength

If complex multi-layer structures are used to improve ballistic performance, then penetration resistance is improved, but device complexity increases

Engineering Contradiction:

Improvepenetration resistanceVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The complex armor assembly is divided into modular subpanels with standardized structures. Each subpanel contains organized layers of fiber sheets with consistent configurations, making the overall complex system manageable through repetition of proven design units. This segmentation simplifies manufacturing, assembly, and maintenance while maintaining high ballistic performance.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20260110521A1Flexible body armor assembly

Publication Date: 2026.04.23 TYR TACTICAL LLC

AI summary

The present disclosure is direct to a soft body armor assembly that comprises a first subpanel and a second subpanel. The first subpanel may have a first portion and a second portion. The first portion may have a first plurality of ultra-high molecular weight polyethylene fiber sheets. Each sheet of the first plurality may have two single layers of unidirectional sheets cross plied at 90 degrees to one another. The second portion may have a second plurality of ultra-high molecular weight polyethylene fiber sheets. The second subpanel may comprise a third portion and a fourth portion. The third portion may have a third plurality of ultra-high molecular weight polyethylene fiber sheets. The fourth portion may have one or more composite sheets.