Multi-layer Woven Fabric with Interwoven Securing Yarns
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Solution Overview
Problem
Conventional methods for securing multiple layers of woven fabrics in ballistic applications are costly, labor-intensive, and can cause damage to the yarns, and may not be compatible with various ballistic threats due to the use of resin or stitching, which can lead to undesirable gaps and weak points.
Innovation Solution
A multi-layer woven fabric design where two or more layers are secured together by interweaving securing yarns that run in different directions, eliminating the need for stitching or resin, thereby forming a unified construction with reduced crimp and enhanced ballistic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If woven fabrics are manufactured separately and joined by resin, then multi-layer structure is achieved, but manufacturing cost increases and compatibility issues with ballistic threats arise
Solution Approach 1:
The patent merges multiple fabric layers into a single woven structure by interweaving securing yarns that bind multiple layers together during the weaving process itself, eliminating the need for separate manufacturing and subsequent resin joining operations
Solution Approach 2:
The securing yarns are incorporated into the fabric construction during the initial weaving process, preliminarily establishing the multi-layer configuration before the fabric is even completed, thereby avoiding post-manufacturing assembly steps
2Stability of the object's composition
If woven fabrics are stitched together after manufacturing, then layers are secured, but needle penetration causes yarn damage and creates gaps
Solution Approach 1:
The layers are secured to each other during the weaving process itself through interwoven securing yarns, performing the layer-bonding action preliminarily before the fabric is completed, thereby eliminating the need for subsequent stitching operations that would damage the yarns
Solution Approach 2:
The patent replaces the mechanical stitching system (needles penetrating yarns) with a weaving-based securing system where securing yarns are interwoven with the fabric layers during construction, substituting a non-damaging mechanical approach for a damaging one
3Reliability
If multiple securing yarns in different directions are interwoven, then fabric integrity and trauma resistance improve, but manufacturing complexity increases
Solution Approach 1:
The securing yarns serve multiple functions simultaneously: they bind multiple fabric layers together, provide structural reinforcement, and enhance trauma resistance, allowing a single element to perform several protective roles without requiring separate systems for each function
Solution Approach 2:
The securing yarns are strategically positioned at specific locations where layer bonding is most critical, providing localized reinforcement and trauma resistance where needed most, rather than uniformly distributing complexity throughout the entire fabric structure
Data Source
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Figure 3A
AI summary
A multi-layer woven fabric (10), including an upper woven layer (11) having upper warp yarns (12) and upper weft yarns (14) that are interwoven together to form the upper woven layer. The cover factor of at least one of the layers is selected so as to inhibit penetration by non-ballistic threats.