Protective Fabric Weave Architecture With Graded Yarn Crimp
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Solution Overview
Problem
Current soft fabric armor technologies face limitations in achieving both ballistic and penetration protection while maintaining flexibility, as uni-directional constructions sacrifice comfort and flexibility for increased protection, and existing crimped fabrics do not adequately explore functionally graded crimping for enhanced protection levels.
Innovation Solution
The method involves varying crimp levels within and across layers of a multi-layer fabric armor system by controlling yarn tensions and applying a temporary coating to create crimp-imbalanced yarns, allowing for functionally graded protection against ballistic and stab threats while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uni-directional constructions are used to increase protection, then ballistic protection is improved, but flexibility and comfort deteriorate
Solution Approach 1:
The patent applies different crimp levels to different yarn families (warp vs weft) within the same fabric structure. This local differentiation allows certain regions to provide enhanced protection while other regions maintain flexibility, resolving the contradiction between uniform protection and localized comfort.
Solution Approach 2:
The invention creates asymmetric crimp distribution where one yarn family has higher crimp content than the other. This asymmetry enables the fabric to exhibit direction-dependent mechanical properties, providing protection in specific directions while maintaining flexibility in others.
2Use of energy by moving object
If higher crimp content is applied to enhance protection, then energy absorption is improved, but fabric density and penetration resistance deteriorate
Solution Approach 1:
The patent concentrates higher crimp content in specific yarn families rather than uniformly distributing it throughout the fabric. This localized approach allows energy absorption to be enhanced in specific regions while maintaining adequate fabric density in other areas for penetration resistance.
3Strength
If functionally graded crimping is implemented to optimize protection, then ballistic performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent achieves functionally graded crimping by modifying physical parameters such as yarn tension during weaving and yarn diameter through coating applications. These parameter changes enable different crimp levels in different yarn families using conventional weaving technology, avoiding the need for complex manufacturing equipment.
Data Source
AI summary
Crimp-imbalanced protective fabric is accomplished by varying the levels of yarn crimp within and across a layer or layers of a multi-layer fabric armor system. The method includes developing a crimp in the yarn (utilized for producing a fiber layer) by pulling the yarn through a solution that substantially coats the yarn. The 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 layer or layered to produce a soft armor form.