Puncture Resistant Composite Using High Tenacity Fibers and Particulate Coatings
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Solution Overview
Problem
Current materials lack effective puncture resistance against sharp objects and ballistic projectiles, failing to provide adequate protection in personal body armor as per National Institute of Justice standards.
Innovation Solution
A puncture-resistant composite is created by stacking textile layers with high tenacity fibers, coated with particles of 20 μm or less, which are assembled to enhance the composite's resistance, potentially incorporating ballistic resistant laminates and other materials for added protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional textile materials are used in body armor, then the material is flexible and comfortable, but it lacks effective puncture resistance against sharp objects and ballistic projectiles
Solution Approach 1:
The patent applies composite materials by combining textile layers with particulate coatings to create a puncture-resistant composite. The coating comprises particles (such as ceramic or metallic particles) applied to the textile layer, forming a composite structure that resists penetration by sharp objects and ballistic projectiles while maintaining the flexibility of the underlying textile material.
2Strength
If heavy coating or thick layers are applied to achieve puncture resistance, then protection level increases, but flexibility and comfort of the body armor decreases
Solution Approach 1:
The patent applies local quality by concentrating the protective function in a thin particulate coating layer applied only to the surface of the textile, rather than thickening the entire structure. The particles are distributed locally on the textile surface to provide puncture resistance, while the bulk textile layer maintains its flexibility and comfort properties.
3Strength
If multiple layers of textile are stacked to improve puncture resistance, then protection level increases, but the device complexity and weight increases
Solution Approach 1:
The patent reduces device complexity by using a composite structure with a particulate coating on a single or few textile layers, rather than stacking multiple thick textile layers. This composite approach achieves equivalent or superior puncture resistance with fewer layers, simplifying the overall structure and reducing weight.
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 composite achieves significant puncture resistance, preventing penetration by sharp objects and ballistic projectiles, meeting or exceeding Level 1 Spike class and Type I body armor standards, while maintaining flexibility comparable to uncoated materials.
Implementation Method 1
at least one of the lower surface of the first textile layer and the upper surface of the second textile layer comprises about 10 wt. % or less, based on the total weight of the textile layer, of a coating comprising a plurality of particles
Implementation Method 2
a first textile layer comprising a plurality of yarns or fibers having a tenacity of about 8 or more grams per denier
Data Source
AI summary
A puncture resistant composite comprises a first textile layer and a second textile layer, each of which comprises a plurality of yarns or fibers having a tenacity of about 8 or more grams per denier. The layers are stacked so that the upper surface of the second textile layer is adjacent to the lower surface of the first textile layer. At least one of the lower surface of the first textile layer and the upper surface of the second textile layer comprises about 10 wt. % or less, based on the total weight of the textile layer, of a coating comprising a plurality of particles having a diameter of about 20 μm or less. The coating can also comprise a binder. The composite can also be used in combination with other puncture resistant and/or ballistic resistant materials or components. A process for producing a puncture resistant composite is also provided.