Segmented Ballistic Composite Armor with Flexible Hinges
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Solution Overview
Problem
Existing ballistic body armor is either rigid and uncomfortable to wear or flexible but inadequate in protecting against knife stabs and projectile fragments, and often causes trauma from bullet impact due to short stopping paths in soft armor.
Innovation Solution
A flexible composite material composed of high tenacity fibers in a resin matrix, with selectively consolidated areas forming rigid portions and unconsolidated areas acting as hinges, providing both ballistic resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid body armor is used, then resistance to puncture by sharp objects is improved, but comfort and flexibility deteriorate
Solution Approach 1:
The body armor is divided into multiple layers with different functions: rigid composite layers (consolidated fibrous layers) provide puncture resistance, while flexible layers (unconsolidated fibrous layers) provide comfort and flexibility. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The invention uses a composite structure combining rigid composite material (consolidated fibrous layers with resin matrix) and flexible material (unconsolidated fibrous layers). This composite approach integrates the advantages of both rigid and flexible materials to achieve both protection and comfort.
2Ease of operation
If flexible body armor is used, then comfort and flexibility are improved, but resistance to knife stabs and projectile fragments deteriorates
Solution Approach 1:
The armor is segmented into protective zones (rigid consolidated layers) that resist sharp objects and projectiles, and flexible zones (unconsolidated layers) that provide comfort. The segmented structure ensures protection where needed while maintaining overall flexibility.
Solution Approach 2:
The composite structure combines consolidated fibrous layers (for stab and fragment resistance) with unconsolidated fibrous layers (for flexibility). This composite design enables the armor to simultaneously achieve high strength against sharp threats and comfortable wearability.
3Strength
If soft armor with high tenacity fibers is used, then bullet penetration resistance is improved, but trauma to the wearer increases due to short stopping path
Solution Approach 1:
The stopping path is segmented into multiple layers that progressively decelerate the bullet. The consolidated rigid layers and unconsolidated flexible layers alternate to create a multi-stage energy absorption process, extending the stopping path and reducing trauma.
Solution Approach 2:
The composite structure of consolidated and unconsolidated layers creates varying density and elasticity zones that extend the bullet stopping path. This progressive energy absorption reduces the peak forces transmitted to the wearer, thereby reducing trauma while maintaining bullet penetration resistance.
Data Source
AI summary
Flexible composites which are ballistic and stab resistant. The composites are formed from at least one, and preferably a plurality of, fibrous layer comprising a network of high tenacity fibers. A stack of a plurality of fibrous layers is consolidated in a desired pattern over a substantial portion of its surface area which results in areas which are consolidated and areas that are unconsolidated. The unconsolidated areas provide flexibility to the overall composite structure and the structure is resistant to ballistic projectiles and/or sharp objects. Body armor formed from the composites is comfortable to wear and reduces the degree of trauma to the wearer as a result of impact by the ballistic projectile or sharp object.