Stab proof material in roll form, method and plant for the production thereof
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Solution Overview
Problem
Conventional methods for producing stab proof materials are inefficient, requiring complex processes and infrastructure for shaping flat sheets, leading to high manufacturing waste and costs, and limiting versatility in product configuration.
Innovation Solution
A fiber-reinforced and pre-impregnated composite material in roll form is produced using a plant with a double belt system that deposits and melts micrometric powder onto a textile structure, allowing for flexible and continuous production of a laminate with improved resistance to cutting and stabbing, enabling manufacturers without shaping infrastructure to work with MTP materials like fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating/lamination systems are used to produce stab proof materials, then ballistic and stab proof properties are achieved, but the manufacturing process becomes complex and requires specialized infrastructure for shaping flat sheets
Solution Approach 1:
The invention changes the physical state of the matrix material from liquid/resin form to micrometric powder form. This parameter change allows the matrix to be deposited as a dry powder and then melted in-situ during the lamination process, eliminating the need for complex coating equipment and specialized infrastructure while maintaining the required ballistic and stab proof properties
Solution Approach 2:
The invention replaces the conventional mechanical coating/lamination system with a thermal processing system. Instead of using complex mechanical equipment to apply and bond resin coatings, the process uses heat to melt micrometric powder and achieve bonding, thereby simplifying the manufacturing infrastructure requirements
2Reliability
If conventional sheet production methods are used, then stab proof materials are produced, but manufacturing waste increases and costs rise
Solution Approach 1:
The invention enables continuous production by depositing micrometric powder and laminating in a continuous process rather than batch processing individual sheets. This continuity eliminates the waste associated with sheet-by-sheet handling, cutting, and setup, while maintaining consistent stab proof protection throughout the production run
Solution Approach 2:
The micrometric powder is pre-prepared and can be stored without degradation, allowing production to proceed continuously without waste-generating interruptions. The powder deposition is also performed as a preliminary step before lamination, optimizing material utilization and reducing waste
3Reliability
If conventional lamination processes are used, then ballistic materials are produced, but versatility in product configuration is limited
Solution Approach 1:
The invention introduces dynamic flexibility by using micrometric powder that can be deposited in varying quantities and configurations. This allows the basis weight and layer structure to be dynamically adjusted during production to create different product configurations while maintaining required ballistic performance, unlike fixed conventional lamination systems
4Productivity
If micrometric powder is deposited and melted onto fabric, then a continuous roll in roll form is produced, but new production infrastructure is required
Solution Approach 1:
The invention extracts the matrix material from its conventional liquid/resin state and uses it in micrometric powder form. This extraction of the matrix in a different physical state allows for simplified deposition equipment and eliminates the need for complex resin handling, pumping, and coating infrastructure, enabling continuous roll production with a more straightforward production plant
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 solution provides a cost-effective, versatile, and efficient production method that reduces waste and manufacturing costs by allowing for adjustable basis weights and easy coupling on both sides, achieving performance comparable to conventional sheets with fewer layers and improved resistance to stabbing and ballistic threats.
Implementation Method 1
deposition and pressure melting treatment of a micrometric powder which is distributed over the whole surface of both faces of a textile structure
Implementation Method 2
the micrometric powder which is distributed over the whole surface of both faces of a textile structure, by means of a powder scattering station. This deposition is followed by entry of the material into the heart of the production line
Implementation Method 3
pressure melting of the powder over the latter
Data Source
AI summary
A stab proof material in roll form comprising a matrix distributed over both the surfaces of a textile structure and forming a surface film totally interpenetrated in said textile structure. The production method comprises the steps of: unwinding an aramid fabric on conveyor means; distributing an amorphous thermoplastic matrix starting from a micrometric powder, over both surfaces of the aramid fabric as it is unwound; passing the material through a first hot section and then through a second relatively cold section; the first section applies a temperature and a pressure such as to form an amorphous thermoplastic film on the fabric; the second section facilitates detachment of the coated material from the conveyor means. The plant comprises a conveyor belt on which an aramid fabric is unwound; a powder scattering station adapted to distribute a micrometric powder on the aramid fabric as it is unwound on the conveyor belt; a system of double belts in contact through which the fabric is conveyed; the system of double belts in contact defines a first hot section and a second relatively cold section; the first section applies a temperature and a pressure functional to the formation of an amorphous thermoplastic film on the fabric; the second section facilitates detachment of the fabric.