Symmetrical Ballistic Panel Warping Reduction
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Solution Overview
Problem
Conventional ballistic panels suffer from warping during hot bonding due to non-symmetric construction, leading to increased manufacturing time, scrap rates, and loss of mechanical properties, which is not feasible to address without compromising ballistic specifications or increasing weight.
Innovation Solution
A symmetrical ballistic panel design incorporating ballistic gel layers on both major surfaces of a core layer with a ballistic resistant material, using hot bonding methods to reduce warping while maintaining desired ballistic protection and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a non-symmetric multi-ply laminate construction is used to meet ballistic specifications, then ballistic protection is achieved, but warping occurs during hot bonding and manufacturing time increases
Solution Approach 1:
The patent applies asymmetry in reverse by creating a symmetric panel construction where ballistic gel layers are positioned on both the first and second major surfaces of the core layer. This symmetric arrangement balances the thermal expansion and contraction during hot bonding, preventing warping and allowing for faster manufacturing while maintaining the required asymmetric ballistic protection through the gel material properties rather than structural asymmetry
2Stability of the object's composition
If cold bonding methods are used to reduce warping in non-symmetric panels, then warping is reduced, but manufacturing time increases and scrap rates increase
Solution Approach 1:
The patent changes the structural parameter from non-symmetric to symmetric construction, which fundamentally alters the thermal behavior during bonding. This parameter change allows the use of hot bonding methods without experiencing the warping issues that would otherwise require cold bonding, thereby maintaining both warping reduction and manufacturing efficiency
3Productivity
If symmetric construction is used to reduce warping, then warping is reduced and productivity increases, but ballistic protection may be compromised
Solution Approach 1:
The patent employs composite materials by combining the core layer with ballistic gel material layers on both surfaces. The ballistic gel material provides the necessary ballistic protection through its energy-absorbing properties rather than relying on the structural asymmetry of traditional fabric laminates. This allows symmetric construction for manufacturing efficiency while maintaining ballistic performance through the gel material's inherent properties
4Strength
If traditional multi-ply laminate construction is used, then ballistic protection is achieved, but weight increases
Solution Approach 1:
The patent utilizes the porous, cellular structure of the ballistic gel material to provide ballistic protection with reduced weight. The gel material's foam-like structure allows it to absorb ballistic energy through cell collapse and material deformation rather than requiring dense, heavy fabric laminates. This porous structure enables weight reduction while maintaining the necessary protective function
Data Source
AI summary
A ballistic panel is described including a core layer having a first major surface and a second major surface, the core layer including a ballistic resistant material. A first layer comprising a ballistic gel material is disposed on the first major surface of the core layer. A second layer comprising a ballistic gel material is disposed on the second major surface of the core layer.