Thermoplastic Ballistic Panel Geometry for Blunt Force Dispersion
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Solution Overview
Problem
Current ballistic protection systems face limitations in effectively stopping projectiles of varying configurations and velocities, particularly due to the use of materials like steel, ceramics, and polyethylene, which are heavy, fragile, or require complex manufacturing processes, and fail to adequately disperse blunt force trauma energy.
Innovation Solution
A ballistic panel formed from engineered thermoplastics containing carbon additives, designed with geometrical protrusions to increase surface contact with projectiles, causing yaw and redirection, thereby dispersing blunt force trauma energy and preventing penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel or hardened steel is used for ballistic plates, then projectile stopping effectiveness is improved, but weight increases and comfort deteriorates
Solution Approach 1:
The patent uses composite materials consisting of multiple layers of fiber-reinforced plastics (such as carbon fiber, glass fiber, or aramid fiber) combined with thermoplastic matrices. This composite structure provides high strength-to-weight ratio, achieving effective projectile stopping power while significantly reducing weight compared to solid steel plates.
Solution Approach 2:
The ballistic plate incorporates varying fiber orientations, densities, and material compositions in different regions to optimize protection where needed while minimizing weight elsewhere. The front surface features a textured pattern with varying fiber density to handle projectile impact, while the rear surface has a smoother finish for comfort against the wearer's body.
2Weight of moving object
If ceramic or glass plates are used, then weight is reduced compared to steel, but the material becomes fragile and loses effectiveness after single impact
Solution Approach 1:
The patent employs thermoplastic composite materials that can undergo reversible structural changes upon impact. The thermoplastic matrix allows the composite to absorb impact energy through controlled deformation and then return to its original state upon cooling, enabling multiple uses. The fiber-reinforced structure maintains its mechanical properties after impact, unlike brittle ceramics.
Solution Approach 2:
The multi-layer composite structure is designed with energy-absorbing layers that activate before the main protective barrier. The initial layers deform to absorb impact energy, preventing direct transmission to the wearer and reducing the stress on the primary protective structure, thereby maintaining its effectiveness for subsequent impacts.
3Weight of moving object
If multiple compressed fiber sheets are used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single monolithic composite structure. The fiber-reinforced thermoplastic composite is manufactured as one unified piece through processes like resin transfer molding or autoclave curing, eliminating the need to assemble multiple separate fiber sheets. This merging of layers and functions simplifies manufacturing while maintaining the weight advantages of composite materials.
4Ease of manufacture
If traditional flat plate design is used, then manufacturing is simpler, but blunt force trauma energy dispersion is insufficient
Solution Approach 1:
The patent incorporates curved and contoured surfaces in the ballistic plate design, including an arched front surface and ergonomic back contouring. These curved geometries help distribute impact forces across larger surface areas and redirect blunt force trauma energy away from concentrated points, reducing the risk of injury to the wearer while maintaining manufacturing feasibility through composite molding processes.
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 enhanced protection by effectively stopping projectiles regardless of configuration and velocity, reducing weight and manufacturing complexity while dispersing blunt force trauma energy, thus improving wearer safety.
Implementation Method 1
causing yaw and redirection, thereby dispersing blunt force trauma energy
Implementation Method 2
designed with geometrical protrusions to increase surface contact with projectiles, causing yaw and redirection
Data Source
AI summary
A ballistic panel providing ballistic protection has at least one plate. The at least one plate is formed of at least one engineered thermoplastic sheet having carbon additives.