Self-Reinforced Thermoplastic Trauma Pack Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing trauma packs fail to adequately reduce trauma effects when subjected to impact, particularly in the outer region, and are inadequate for advanced body armor applications.
Innovation Solution
A trauma pack comprising a self-reinforced thermoplastic material with textile fabric layers made from high-tensile strength fibers, where the textile fabric is bonded over its entire surface to the thermoplastic material, either through lamination or integrated into the manufacturing process, enhancing the material's mechanical properties and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plastic panel with affixed ballistic fabric layer is used, then penetration resistance is improved, but trauma effect is increased
Solution Approach 1:
The patent employs a composite structure consisting of a self-reinforced thermoplastic panel bonded to ballistic fabric layers. The thermoplastic panel itself is composite, made by bonding together fabric layers of the same polymer material through heat and pressure. This multi-layer composite structure distributes impact forces more effectively, reducing trauma to the wearer while maintaining penetration resistance.
Solution Approach 2:
The patent specifies using self-reinforced thermoplastic material with specific mechanical properties (diagonal elongation of 5-15%, tensile strength of at least 80 MPa). By carefully controlling these material parameters, particularly the diagonal elongation property, the panel can deform to absorb impact energy and reduce trauma effect while maintaining sufficient strength to stop bullets.
2Ease of manufacture
If conventional thermoplastic material is used, then ease of manufacture is improved, but mechanical properties and impact resistance are insufficient
Solution Approach 1:
The self-reinforced thermoplastic material is manufactured by bonding together fabric layers made from the same polymer material through heat and pressure. The material essentially bonds itself - the thermoplastic fabric layers are heated to melt and fuse together, creating a rigid panel without requiring additional reinforcing materials or complex assembly processes. This self-service approach maintains ease of manufacture while dramatically improving mechanical properties.
Solution Approach 2:
The manufacturing process utilizes the phase transition of the thermoplastic material from solid to molten state and back. The fabric layers are heated above the melting point of the polymer, allowing them to flow and bond together, then cooled to form a rigid solid panel. This phase transition enables the material to transform from flexible fabric to rigid structural panel, achieving high mechanical strength while maintaining manufacturing simplicity.
3Strength
If textile fabric is stitched to plastic panel, then bonding is achieved, but bonding strength and integration are insufficient
Solution Approach 1:
The patent integrates the bonding of ballistic fabric to the thermoplastic panel into the panel manufacturing process itself. When the self-reinforced panel is being formed by heat and pressure, the ballistic fabric layers are simultaneously bonded to the panel surface. This merging of operations eliminates separate bonding steps, achieving strong integration while simplifying the overall process.
Solution Approach 2:
The patent replaces mechanical stitching or spot-bonding methods with thermal bonding. The thermoplastic material is heated to melt and fuse the ballistic fabric to the panel surface through heat and pressure. This substitution of thermal-mechanical bonding for mechanical stitching creates a more integrated, stronger bond without the complexity of needlework patterns or multiple attachment points.
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 significantly reduces trauma effects in both inner and outer regions by improving mechanical properties and impact strength, making it suitable for advanced body armor such as bullet-proof vests.
Implementation Method 1
bonded to one another at elevated temperatures by partial fusion of the polymer and subsequent compression
Implementation Method 2
bonded to one another at elevated temperatures by partial fusion of the polymer and subsequent compression
Implementation Method 3
the textile fabric can also be laminated onto the self-reinforced thermoplastic material by means of a thermoplastic film
Data Source
AI summary
The invention relates to a trauma pack comprising at least one panel of a plastic material and at least one textile fabric layer affixed to the panel and made of yarns with fibers having a tensile strength of at least 900 MPa, wherein the plastic material of the panel is a self-reinforced thermoplastic material made of filaments, fibers, tapes or strips of a polyolefin polymer, and wherein at least one textile fabric layer is bonded over its entire surface to the self-reinforced thermoplastic material.