Zoned Fabric-Resin Composite for Flexible Soft Body Armor
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Solution Overview
Problem
There is a need to enhance the flexibility of fabric-resin composites used in soft body armor without compromising protection against multiple threats such as bullets, knives, stabs, and needles.
Innovation Solution
A flexible composite structure comprising a polymeric fibrous fabric core section without resin and a polymeric fibrous fabric section impregnated with an elastomeric or thermoplastic resin, where the resin fills up to 100% of the fiber-free volume and has an elongation to break of between 20 to 1200%, achieving a balance between flexibility and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fabric-resin composite is used for ballistic protection, then protection against bullets and fragments is improved, but flexibility is reduced
Solution Approach 1:
The patent applies local quality by creating distinct zones within the composite: a resin-impregnated zone (5-50 wt% resin) for ballistic protection and a resin-free zone (50-95 wt% fabric) for flexibility. This spatial differentiation allows each region to perform its optimal function without compromising the other.
Solution Approach 2:
The composite is segmented into multiple functional layers including fabric layers, resin-impregnated fabric layers, and resin-free fabric layers. This segmentation allows the material to exhibit both protective and flexible characteristics in different regions, resolving the contradiction between rigidity and flexibility.
2Reliability
If resin content is increased to improve protection, then ballistic resistance is improved, but flexibility and comfort are reduced
Solution Approach 1:
The patent optimizes the resin content parameter within a specific range (5-50 wt%) to achieve the desired balance between protection and flexibility. By controlling this critical parameter, the composite maintains adequate ballistic resistance while preserving flexibility for wearer comfort.
Solution Approach 2:
Different regions of the composite have different resin concentrations: the resin-impregnated zone (5-50 wt% resin) provides protection, while the resin-free zone (50-95 wt% fabric) maintains flexibility. This local variation in composition resolves the contradiction between protection and flexibility.
3Strength
If resin is fully impregnated into fabric, then structural integrity is improved, but flexibility is reduced
Solution Approach 1:
The patent segments the composite into impregnated and non-impregnated zones, allowing full resin penetration only in specific regions (5-50 wt% resin content zones) while leaving other regions (50-95 wt% fabric zones) resin-free. This selective segmentation maintains structural integrity where needed while preserving flexibility elsewhere.
Solution Approach 2:
The composite exhibits local quality through spatially varying resin distribution: highly impregnated regions provide structural integrity and ballistic protection, while resin-free regions provide flexibility and comfort. This local differentiation resolves the contradiction between strength and flexibility.
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 composite meets the technical requirements of NIJ 0101.04 level IIIA and HOSDB KR1/SP1 E1 protection standards, providing improved flexibility and resistance to knife, spike, bullet, and fragment threats while maintaining ballistic performance.
Implementation Method 1
the resin has an elongation to break of between 20 to 1200 percent
Implementation Method 2
the thermoplastic composition comprises at least a first thermoplastic polymer that has a melting point different to the melting point of a second thermoplastic polymer
Data Source
AI summary
A flexible composite suitable for use in a knife, pick, bullet and fragment-resistant article comprising(i) a first zone comprising fabric but no resin, the first first zone comprising from 10 to 90 percent of the total thickness of the composite,(ii) a third zone comprising an elastomeric or thermoplastic resin but no fabric, the third zone comprising from 0 to 50 percent of the total thickness of the composite and(iii) a second zone, located between the first and third zones, comprising fabric and an elastomeric or thermoplastic resin, the second zone comprising from 10 to 90 percent of the total thickness of the composite.