Creep‐Stabilized Durable Outer Shell Fabrics of Ballistic Jacket Using TiO 2 – SiO 2 Functionalized Aliphatic TPU Nano‐Hybrid Coating

ABSTRACT Outer shell fabrics (OSFs) are critical yet life‐limiting components of bulletproof jackets, continuously exposed to ultraviolet radiation, moisture, abrasion, and thermal stress. This study develops a nano‐hybrid aliphatic thermoplastic polyurethane (TPU)‐coated ripstop woven OSF with enhanced durability and extended service life. Ripstop woven Nylon 6, polyester, and high‐tenacity (HT) polyester fabrics were dyed, camouflage printed, and coated with aliphatic TPU containing Titanium dioxide (TiO 2 ) and Silicon dioxide (SiO 2 ) nanoparticles. Among all fabrics, the nano‐hybrid TPU‐coated HT polyester exhibited the highest tensile and tear strength, excellent abrasion resistance (mass loss < 1% after 6000 Martindale cycles), water repellency (contact angle > 100°), and superior flame‐retardant performance (LOI 32.4% with zero dripping). FESEM confirmed the formation of a continuous coating layer, EDS verified the presence of Ti and Si in the coating, and capillary flow porometry confirmed a controlled microporous structure with effective pore sizes below 10 μm. Creep modeling predicted less than 4.5% deformation over 5 years for HT polyester, suggesting a relationship between substrate creep behavior and coating durability and providing a predictive framework for designing long‐lasting ballistic jacket outer‐shell fabrics.