3D Architected Armor Truss for Weight and Multi-Hit Trade-off
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Solution Overview
Problem
Conventional armor technologies face challenges in achieving a balance between weight reduction and maintaining multi-hit capability while providing effective projectile defeat characteristics, as traditional metal and ceramic armor solutions are either excessively heavy or suffer from poor durability.
Innovation Solution
A three-dimensional architected composite armor structure comprising a core structure with impact, joint, and connection members, and a matrix material that fills the spaces between them, where the core structure is made of harder materials like steel or ceramic nanoparticles and the matrix is softer, providing a functionally graded hardness and enhanced energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal armor plates are used to defeat projectiles, then projectile defeat capability is improved, but weight becomes excessive
Solution Approach 1:
The armor is segmented into a hierarchical structure with impact members at the front, joint members in the middle, and connection members forming a three-dimensional truss framework. This segmentation allows each component to be optimized for specific functions while collectively providing projectile defeat capability with reduced weight compared to solid metal plates.
Solution Approach 2:
The invention uses composite materials combining metal base material (such as aluminum, steel, or titanium) with ceramic nanoparticles (such as tungsten carbide, silicon carbide, or alumina). The metal provides ductility and toughness while the ceramic nanoparticles provide hardness and wear resistance, achieving superior strength-to-weight ratio for projectile defeat.
2Weight of moving object
If ceramic armor is used to reduce weight, then weight is reduced, but multi-hit capability deteriorates due to fracturing
Solution Approach 1:
The armor structure implements local quality by concentrating ceramic nanoparticles primarily in the impact members that directly face incoming projectiles, while using lighter metal base material in the joint and connection members. This localized reinforcement provides fracture resistance where needed while maintaining overall light weight and multi-hit capability through the ductile metal framework.
Solution Approach 2:
The three-dimensional truss structure with multiple joint members and connection members provides a ductile metal framework that absorbs and distributes impact energy before it can cause catastrophic fracturing. This beforehand cushioning effect protects the ceramic components and maintains structural integrity for subsequent hits.
3Strength
If bulk composite armor with mixed metal materials is used, then projectile defeat capability is improved, but cost increases due to exotic metals
Solution Approach 1:
The armor uses a porous or partially filled structure where ceramic nanoparticles are dispersed within the metal base material rather than creating fully dense bulk composites. This reduces material costs while maintaining strength through the high surface area and strategic distribution of ceramic reinforcement in the three-dimensional truss framework.
Solution Approach 2:
The invention optimizes the concentration and size parameters of ceramic nanoparticles within the metal base material. By controlling the volume fraction, particle size distribution, and spatial arrangement of ceramic reinforcement, the armor achieves required projectile defeat capability using cost-effective material combinations rather than expensive exotic metals.
4Strength
If stacked layers of metal and ceramic plates are used, then projectile defeat capability is improved, but weight remains high due to metal plates
Solution Approach 1:
The invention transitions from traditional two-dimensional stacked plate armor to a three-dimensional architected truss structure. The connection members extend in multiple directions creating a volumetric framework that provides superior strength-to-weight ratio compared to planar stacked layers, enabling lighter weight while maintaining or improving projectile defeat capability.
Data Source
AI summary
According to an embodiment of the present invention, a three-dimensional architected armor structure includes a core structure and a matrix. The core structure includes: a plurality of impact members; a plurality of joint members below the impact members; and a plurality of connection members respectively extending between one of the impact members and one of the joint members. The matrix fills at least a portion of a space between the impact members, the joint members, and the connection members.