Chemical Surface Pretreatment for Ballistic Armor Adhesion

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Solution Overview

Problem

Existing methods for producing armor against ballistic projectiles, such as hollow charges, often result in material distortion, reduced fatigue strength, and compromised ballistic performance due to mechanical surface treatments like sandblasting or grinding, which weaken the components and require continuous processing without storage.

Innovation Solution

A chemical surface pretreatment process is used for metal plates or sheets, including zinc phosphating followed by KTL coating, which enhances adhesion properties and corrosion protection, allowing for storage and assembly with improved dimensional accuracy and ballistic efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical surface treatment processes (sandblasting or grinding) are used to enable adhesion, then adhesion properties are improved, but the component is weakened, material is removed, and surface tension is lost

Engineering Contradiction:

Improveadhesion propertiesVSAvoidfatigue strength and reverse bending strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces mechanical surface treatment processes (sandblasting, grinding) with a chemical surface treatment process. The chemical process modifies the surface properties to enhance adhesion without mechanically removing material or creating surface defects, thus avoiding the weakening effect while achieving the desired adhesion improvement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the surface treatment approach from mechanical to chemical, altering the surface properties through chemical reactions rather than physical removal. This parameter change allows surface modification without material loss, preserving the structural integrity and strength of the component while improving adhesion.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If mechanical surface treatment is applied to improve adhesion, then bondability is enhanced, but dimensional accuracy is reduced due to material removal and surface distortion

Engineering Contradiction:

ImprovebondabilityVSAvoiddimensional accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent substitutes mechanical surface treatment with chemical surface treatment, eliminating the material removal and surface distortion associated with mechanical processes. This allows the maintenance of dimensional accuracy while achieving improved bondability through chemical modification of the surface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If mechanical surface treatment is used to create adhesion conditions, then adhesion is improved, but ballistic performance is reduced due to material weakening

Engineering Contradiction:

ImproveadhesionVSAvoidballistic protective effect

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical surface treatment with chemical surface treatment, avoiding the material removal and structural weakening that compromise ballistic performance. The chemical process enhances adhesion without creating surface defects or reducing the material's ability to withstand ballistic impacts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If continuous processing is required to avoid surface deactivation, then adhesion is maintained, but machine usage increases and storage is not possible

Engineering Contradiction:

Improveadhesion propertiesVSAvoidmachine usage and process continuity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies a preliminary chemical surface treatment that creates long-lasting adhesion properties. This preliminary action eliminates the need for continuous processing or immediate assembly, allowing parts to be stored without degradation while maintaining adhesion capabilities when needed.

Inventive Principle:

Principle #10Preliminary action

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 method preserves the full ballistic protective effect, offers improved bondability and resistance to aging, and enables storage without material weakening, resulting in enhanced ballistic performance and cost-effectiveness.

Implementation Method 1

zinc phosphating is carried out on the surface to be treated

Methodology Applied

Scientific EffectPhosphating:

Implementation Method 2

KTL coating (cataphoretic dip coating) carried out as surface treatment

Methodology Applied

Scientific EffectCataphoretic dip coating: Electrophoretic Deposition

Data Source

PatentEP1990598B1Method for producing a sandwich structure for use as armour against ballistic missiles, in particular hollow charges

Publication Date: 2012.11.21 KRAUSS MAFFEI WEGMANN GMBH & CO KG

Figure 1
Figure 2A~2B
Figure 3A

AI summary

The method involves providing surface treatment of metallic plates or sheets (1) and connecting the plates and sheets with each other by sticking or vulcanization, where a cataphoretic painting (KTL) (3) coating is performed as surface treatment, and surface finish is produced on joint parts of the plates or sheets. A zinc phosphate coating (2) is performed before the KTL coating. The plates or sheets are subjected to a physico-chemical surface pretreatment before the surface treatment. The plates or sheets are additionally galvanized, and powder-coated.