Backface Signature Testing Spacer for Ballistic Armor
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Solution Overview
Problem
Current methods for measuring the backface signature of ballistic resistant composites, particularly for rigid helmets, are inaccurate when using molded flat panels due to direct contact with clay, which does not correlate well with actual field performance, and require costly prototype helmet fabrication for testing.
Innovation Solution
An apparatus and method involving a deformable backing medium with a spacer creating an air gap between the fibrous material and the backing medium, allowing for minimal clay contact and accurate measurement of backface signature by positioning the fibrous material spaced apart from the clay, facilitating repeated testing with reduced error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molded flat panels are placed directly on clay for BFS testing, then the testing process is simple and cost-effective, but the measurement accuracy does not correlate well with actual field helmet performance
Solution Approach 1:
The patent introduces a rigid backing plate as an intermediary element between the fibrous material and the deformable backing medium. This mediator allows the deformation to occur within the controlled air gap space rather than directly contact with clay, enabling accurate BFS measurement that correlates with field performance while maintaining testing simplicity
Solution Approach 2:
The patent creates a three-dimensional air gap space between the fibrous material and the deformable backing medium, allowing deformation to occur in this controlled volumetric space rather than in direct two-dimensional contact with clay. This dimensional approach enables more accurate correlation with actual field helmet performance
2Measurement precision
If prototype helmets are fabricated for BFS testing, then the measurement correlates with actual field performance, but the cost and complexity increase significantly
Solution Approach 1:
The patent creates a simplified test setup that copies the essential deformation characteristics of actual helmet-field interaction without requiring full prototype helmets. The fibrous material panel with controlled air gap replicates the key mechanical behavior, providing accurate BFS data at fraction of the cost and complexity of prototype fabrication
Solution Approach 2:
The patent extracts the essential testing function from complex prototype helmets by isolating the fibrous material layer and its interaction with a deformable medium through a controlled air gap. This extraction maintains measurement accuracy while eliminating the need for complete helmet prototypes
3Device complexity
If fibrous material is in direct contact with deformable backing medium, then the setup is simple, but clay disturbance increases measurement error
Solution Approach 1:
The rigid backing plate serves as a mediator that separates the fibrous material from direct contact with the deformable backing medium, allowing deformation to occur in the air gap space. This prevents clay disturbance while maintaining apparatus simplicity
Solution Approach 2:
The patent segments the deformation space into a controlled air gap region between the fibrous material and deformable medium. This segmentation isolates the deformation zone from direct clay contact, reducing measurement error while keeping the setup simple
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
This approach provides a more accurate and consistent measurement of backface signature by minimizing clay disturbance and allowing for the bulk of deformation to occur within the air gap, improving the correlation with actual field performance without the need for helmet prototypes.
Implementation Method 1
measuring the depth or volume of the resulting hole in the clay block
Implementation Method 2
deformable backing medium having a front surface
Data Source
AI summary
An apparatus and method are provided for evaluating the backface signature of flat panel ballistic resistant composites with accuracy, repeatability and improved correlation to the expected backface signature of shaped ballistic resistant composites in actual field use. The apparatus separates the composite from a clay backing material with a suitable spacer so that the bulk of the backface deformation is inside an air gap space with minimal clay disturbance, thereby eliminating conventional testing error and producing an accurate test result.