Multi-layer Armor Plate Lattice Energy Absorption
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Solution Overview
Problem
Current body armor solutions fail to adequately absorb backside deformation energy, which can lead to injury or death despite stopping projectiles, as trauma pads made of open cell foam are insufficient in energy absorption.
Innovation Solution
A multi-layer armor plate design comprising a strike plate, structural mesh layer, outer skin, compliant mesh layer, and inner skin layer, where the structural mesh layer and strike plate prevent projectile penetration, and the compliant mesh layer absorbs backside deformation energy using lattice structures with varying structural compliance, formed via additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If trauma pads made of open cell foam are used to reduce backside deformation, then some energy absorption is achieved, but the energy absorption is insufficient and injury prevention is inadequate
Solution Approach 1:
The armor plate is divided into multiple functional layers: a rigid strike plate for projectile stopping, a structural mesh layer for initial energy absorption, and a compliant mesh layer for backside deformation absorption. This segmentation allows each layer to specialize in specific energy absorption mechanisms, collectively providing superior protection compared to a single homogeneous trauma pad material.
Solution Approach 2:
The invention uses composite structures combining rigid metallic materials (strike plate) with lattice structure materials (structural mesh and compliant mesh layers). The composite design leverages the high strength of metals for projectile stopping while utilizing the energy absorption characteristics of lattice structures for backside deformation mitigation, achieving both penetration resistance and injury prevention.
2Strength
If thicker armor plates are used to stop projectiles, then penetration resistance is improved, but weight and bulk increase
Solution Approach 1:
The armor system is segmented into specialized layers with distinct functions: the thin rigid strike plate handles projectile stopping, while the lattice structure layers handle energy absorption. This segmentation allows optimization of each layer's thickness and material properties, achieving high protection with reduced overall weight compared to a single thick homogeneous plate.
Solution Approach 2:
The structural mesh and compliant mesh layers utilize porous lattice structures that provide high energy absorption per unit volume. These porous materials absorb projectile energy through controlled deformation and collapse mechanisms, enabling thin armor designs that would otherwise require much greater thickness to achieve the same protection level.
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 multi-layer armor plate effectively absorbs backside deformation energy, providing enhanced protection against projectiles while being thinner, lighter, and safer to wear, capable of withstanding multiple hits and reducing negative buoyancy.
Implementation Method 1
the compliant mesh layer absorbs backside deformation of the strike plate and/or the structural mesh layer, thereby preventing injury to the wearer
Data Source
AI summary
A multi-layer armor plate comprises a strike plate, a structural mesh layer, an outer skin, a compliant mesh layer, and an inner skin layer. The strike plate has an outer surface and an inner surface. The structural mesh layer is positioned on the outer surface of the strike plate and includes lattice structure with a first structural compliance. The outer skin layer is positioned over the structural mesh layer. The compliant mesh layer is positioned on the inner surface and includes lattice structure with a second structural compliance that is greater than the first structural compliance. The inner skin layer is positioned over the compliant mesh layer.