Armor Structures with Overlapping Shell Layers
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Solution Overview
Problem
Conventional lightweight armor materials, such as high performance polyethylene (HPPE), suffer from weak inter-laminar strength, soft resin systems, and susceptibility to fluid damage, leading to reduced durability and effectiveness in stopping projectiles and withstanding environmental chemicals.
Innovation Solution
The armor structure comprises a ballistics arresting core sealed by overlapping shell layers, with each shell layer including multiple plies of fiber-reinforced polymer, and featuring apertures and exterior coatings, allowing for enhanced strength, fluid resistance, and improved mounting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional lightweight materials like HPPE are used for armor, then weight is reduced, but durability and inter-laminar strength are significantly weakened
Solution Approach 1:
The patent employs a composite structure consisting of multiple shell layers (including fiber-reinforced polymers) combined with a ballistics arresting core. This composite approach allows the armor to maintain lightweight properties while achieving superior inter-laminar strength and durability through the synergistic combination of different materials with complementary properties.
Solution Approach 2:
The armor is divided into distinct functional segments: outer shell layers providing structural integrity and chemical resistance, and an inner ballistics arresting core providing projectile stopping capability. This segmentation allows each component to be optimized for its specific function while working together to solve the contradiction between weight and strength.
2Ease of manufacture
If conventional single-sheet wrapping methods are used, then manufacturing is simplified, but fluid resistance and strength are significantly reduced
Solution Approach 1:
The manufacturing process is segmented into multiple sequential steps: forming the ballistics arresting core, applying first shell layers, and applying second shell layers. This multi-stage approach, while more complex than single-sheet wrapping, enables superior fluid resistance and strength by allowing each layer to be independently optimized and properly sealed.
Solution Approach 2:
The patent transitions from conventional two-dimensional single-sheet wrapping to a three-dimensional multi-layer construction where shell layers wrap around and seal the ballistics core. This dimensional evolution enables comprehensive fluid sealing and enhanced strength while maintaining manufacturing feasibility through systematic process design.
3Weight of moving object
If HPPE with soft resin system is used, then weight is reduced, but susceptibility to fluid damage and chemical damage increases
Solution Approach 1:
The armor uses a composite material system where the ballistics arresting core (lightweight HPPE) is encapsulated by shell layers made of fiber-reinforced polymers with resin systems resistant to fluids and chemicals. This composite structure protects the lightweight core material from environmental degradation while maintaining overall weight efficiency.
Solution Approach 2:
The shell layers act as intermediary protective barriers between the ballistics arresting core and the external environment (fluids and chemicals). These shell layers absorb and resist environmental harmful factors, preventing them from reaching and damaging the lightweight HPPE core material.
4Ease of manufacture
If conventional armor structures are used, then manufacturing is simpler, but ballistic performance and impact resistance are reduced
Solution Approach 1:
The armor structure is segmented into functionally distinct components: ballistics arresting core for projectile stopping, first shell layers for structural support, and second shell layers for sealing and additional protection. This segmentation enables each component to be optimized for its specific ballistic function, achieving superior overall ballistic performance.
Solution Approach 2:
The multi-layer composite structure combines materials with different mechanical properties to achieve superior ballistic performance. The fiber-reinforced polymer shell layers provide tensile strength and structural integrity, while the ballistics arresting core provides projectile stopping capability, creating a synergistic system that outperforms conventional single-material structures.
Data Source
AI summary
An item of armor includes a ballistics arresting core, a first shell layer disposed on a first side of the ballistics arresting core, and a second shell layer disposed on a second side of the ballistics arresting core such that the second shell layer partially overlaps the first shell layer at an edge of the first shell layer to seal the ballistics arresting core within the first shell layer and the second shell layer.