Composite Armor Release Layer for Lightweight Ballistic Protection
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Solution Overview
Problem
Conventional body armor made from metal plates and high tensile-strength fibers is heavy and bulky due to increased thickness or fiber coating, which does not effectively provide lightweight, flexible, and effective ballistic protection.
Innovation Solution
A composite armor system comprising multiple bonded fibrous layers with a release layer preventing bonding between specific layers, allowing for mechanical joining through apertures, and a manufacturing method involving stitching and temperature curing under pressure to create a lightweight yet rigid armor unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more combined layers are added to improve anti-ballistic capabilities, then ballistic protection is enhanced, but the panel becomes thick and bulky
Solution Approach 1:
A release layer is introduced as an intermediary between fibrous layers. This release layer has selective bonding properties - it prevents bonding between certain layers while allowing bonding in other areas, enabling controlled layer separation that improves ballistic performance without requiring increased thickness
Solution Approach 2:
The release layer creates local variations in bonding characteristics across the panel. By having regions with different bonding strengths and separation capabilities, the panel achieves enhanced ballistic protection through localized energy absorption and deformation mechanisms rather than uniform thickening
2Reliability
If metal plates are added in front of or in-between fabric layers to reduce thickness, then anti-ballistic capability is improved, but the armor becomes heavy and bulky
Solution Approach 1:
The invention uses composite structures combining multiple fibrous layers with a release layer, eliminating the need for metal plates. The composite fibrous structure achieves comparable or superior ballistic protection through layered energy absorption mechanisms while maintaining lightweight characteristics
Solution Approach 2:
The release layer changes the bonding parameters between layers, creating controlled weak interfaces that allow for energy absorption through layer separation. This parameter change enables the structure to achieve ballistic protection through controlled failure modes rather than relying on heavy metal reinforcement
3Strength
If individual fibers are substantially coated with elastomer to improve panel rigidity, then structural strength is enhanced, but the manufacturing process becomes complex and costly
Solution Approach 1:
The invention extracts the complexity of individual fiber coating by replacing it with a simpler release layer applied between completed fibrous layers. This eliminates the need for complex coating equipment and processes while achieving the desired structural properties through inter-layer release characteristics rather than intra-fiber modification
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 solution significantly enhances ballistic performance by maintaining structural integrity while reducing weight and bulk, allowing for effective deflection and separation of projectiles without excessive material thickness.
Implementation Method 1
temperature curing the fibrous layers within the joined substratum layer and the third bulk section
Implementation Method 2
A compressive force is applied to the joined substratum layer and the third bulk section of uncured fibrous layers
Implementation Method 3
The release layer prevents bonding between the second bonded fibrous layer and the third bonded fibrous layer at opposite portions of the release layer contacting both the second bonded fibrous layer and the third bonded fibrous layer
Data Source
AI summary
The present disclosure is directed to a composite armor system and method of manufacturing the same including a composite armor system that includes a first bulk bonded fibrous layer, a second bonded fibrous layer bonded to the first bulk bonded fibrous layer and a third bonded fibrous layer. At least one release layer is disposed between the second bonded fibrous layer and the third bonded fibrous layer and a joining mechanism that joins the second bonded fibrous layer to the third bonded fibrous layer through apertures in the release layer into a joined bonded substratum layer. The release layer prevents bonding between the second bonded fibrous layer and the third bonded fibrous layer at opposite portions of the release layer contacting both the second bonded fibrous layer and the third bonded fibrous layer.