Armored Building Modules With Z-Shape Segmentation
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Solution Overview
Problem
Existing armored building modules are not effectively designed to provide low-cost, lightweight protection against mortar projectiles and blasts, and they lack the ability to be quickly and easily repaired without disturbing adjacent modules.
Innovation Solution
The development of armored building modules with a Z-shaped structure, where parallel plates are connected by side members to form a continuous beam-like structure, allowing for side-by-side and end-to-end nesting without clear-through seams, and incorporating energy-absorbing materials to absorb projectile and blast energy, enabling easy removal and replacement of damaged modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy materials like massive concrete and thick high-strength steel plates are used for armor, then protection effectiveness against mortar threats is improved, but cost and weight increase significantly
Solution Approach 1:
The armor panel is segmented into multiple steel plates of different thicknesses arranged in layers. Thinner plates (e.g., 1/4 inch) are positioned on the exterior where they intercept and fragment incoming projectiles, while thicker plates (e.g., 3/8 inch or 1/2 inch) are positioned on the interior to stop penetrating fragments. This segmentation allows each plate to perform a specific function, achieving effective protection with lighter overall weight compared to using uniformly thick heavy plates throughout.
Solution Approach 2:
Different regions of the armor structure use plates with locally optimized thicknesses. The exterior plates are thinner since their function is to intercept and fragment projectiles before they penetrate deep into the structure. The interior plates are thicker to provide the necessary stopping power against fragmented debris. This local quality approach ensures that material is distributed efficiently, providing maximum protection where needed while minimizing unnecessary weight in other areas.
2Reliability
If uniformly thick heavy steel plates are used throughout the structure, then protection against projectile penetration is improved, but cost increases and deployment speed decreases
Solution Approach 1:
The structure is divided into modular panels, each consisting of multiple plates of different thicknesses. These panels can be pre-assembled and then rapidly deployed by positioning them into place. The segmentation into standard-sized modules with consistent thickness variations allows for mass production and quick installation, achieving both protection effectiveness and rapid deployment capability.
Solution Approach 2:
The armor panels are pre-assembled with plates of different thicknesses already positioned in their correct locations before deployment. This preliminary action of pre-positioning the varying thickness plates during manufacturing eliminates the need for complex on-site assembly during rapid deployment scenarios. The modules are ready-to-install units that can be quickly positioned and secured, maintaining both protective effectiveness and deployment speed.
3Ease of manufacture
If plates are connected only at longitudinal ends by end caps, then manufacturing simplicity is maintained, but structural resistance to bending from external blasts is insufficient
Solution Approach 1:
The connection system merges multiple connection methods: end caps continue to provide longitudinal end connections, while additional lateral connectors attach adjacent panels along their side edges. This combination creates a integrated structural system where forces from external blasts are distributed across multiple connection points rather than being concentrated at single end caps. The merged connection system maintains manufacturing simplicity by using standardized components while significantly improving resistance to bending and blast loads.
Solution Approach 2:
The connection approach transitions from one-dimensional end-cap-only connections to two-dimensional connectivity by adding lateral connections along the panel edges. This dimensional expansion creates a grid-like connection pattern that provides structural support in multiple directions, improving the panel assembly's ability to resist bending forces from external blasts while maintaining ease of manufacture through modular, repeatable connection details.
4Strength
If I-beam configurations are used to strengthen face panels, then individual panel strength is improved, but the interconnection between front and back face panels remains weak
Solution Approach 1:
The structure merges the strengthening function and interconnection function into a unified plate assembly system. Multiple plates of varying thicknesses are positioned in layers with both front and back faces, and lateral connectors join adjacent panels along their edges. This merged system provides both individual panel strength (through the layered plate configuration) and interconnection stability (through the lateral connectors binding the assembly together), eliminating the need for separate I-beam strengthening elements.
Solution Approach 2:
The multi-layer plate assembly with lateral connections serves multiple functions simultaneously: it strengthens individual panels through the layered configuration, connects front and back faces through the spatial arrangement of plates, and provides inter-panel stability through lateral connectors. This universal structure performs both strengthening and interconnection roles that were previously separated into different components, simplifying the overall design while improving performance.
5Reliability
If modules are designed with overlapping side lap overhangs for continuous protection, then protection continuity is improved, but ease of repair by removing damaged modules becomes difficult
Solution Approach 1:
The armor system is segmented into modular panels with standardized overlapping configurations. Each panel is designed as an independent replaceable unit with consistent overhang dimensions. This segmentation allows damaged panels to be identified and removed as discrete modules while maintaining protection continuity through the overlapping design. The standardized segmentation enables rapid replacement by simply installing new modules in the same configuration, achieving both protection continuity and ease of repair.
Solution Approach 2:
The modular design with standardized overlaps enables the discard-and-recover repair approach. When a panel is damaged, the entire module can be quickly removed and replaced with a new or refurbished module from inventory. The overlapping configuration ensures that during removal and installation, continuous protection is maintained. This approach trades the complexity of in-situ repair for rapid module replacement, improving both protection continuity and ease of repair for field conditions.
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 provides effective protection against mortar shells and shrapnel, allowing for the rapid replacement of damaged modules without disturbing adjacent ones, ensuring continuous protection and structural integrity.
Implementation Method 1
incorporating energy-absorbing materials to absorb projectile and blast energy
Data Source
AI summary
Panels and their modules, such as for walls and roofs, are disclosed that provide armored shelter for protecting people and equipment from ballistic projectiles and mortar attacks. Each module is made from multiple co-parallel plates arranged in a stack, spaced apart, and held together along their sides by side elements. This is done in such a way that, when assembled side-by-side or end-to-end into panels, adjacent modules overlap one another to prevent straight-through seams yet allow any damaged module to be removed and replaced without moving adjacent modules. Space within a module, between plates and sides, can contain energy absorbing material in a variety of shapes. Plates serve as structural flanges, and side elements comprise structural webs, to permit each module to function as a structural beam.