Armored Vehicle Protective Element With Welded Profiles and Sharp Edges
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Solution Overview
Problem
Existing methods for producing protective elements for motor vehicles result in weakened protective areas due to bending radii and heat-affected zones, which compromise the ballistic resistance and integrity of the armor plating.
Innovation Solution
A method involving the use of individual profiles welded at specific angles and hardness configurations, followed by hot-forming and tempering, to create sharp edges and minimize bending radii and heat-affected zones, ensuring a homogeneous hardness distribution and improved impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If individual profiles are welded together to form protective elements, then the structural integrity and protective function are improved, but the heat-affected zone from welding reduces the hardness and creates soft weld seams that are not bullet-proof
Solution Approach 1:
The patent applies different filler materials with different hardness levels at different locations of the weld seam. A first filler material with higher hardness is used for the first weld seam, while a second filler material with lower hardness is used for the second weld seam, creating localized quality variations that optimize both protective function and stress management
Solution Approach 2:
The patent uses composite welding filler materials with varying hardness characteristics to create weld seams that combine the benefits of high hardness for bullet resistance with appropriate ductility for stress compensation, effectively creating a composite structure at the weld interface
2Ease of manufacture
If protective elements are formed from molded parts with bending radii, then the shaping flexibility is improved, but the bending radii reduce the protective area and allow projectile deflection that compromises safety
Solution Approach 1:
The patent divides the protective element into multiple straight individual profiles that are welded together at specific angles, eliminating the need for continuous bending radii while maintaining the ability to create complex shapes through angular connections of segmented components
Solution Approach 2:
Instead of forming continuous curved surfaces through bending, the patent inverts the approach by assembling straight segments at angles to achieve the desired geometry, thereby eliminating bending radii while preserving shaping flexibility
3Shape
If small bending radii are used to increase bend sharpness, then the shape complexity is improved, but the material thickness at the bending point decreases and strength is reduced
Solution Approach 1:
The patent segments the structure into straight profiles connected at angles, eliminating bending operations entirely and maintaining full material thickness at connection points while achieving complex shapes through angular assembly
4Strength
If large bending radii are used to maintain material thickness, then the strength is improved, but the protective area is reduced and the shape complexity is limited
Solution Approach 1:
The patent uses segmented straight profiles that can be assembled into complex shapes without bending, maintaining full material thickness and strength while achieving geometric complexity through angular connections rather than curved transitions
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 method produces protective elements with enhanced ballistic resistance and uniform hardness, eliminating material weaknesses at weld seams and maintaining consistent protective effectiveness across the entire element.
Implementation Method 1
Heating the preform to a temperature higher than the austenitizing temperature of the steel alloy with the higher austenitizing temperature
Implementation Method 2
Placing the preform in a hot-forming tool, final forming of the preform to form the protective element in the hot-forming tool
Implementation Method 3
wherein the protective element is hardened in a final process step
Data Source
Figure 1~2
Figure 3~4c
Figure 5~6
AI summary
The invention relates to a process for manufacturing a protective element (1) for the armoring of a motor vehicle, formed from several individual profiles (2, 3, 4), in which at least two of the individual profiles (2, 3, 4) are arranged adjacent to each other, comprising the following process steps: a) providing the individual profiles (2, 3, 4) made of the same steel alloy or of different steel alloys, b) welding the individual profiles (2, 3, 4) together to form a preform of the protective element (1), c) heating the preform to a temperature higher than the austenitizing temperature of the steel alloy with the higher austenitizing temperature, d) placing the preform into a hot forming tool, e) final forming of the preform into the protective element (1) in the hot forming tool, characterized in that the welding in step b) is carried out by forming at least one first weld (6) and one second weld (5).wherein the first weld (6) is located further away from a side (9) facing the firing line of the individual profiles (2, 3, 4) than the second weld (5), and the protective element is hardened in a final process step.