Ballistic Armor Manufacturing via Extrusion and Thermal Pretension
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Solution Overview
Problem
Current manufacturing methods for ballistic armors are complex, limited in adaptability to serial production, and result in excessive weight due to the use of ceramic elements, which are difficult to shape and lack sufficient tensile strength, making them unsuitable as load-bearing structures in vehicles.
Innovation Solution
A method involving the alignment of armor elements, such as ceramic tiles or hard steels, within a casing arrangement supported by guides and stoppers, where the casing is supplied around the elements, allowing for attachment via adhesive materials or welding, and enabling the structure to function both as ballistic armor and a load-bearing structure by utilizing thermal expansion for pretension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic elements are used in ballistic armor to increase hardness and projectile damage capability, then the armor can effectively damage penetrators, but the manufacturing complexity increases and the structure becomes more massive
Solution Approach 1:
The patent changes the manufacturing parameters by transitioning from manual assembly to automated extrusion processes, and from room temperature assembly to high-temperature casting processes, thereby reducing manufacturing complexity while maintaining ceramic element functionality
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated extrusion and casting processes, substituting complex manual labor with streamlined thermal and mechanical processes that achieve the same protective function with less complexity
2Ease of manufacture
If ceramic elements are glued to a frame structure, then the armor can be assembled, but the structure becomes excessively massive and cannot function as a load-bearing structure
Solution Approach 1:
The patent merges the frame structure and ceramic element assembly into a single integrated extrusion process, where the metal matrix and ceramic elements are combined in one continuous manufacturing step, eliminating the need for separate assembly operations and reducing overall structure mass
Solution Approach 2:
The patent creates a universal structure where the metal matrix serves multiple functions: it provides the load-bearing frame, acts as the bonding medium for ceramic elements, and enables automated manufacturing, thereby eliminating the need for separate assembly components and reducing weight
3Strength
If high accuracy dimensional tolerances are required for ceramic elements compressed by metal casing, then the pretension effect is achieved, but the manufacturing precision requirements become excessively high
Solution Approach 1:
The patent utilizes the phase transition of metal from molten to solid state during cooling, where the natural contraction of solidifying metal automatically generates the required pretension on ceramic elements, eliminating the need for high-precision dimensional control during assembly
Solution Approach 2:
The patent employs a self-adjusting mechanism where the cooling and contraction of the metal matrix automatically applies the necessary pretension to ceramic elements, with the system self-regulating the compressive force without requiring external precision control systems
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
This method simplifies the manufacturing process, allows for more flexible design and lighter weight structures, enabling the ballistic armor to be both effective against projectiles and serve as a load-bearing component in vehicles, while also being modular and easily adaptable to different shapes and sizes.
Implementation Method 1
The big difference in the ceramic elements' and aluminium's thermal expansion creates a compressing pretension for the ceramic elements when the molten metal cools down to solid material contracting at the same time.
Implementation Method 2
The big difference in the ceramic elements' and aluminium's thermal expansion creates a compressing pretension for the ceramic elements when the molten metal cools down to solid material contracting at the same time.
Implementation Method 3
The armor elements are attached to the frame structure with adhesive material
Data Source
Figure 1~1b
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a method for manufacturing a ballistic armor, comprising at least the steps of aligning armor elements (102) in front of a casing provider arrangement (104), and supplying a casing around the armor elements (102) such that the armor elements remain inside the casing. Further, the present invention relates to a method for inserting armor elements to a casing structure, comprising at least the steps of manufacturing a casing, and inserting armor elements in the cavities of the casing. Further, the present invention relates to a ballistic armor comprising a number of armor elements capsuled in a casing, and a casing forming a number of longitudinal cavities for the armor elements.