Ballistic-Layer Inserts for Vehicle Structures Against Fragmentation
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Solution Overview
Problem
Existing vehicle structural members lack sufficient reinforcement to prevent penetration by debris or fragmentation, particularly in inaccessible areas, and require extensive retrofitting for ballistic protection, which is costly and inefficient.
Innovation Solution
An insert with a ballistic material, such as Kevlar or aramid fibers, is integrated into structural members using a core/shell structure or multilayered design, secured with adhesives or fasteners, to enhance structural integrity and prevent penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive retrofitting is performed to reinforce vehicle frame, then ballistic protection is improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by integrating ballistic inserts into structural members during the original vehicle manufacturing process, before the vehicle is delivered to customers. This allows ballistic protection to be built-in from the start, eliminating the need for costly and complex retrofitting operations later. The inserts are positioned within structural members during factory assembly, making the armored vehicle production as straightforward as conventional vehicle manufacturing.
Solution Approach 2:
The patent segments the ballistic protection system into discrete inserts that can be individually placed within specific structural members of the vehicle frame. Rather than requiring complete frame replacement or extensive modification, the protection system is divided into modular units (inserts) that fit into predetermined locations, simplifying both manufacturing and assembly while maintaining comprehensive coverage of vulnerable areas.
2Strength
If traditional reinforcement methods are used, then structural integrity is improved, but protection against debris and fragmentation is insufficient
Solution Approach 1:
The patent employs composite materials by combining a core material (such as foam, rubber, or plastic) with a ballistic material (such as Kevlar®, aramid fibers, or other high-strength fibers) to create an insert that provides both structural integrity and ballistic protection. The core provides structural support and energy absorption, while the ballistic material layer prevents penetration by debris and fragmentation, achieving dual functionality in a single component.
Solution Approach 2:
The patent applies the nested doll principle by placing the ballistic insert within the hollow cavity of existing structural members. The insert is nested inside the structural member, utilizing the available space without requiring replacement of the outer shell. This nested configuration allows the ballistic protection to be integrated within the existing structural framework, maintaining structural integrity while adding protective functionality.
3Productivity
If structural members are reinforced during original assembly, then production efficiency is improved, but inaccessible areas remain unprotected
Solution Approach 1:
The patent achieves universality by designing inserts that can be applied to a wide variety of structural members and vehicle configurations. The standardized insert design allows the same basic component to be used in different locations (pillars, joints, frame sections) and even across different vehicle models, enabling comprehensive protection of previously inaccessible areas while maintaining efficient, standardized manufacturing processes.
Data Source
AI summary
An insert for structurally reinforcing a cavity of a structural member, wherein the insert includes a ballistic material to prevent penetration of the structural member by flying debris, fragmentation, or both.