Ballistic Panel Composite Structure for Aircraft Weight Reduction
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Solution Overview
Problem
Current ballistic resistant composites for vehicles, such as airplanes, do not adequately meet the requirements for both high structural integrity and lightweight design while providing superior ballistic and impact resistance, particularly for applications like commercial airlines and maritime vessels.
Innovation Solution
A composite structure comprising non-woven fibrous layers coated with a polymeric composition, consolidated to achieve high tenacity and tensile modulus, sandwiched between a central honeycomb panel with closely packed geometric cells, and optionally attached with fire-resistant materials, to enhance structural and ballistic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ballistic resistant composites are used, then ballistic resistance is provided, but structural integrity and weight requirements are not adequately met
Solution Approach 1:
The patent employs a composite structure combining ballistic resistant fibrous layers (made from high strength fibers like ultra-high molecular weight polyethylene or aramid) with a honeycomb core structure. This composite design achieves superior ballistic resistance while maintaining lightweight properties, as the honeycomb provides structural support with minimal weight addition. The fibrous layers are consolidated into rigid or flexible fabrics and integrated with the honeycomb core to create a multi-functional composite panel that simultaneously delivers ballistic protection and structural integrity.
Solution Approach 2:
The patent applies different material properties to different regions of the composite structure. The ballistic resistant fibrous layers are positioned on the outer surfaces to provide impact resistance, while the honeycomb core provides internal structural support and energy absorption. This localized distribution of material functions optimizes both ballistic performance and weight efficiency, allowing each component to perform its specialized function without unnecessary weight.
2Reliability
If ballistic resistant panels are used, then security protection is improved, but structural performance requirements are not adequately met
Solution Approach 1:
The patent creates a composite structure where ballistic resistant fibrous layers are integrated with a honeycomb core to simultaneously achieve security protection and structural performance. The fibrous layers provide ballistic resistance while the honeycomb structure contributes rigidity, compression strength, and overall structural integrity. This composite design ensures that the panel meets both ballistic protection requirements and structural performance standards for aircraft applications.
Solution Approach 2:
The patent merges two distinct functional components - ballistic resistant fibrous layers and honeycomb structural core - into a single integrated panel. The fibrous layers are consolidated into rigid or flexible fabrics and combined with the honeycomb core through bonding or lamination processes. This merging creates a unified structure that delivers both security protection and structural performance without requiring separate components.
3Weight of moving object
If lightweight composite structures are used, then weight is reduced, but ballistic resistance and structural integrity are compromised
Solution Approach 1:
The patent uses a composite structure combining lightweight fibrous layers with a honeycomb core to achieve superior strength-to-weight ratio. The high strength fibers (such as ultra-high molecular weight polyethylene or aramid) provide ballistic resistance with minimal weight, while the honeycomb core adds structural integrity without significant weight penalty. This composite design outperforms conventional materials by delivering enhanced ballistic resistance and structural strength at reduced weight.
Solution Approach 2:
The patent optimizes the parameters of the composite structure, including fiber orientation, layer thickness, honeycomb cell size, and material density, to achieve the optimal balance between weight and performance. By carefully controlling these parameters, the design maximizes ballistic resistance and structural integrity while minimizing weight, allowing the panel to meet all performance requirements at reduced weight compared to conventional designs.
Data Source
AI summary
Ballistic resistant composites and articles formed therefrom for use in airplanes and other vehicles which meets particular structural, impact and ballistic requirements. An aerospace-specification grade honeycomb is positioned between panels comprising non-woven ballistic resistant fibrous layers, and optionally one or more fire resistant layers. The composites and the articles formed therefrom have superior structural, impact, fire resistance and ballistic performance at a light weight.