Ballistic Panel Void Filling With Equivalent Repair Material
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Solution Overview
Problem
Ballistic concrete barriers used in training facilities for live ammunition training degrade over time, creating voids that compromise their integrity and safety, necessitating a method to fill these voids with materials that maintain the ballistic properties of the original panel.
Innovation Solution
A system involving an injector assembly that fills voids in ballistic panels with a specially formulated ballistic replacement material, comprising Portland cement, fine aggregate, air entrainment additive, fiber, and calcium phosphate, ensuring the filled voids exhibit equivalent ballistic properties to the original panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ballistic concrete barriers are used in training facilities, then ballistic protection is provided, but the barriers degrade over time creating voids that compromise integrity
Solution Approach 1:
The patent applies preliminary action by injecting void-filling material into deteriorating areas of the ballistic barrier before complete failure occurs. The system detects voids and immediately fills them with injection equipment, preventing further degradation and maintaining ballistic integrity throughout the extended service life of the barrier.
2Strength
If voids are filled with traditional concrete, then structural integrity is restored, but ballistic properties are not equivalent to original panel
Solution Approach 1:
The patent applies parameter changes by carefully controlling the composition, density, and mechanical properties of the void-filling material to match the original ballistic concrete. The injection material is formulated with specific cementitious binders, aggregates, and admixtures to achieve equivalent ballistic performance, ensuring that repaired areas maintain the same protective characteristics as the original panel.
3Reliability
If the barrier is completely replaced, then full ballistic integrity is restored, but cost and time are significantly increased
Solution Approach 1:
The patent applies the extraction principle by removing only the deteriorated portions (voids) from the ballistic barrier and replacing them with injection material, rather than removing and replacing the entire structure. This localized repair approach significantly reduces maintenance time, cost, and disruption while restoring full ballistic integrity to the affected areas.
4Ease of manufacture
If voids are left unfilled, then maintenance cost is reduced, but safety and operational capability are compromised
Solution Approach 1:
The patent applies feedback by implementing a monitoring system that detects void formation in the ballistic barrier and triggers immediate repair actions. The system continuously assesses the condition of the barrier, provides feedback on deterioration, and initiates targeted injection repairs only when and where needed, optimizing the balance between maintenance cost and safety.
Data Source
AI summary
A ballistic panel formed with a ballistic material, the panel comprising: a panel with a filled void; wherein the filled void is filled with a ballistic replacement material; and wherein the filled void exhibits ballistic properties equivalent to the ballistic panel formed with the ballistic material; wherein the ballistic replacement material and the ballistic material comprise between about 1121 kg/cubic meter (about 70 pounds per cubic foot) and about 1442 kg/cubic meter (about 90 pounds per cubic foot); and wherein the ballistic replacement material and the ballistic material comprise: about 1 part by mass Portland cement; about 0.5 to 1.5 part by mass fine aggregate; and about 0.0005 to 0.05 part by mass air entrainment additive; about 0.005 to 0.15 part by mass fiber; about 0.005 to 0.05 part by mass aluminum hydroxide and about 0.005 to 0.05 part by mass calcium phosphate.