Ballistic Protection Material Using Composite Mesh and Ceramic Particulates
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Solution Overview
Problem
Current ballistic protection materials are heavy, expensive, and thicker than necessary for effective deployment, while lacking cost-effectiveness and efficiency in resisting ballistic threats.
Innovation Solution
A composite ballistic protection material comprising a metal mesh embedded in a compacted ceramic particulate material bound by a polymer matrix, utilizing a displacement mechanism to arrest projectiles through structural failure or movement of particles, and featuring multiple layers of different materials for enhanced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ballistic protection materials are used, then ballistic resistance is achieved, but weight increases and thickness increases
Solution Approach 1:
The patent applies composite materials by combining metal mesh with ceramic particulate material (such as aluminium oxide) bound by a polymer matrix. This composite structure achieves ballistic resistance through the synergistic effects of the metal mesh (providing structural integrity and tensile strength) and the ceramic particles (providing hardness and projectile disruption), while reducing overall weight compared to traditional solid ceramic or metal armour plates.
Solution Approach 2:
The patent utilizes porous or particulate ceramic material in the form of compacted particles rather than solid dense material. The particulate structure with interstitial spaces bound by polymer matrix provides ballistic protection through particle displacement and structural failure mechanisms while maintaining lower density and weight compared to solid equivalent-strength materials.
2Strength
If traditional ballistic protection materials are used, then ballistic resistance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent changes the physical state and form of the ceramic material from solid plates or blocks to compacted particulate form, and binds it with a polymer matrix rather than traditional resins or adhesives. This parameter change in material form and binding method reduces manufacturing complexity and cost while maintaining ballistic performance.
Solution Approach 2:
The composite structure of metal mesh combined with ceramic particles and polymer binder creates a material that can be manufactured using simpler, more cost-effective processes compared to traditional monolithic ceramic or metal armour, reducing overall manufacturing cost while achieving required ballistic resistance.
3Strength
If traditional ballistic protection materials are used, then ballistic resistance is achieved, but thickness increases
Solution Approach 1:
The composite structure combines metal mesh with ceramic particles in a polymer matrix, creating a thinner protective layer that achieves the same ballistic resistance as thicker traditional materials. The metal mesh provides structural support in a thin configuration while the ceramic particles provide projectile disruption capability.
Solution Approach 2:
The patent applies local quality by distributing ceramic particles throughout the polymer matrix and embedding metal mesh at strategic locations to provide localized reinforcement. This distributed reinforcement approach achieves effective ballistic protection with reduced overall thickness compared to uniform traditional armour structures.
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 solution provides effective ballistic resistance against normal and armor-piercing ammunition, meeting European and NATO standards, while being lighter, thinner, and more cost-effective than existing materials, with a manufacturing process using readily available equipment and materials.
Implementation Method 1
structural failure of individual particles of particulate material
Implementation Method 2
movement of individual particles of the particulate material relative to adjacent particles of said material
Implementation Method 3
breaking of the bond between particles of the particulate material formed by the binder material
Data Source
AI summary
A ballistic protection material (10) having a composite layer (16) that comprises a mesh (54) embedded in a mass of compacted particulate material (56) that is bound together by a binder material (66). The mesh (54) may be a metal mesh, the particulate material (56) may comprise ceramic particles (64) and the binder material (66) may be an epoxy resin matrix. The ballistic protection material (10) may comprise additional layers, for example, a first layer (12) comprising a first class of steel and a second layer (14) comprising a second class of steel that is different to the first class of steel. The second layer (14) can be positioned intermediate the first layer (12) and the composite layer (16).