Ballistic Radome Cover With Impedance-Matched Ceramic Core
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Solution Overview
Problem
Electronic scanned array (ESA) sensors used in combat settings face challenges due to exposure to gunfire and fragmentation armaments, which can render them inoperable, and existing radome solutions do not adequately balance ballistic protection with electromagnetic signal transmission and water vapor protection.
Innovation Solution
A radome cover with a partially tiled multi-layered core construction using ceramic composite materials, including alumina, sandwiched between impedance-matched layers to dissipate kinetic energy and minimize water vapor permeation, ensuring transparency to electromagnetic signals while providing ballistic protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a radome cover uses thick ballistic protective material, then ballistic protection is improved, but electromagnetic signal transmission deteriorates
Solution Approach 1:
The radome cover employs a composite structure combining ceramic material (providing ballistic protection) with rubber material (providing electromagnetic transparency). This composite approach allows the integration of materials with complementary properties to simultaneously achieve both ballistic protection and electromagnetic signal transmission.
Solution Approach 2:
The patent optimizes the thickness parameters of different layers to balance ballistic protection and electromagnetic transmission. The ceramic layer thickness is controlled at 0.5-2.0 cm for adequate ballistic protection, while the rubber layer thickness is optimized at 0.2-0.5 cm to maintain electromagnetic transparency. These parameter adjustments resolve the contradiction between protection and signal transmission.
2Ease of manufacture
If a radome cover uses homogeneous single-layer construction, then manufacturing is simplified, but performance balance between ballistic protection and signal transmission deteriorates
Solution Approach 1:
The radome cover is divided into multiple functional layers: a ceramic layer for ballistic protection and a rubber layer for electromagnetic transparency. This segmentation allows each layer to be optimized for its specific function while maintaining overall manufacturing feasibility through standardized bonding processes.
3Ease of manufacture
If a radome cover uses traditional bonding methods for multi-layer construction, then assembly is simplified, but water vapor permeation increases
Solution Approach 1:
The bonding process parameters are optimized to achieve both ease of assembly and water vapor protection. The bonding temperature is controlled at 20-50°C and bonding pressure at 0.1-0.5 MPa, creating strong bonds that prevent water vapor permeation while maintaining manufacturing simplicity.
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 radome cover effectively dissipates kinetic energy from ballistic threats, maintains low RF signal loss, and prevents water vapor ingress, protecting non-hermetic electronics while allowing efficient electromagnetic signal transmission.
Implementation Method 1
the tiles are bonded together to form a layer to dissipate kinetic energy from impacts thereto
Implementation Method 2
the at least two layers having a construction such that they are impedance matched to the core over a frequency band
Implementation Method 3
the core is constructed to provide an ultra-low permeation path of water vapor to protect non-hermetic electronics within the radome cover
Data Source
Figure 1~2
Figure 3~4
Figure 5A~7A
AI summary
According to one embodiment of the invention, a radome cover (40; 40A; 40B; 40C) for an RF sensor has been provided. The radome cover comprises a ceramic core (50) and at least two layers (42A, 44A). The ceramic core (40) is sandwiched between the at least two layers (42, 44)and the at least two layers are impedance matched to the ceramic core. The radome cover provides ballistic protection for the RF sensor.