Ballistic Panel Void Repair With Density-Matched Fill Material
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Solution Overview
Problem
Ballistic concrete barriers used in live-fire training facilities degrade over time, creating voids that compromise their integrity and safety, necessitating a method to fill these voids with a material that maintains the panel's ballistic properties.
Innovation Solution
A system using an injector assembly to fill voids in ballistic panels with a specially formulated ballistic replacement material, comprising Portland cement, fine aggregate, air entrainment additive, fiber, and calcium phosphate, which matches the density and ballistic performance of the original panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ballistic concrete barriers are used in live-fire 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 providing a repair system that can be applied before complete failure occurs. The void detection and repair methodology allows operators to identify and fix degradation issues (voids) in ballistic panels before they compromise the overall ballistic integrity of the barrier, thus extending the service life while maintaining reliability.
2Stability of the object's composition
If voids are filled with traditional concrete, then structural continuity is restored, but ballistic properties are not maintained
Solution Approach 1:
The patent applies parameter changes by carefully controlling the density and composition of the repair material to match the original ballistic concrete. The specified density range (1121-1442 kg/cubic meter) ensures that the filled void restores both structural continuity and ballistic properties. The material formulation including Portland cement, fine aggregate, air entrainment additive, fiber, aluminum hydroxide, and calcium phosphate is designed to replicate the ballistic performance of the original panel.
3Reliability
If the ballistic panel is replaced entirely, then ballistic integrity is restored, but cost and time are increased
Solution Approach 1:
The patent applies segmentation by treating the repair as a localized operation rather than a complete replacement. The injector assembly delivers repair material directly into specific voids within the ballistic panel, allowing only the affected portions to be repaired while the rest of the panel remains in service. This segmented approach minimizes downtime and cost compared to complete panel replacement.
4Reliability
If the ballistic panel is replaced entirely, then ballistic integrity is restored, but cost is increased
Solution Approach 1:
The patent applies discarding and recovering by preserving the majority of the original ballistic panel structure and only replacing or repairing the specific degraded portions (voids). This selective recovery approach avoids the waste and cost associated with complete panel replacement, while still restoring ballistic integrity to the affected areas.
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 effectively maintains the ballistic integrity of the panels by ensuring the filled voids exhibit equivalent ballistic properties, enhancing the safety and durability of the training facilities.
Implementation Method 1
about 0.0005 to 0.05 part by mass air entrainment additive
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.