Cellular Composite Armor with Continuous Fiber Grids
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Solution Overview
Problem
Existing armor systems, particularly those using composite materials and ceramic plates, face challenges in preventing projectile penetration due to ineffective management of crack and stress wave propagation, leading to weakened adjacent plates.
Innovation Solution
A composite armor system featuring a one-piece integrally formed cellular structure with continuous fibers and laminates, secured with resins, to radially confine and protect composite inserts, thereby preventing projectile penetration and providing structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick metal armor systems are used to provide protection against penetration, then protection effectiveness is improved, but weight increases significantly
Solution Approach 1:
The patent employs composite materials consisting of ceramic plates combined with fiber grid structures and laminate sheets. The ceramic plates provide penetration resistance while the fiber grid and laminate sheets provide structural support and crack propagation management. This composite approach achieves effective protection against penetration while significantly reducing weight compared to thick metal armor systems.
Solution Approach 2:
The patent applies different materials and structural characteristics to different regions of the armor system. Ceramic plates are used in regions requiring high penetration resistance, while fiber grids and laminate sheets are used in regions requiring structural support and crack management. This localized material assignment optimizes protection effectiveness while minimizing overall weight.
2Reliability
If ceramic plates are used to provide protection against penetrating high speed projectiles, then protection effectiveness is improved, but crack propagation weakens adjacent plates
Solution Approach 1:
The patent introduces fiber grid structures and laminate sheets as intermediary components between ceramic plates. These intermediary elements manage crack propagation by distributing stresses and preventing crack transmission to adjacent ceramic plates. The fiber grid acts as a mediator that absorbs and disperses impact energies, while laminate sheets provide additional crack propagation management, thereby maintaining structural integrity while preserving protection effectiveness.
Solution Approach 2:
The patent creates a composite structure where ceramic plates are combined with fiber grids and laminate sheets. This composite approach allows the ceramic plates to provide penetration resistance while the fiber grid and laminate sheets simultaneously manage crack propagation and maintain structural integrity. The synergistic combination ensures that protection effectiveness is achieved without compromising the strength of adjacent plates.
3Weight of moving object
If multiple layers of composite materials are used to reduce overall weight, then weight is reduced, but armor performance of individual tiles deteriorates
Solution Approach 1:
The patent designs the fiber grid structure to perform multiple functions simultaneously: it provides structural support for ceramic plates, manages crack propagation, and enhances the armor performance of individual tiles. The laminate sheets also serve multiple purposes by providing additional crack management and structural reinforcement. This multi-functionality ensures that weight reduction does not compromise individual tile performance.
Solution Approach 2:
The patent uses composite materials in a layered configuration where each layer contributes specific functions. Ceramic plates provide penetration resistance, fiber grids provide structural support and crack management, and laminate sheets provide additional crack propagation management. This composite approach maintains armor performance of individual tiles while achieving overall weight reduction through the optimized combination of materials.
4Stress or pressure
If grid structures with preform sheets are used to manage stress propagation, then stress management is improved, but crack and debris propagation still weakens adjacent plates
Solution Approach 1:
The patent merges the fiber grid structure with laminate sheets into an integrated composite system. This combination creates a synergistic effect where the fiber grid provides structural support and the laminate sheets enhance crack propagation management. The merged structure effectively manages stress propagation while simultaneously preventing crack and debris propagation that would weaken adjacent plates, thereby maintaining protection effectiveness.
Solution Approach 2:
The patent employs composite materials consisting of fiber grids combined with laminate sheets to create a multi-functional armor system. The fiber grid provides structural support and stress distribution, while the laminate sheets provide enhanced crack propagation management. This composite approach effectively manages stress propagation and prevents crack and debris propagation to adjacent plates, resolving the limitation of prior art systems.
Data Source
AI summary
A composite armor 10 is provided with a cellular structure 12 having a plurality of composite inserts 14 arranged in openings 20 provided in the cellular structure 12. A pair of laminate sheets are arranged on oppositely facing sides of the cellular structure 12 and covering the inserts 14. The laminate sheets 26 and 28 are bonded to the structure 12 and the inserts 14 by an adhesive. The cellular structure 12 includes a plurality of fibers extending continuously throughout the cellular structure 12.