Ceramic Ballistic Panel Multi-Fiber Backing
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Solution Overview
Problem
Existing ballistic armor constructions face challenges in manufacturing capacity, limited availability of high tenacity fibers, and weight considerations, making it difficult to meet varying demand and performance requirements, especially during special needs such as military applications.
Innovation Solution
A ceramic faced ballistic resistant panel is designed with multiple layers of different high tenacity fibers, where the fibrous layer adjacent to the ceramic layer is stiffer than the interior layer, utilizing aramid and high molecular weight polyethylene fibers to enhance ballistic protection and flexibility in meeting demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single type of high tenacity fiber is used in the backing layer, then manufacturing is simpler, but availability is limited during times of special needs
Solution Approach 1:
The patent changes the parameter of fiber type composition by using multiple different high tenacity fiber types (such as aramid fibers, polyethylene fibers, and polypropylene fibers) in the backing layer instead of a single fiber type. This allows substitution between different fiber types while maintaining performance requirements, enabling manufacturing flexibility during times of special needs when certain fibers may be unavailable.
2Reliability
If ceramic plate thickness is increased to provide higher protection, then ballistic protection is improved, but weight increases beyond acceptable limits
Solution Approach 1:
The patent uses a composite structure combining a ceramic plate (such as alumina, silicon carbide, or boron carbide) with a multi-fiber backing layer. The ceramic plate provides hard ballistic protection while the composite fiber backing (using multiple fiber types like aramid, polyethylene, and polypropylene) provides additional protection and energy absorption. This composite approach achieves higher protection levels without requiring increased ceramic thickness, thereby controlling weight.
3Adaptability or versatility
If multiple types of high tenacity fibers are used in the backing layer, then fiber substitution flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates a universal backing layer design that can accommodate multiple different high tenacity fiber types (aramid, polyethylene, polypropylene, etc.) all serving the same protective function. The backing layer is designed to work with any combination of these fibers, allowing substitution based on availability without requiring different designs or processes. This multi-functionality approach enables flexibility in fiber selection while maintaining a consistent, manageable manufacturing process.
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
This configuration provides enhanced ballistic protection, flexibility in fiber substitution, and reduced manufacturing costs by maintaining equivalent areal density, ensuring consistent performance even with limited supply of single fiber types, and accommodating weight considerations.
Implementation Method 1
The ceramic plate is designed to face outwardly in the construction, acting as the primary layer that provides initial protection against ballistic projectiles. These structures are referred to as ceramic faced panels. These panels in general are effective in absorbing and dissipating kinetic energy from projectiles and projectile fragments.
Implementation Method 2
High tenacity fibers that are useful in such applications include high molecular weight polyethylene fibers, aramid fibers, and the like.
Data Source
AI summary
A ballistic resistant panel which is formed from a ceramic layer and a plurality of fibrous backing layers. A first fibrous backing layer is adjacent to the ceramic layer and a second fibrous backing layer is adjacent to the first fibrous backing layer. Each of the fibrous backing layers are formed from a network of high tenacity fibers, but the fibers of each of the backing layers have a different composition. Preferably, the first fibrous layer is stiffer than the second fibrous layer. The panel has a ballistic resistance which is substantially equivalent to or higher than the ballistic resistance of a comparable ceramic panel construction that has only a single fibrous layer of the same type of high tenacity fibers as are in the first and second fibrous backing layers for substantially the same areal density.