Seamless Ceramic Ballistic Plate Crack Propagation Control

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Solution Overview

Problem

Unitary ceramic ballistic plates suffer from severe degradation in ballistic stopping power due to crack propagation, while multi-segment plates have inconsistencies at seams, lacking seamless and continuous protection.

Innovation Solution

A monolithic, unitary, seamless ceramic body with regions of different mechanical, chemical, and microstructural compositions, where one set of regions has a lesser or higher propensity to branch cracks than the other, preventing crack propagation through a network of interconnected regions with varying properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a unitary ceramic ballistic plate is used, then the structure is simple and manufacturing is easier, but crack propagation severely degrades ballistic stopping power

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidballistic stopping power

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The ceramic ballistic plate is divided into multiple segments with varying mechanical properties, where each segment contains regions with different crack propagation resistance. This segmentation allows cracks to be contained within specific segments rather than propagating through the entire plate, thereby maintaining ballistic stopping power while preserving manufacturing feasibility through modular construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions within the ceramic plate are assigned different mechanical properties, specifically varying crack propagation resistance. Regions with higher crack resistance are positioned to intercept and contain cracks, while regions with lower crack resistance allow controlled crack propagation to dissipate impact energy. This local differentiation maintains overall structural integrity and ballistic performance.

Inventive Principle:

Principle #3Local quality

2Reliability

If a multi-segment ceramic ballistic plate is used, then crack propagation is restricted, but seams create inconsistency in ballistic stopping power

Engineering Contradiction:

Improvecrack propagation resistanceVSAvoidballistic stopping power consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Multiple segments with different mechanical properties are merged into a single integrated structure where the segments are positioned and oriented to work together as a unified system. The segmentation is designed so that the interfaces between segments do not create noticeable seams or discontinuities in ballistic performance, achieving both crack restriction and consistent stopping power.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical properties of the ceramic material are varied across different regions and segments to create an optimized distribution of crack propagation resistance. By carefully controlling parameters such as density, composition, and microstructure in each segment, the plate achieves consistent ballistic stopping power while maintaining the ability to restrict crack propagation at segment boundaries.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If a unitary ceramic ballistic plate is used, then the structure is continuous and seamless, but cracks propagate body-wide reducing overall protection

Engineering Contradiction:

Improvestructural continuityVSAvoidoverall protection

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The continuous ceramic structure is segmented into multiple regions with different crack propagation characteristics. This segmentation maintains the overall continuous appearance and structure of the ballistic plate while creating internal boundaries that prevent body-wide crack propagation. Each segment remains connected to maintain structural integrity, but cracks are contained within individual segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ceramic ballistic plate uses composite material construction with varying properties across different regions. The composite structure combines ceramic materials with different mechanical properties, creating a seamless appearance while incorporating regions that resist crack propagation. This composite approach maintains structural continuity while preventing widespread crack propagation that would compromise overall protection.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8598057B1Multi-hit unitary seamless, and continuous ceramic ballistic body for armor including body armor, vehicle armor, and aircraft armor

Publication Date: 2013.12.03 VERCO MATERIALS LLC

AI summary

A monolithic, unitary, seamless and physically continuous ceramic armor plate having first regions of one mechanical property and one chemical composition and one microstructural composition isolated from one another by a network of second regions of another mechanical property different from the one mechanical property and another chemical composition different from the one chemical composition and another microstructural composition different from the one microstructural composition, the one mechanical property and the another mechanical property being the propensity to crack.