Ceramic Tile Wrapping for Armor Chipping Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexible armor systems face challenges with ceramic tiles chipping out during projectile impacts due to near-edge regions, leading to reduced ballistic stopping performance and increased propensity for fracture, especially with multiple hits and rough handling.
Innovation Solution
A method of wrapping ceramic tiles with a plurality of polymer-impregnated wrappers, using isostatic pressing to integrate the wrappers with the tiles, and applying a sequence of star-shaped wrappers with varying leaf lengths to ensure comprehensive coverage and adhesion, enhancing the mechanical bond between the ceramic and the wrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ceramic tiles are used in an imbricated flexible armor system, then body conformability and multi-hit capability are improved, but the tiles are prone to chipping at near-edge regions and fracture with rough handling
Solution Approach 1:
The patent applies composite materials by combining ceramic tiles with polymer-impregnated fabric wrappers. The fabric wrapper acts as a reinforcement layer that bonds to the ceramic tile surface, creating a composite structure that maintains the ceramic's ballistic performance while adding fracture resistance and preventing chipping at edges during rough handling or multiple impacts.
2Reliability
If ceramic tiles are wrapped with fabric to prevent chipping, then edge effects are reduced, but the cohesion between ceramic and wrap is insufficient with conventional methods
Solution Approach 1:
The patent changes the chemical parameter of the wrapping material by using polymer-impregnated fabric instead of conventional non-impregnated fabric. The polymer impregnation creates a chemical bond between the fabric and ceramic tile, significantly improving the cohesion and adhesion at the interface, which prevents delamination and enhances the overall structural integrity of the wrapped tile.
3Manufacturing precision
If multiple wrappers with varying leaf lengths are used, then comprehensive coverage and adhesion are achieved, but the wrapping process complexity increases
Solution Approach 1:
The patent segments the wrapping process by using multiple wrappers with different leaf length configurations. Each wrapper is designed with specific leaf lengths to cover particular regions of the ceramic tile, ensuring complete edge coverage. This segmentation approach, while increasing the number of components, provides systematic and comprehensive coverage that prevents chipping at all edge regions.
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 significantly improves the cohesion between the ceramic tiles and the wrap, reducing the likelihood of chipping and enhancing the armor's ability to withstand multiple impacts and rough handling, resulting in improved ballistic performance and fracture resistance.
Implementation Method 1
isostatic pressing the wrapped tile to integrate the wrappers and the tile while curing the polymer
Implementation Method 2
a plurality of wrappers impregnated with a curable polymer to obtain a wrapped tile and isostatic pressing the wrapped tile to integrate the wrappers and the tile while curing the polymer
Data Source
AI summary
A method of making an armor component that includes wrapping a ceramic tile with a plurality of wrappers that are impregnated with a curable polymer, and forcing the curable polymer into microscopic surface cavities of the ceramic tile by isostatically pressing the wrapped ceramic tile while curing the curable polymer to obtain an armor component that includes the ceramic tile integrated with the wrappers.