Composite Armor Structure with Intumescent Coating
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Solution Overview
Problem
Current armor solutions for law enforcement and military personnel are inadequate due to excessive weight, cost, and limited protection against high-powered rifle fire, armor-piercing rounds, extreme temperatures, and electromagnetic pulse jamming.
Innovation Solution
A composite structure composed of layered Jute or burlap with Kevlar or Carbon Fiber, wrapped around a ballistic-resistant core, with resin saturation and intumescing coating for enhanced protection, which can be molded into various shapes and sizes, providing multi-threat protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional armor materials are used to protect against high-powered rifle fire and armor-piercing rounds, then protection level is improved, but weight increases excessively
Solution Approach 1:
The patent employs a multi-layer composite structure combining Kevlar fabric layers with intermediate cushioning materials and resin saturation. This composite approach achieves high ballistic protection against rifle fire and armor-piercing rounds while maintaining reduced weight compared to traditional monolithic armor materials.
Solution Approach 2:
The armor structure implements a nested multi-layer configuration where Kevlar layers are interleaved with cushioning layers and bound by resin. Each layer serves a specific function in the ballistic protection hierarchy, creating a nested protective system that optimizes both protection and weight characteristics.
2Reliability
If heavier armor materials are used to protect against ballistic threats, then protection level is improved, but cost increases
Solution Approach 1:
The patent uses a composite construction combining Kevlar fabric with resin saturation and cushioning materials. This approach provides high-level ballistic protection while utilizing cost-effective materials and manufacturing processes, avoiding the need for expensive monolithic armor materials.
Solution Approach 2:
The patent modifies the structural parameters of the armor by varying the number of Kevlar layers, resin saturation levels, and cushioning material density to achieve the required protection level. This parameter optimization allows cost-effective production while maintaining effective protection against ballistic threats.
3Reliability
If more layers of protective material are added to stop high-powered rifle fire, then ballistic protection is improved, but weight increases
Solution Approach 1:
The patent creates an optimized multi-layer composite where Kevlar ballistic layers are combined with lighter cushioning materials and resin binding. This composite structure achieves effective stopping power against high-powered rifle fire while the resin and cushioning materials reduce overall weight compared to solid Kevlar construction.
Solution Approach 2:
The armor is segmented into multiple functional layers: Kevlar ballistic layers for primary protection, intermediate cushioning layers for energy distribution, and resin binding for structural integrity. This segmentation allows each layer to be optimized for its specific function, achieving high protection with reduced total weight.
4Reliability
If traditional armor结构设计 is used, then protection against ballistic threats is provided, but protection against electromagnetic pulse and heat is insufficient
Solution Approach 1:
The patent designs a multi-functional armor system where the same layered composite structure provides protection against multiple threat types: ballistic impacts, electromagnetic pulse interference, and extreme heat. The Kevlar-resin-cushioning combination delivers universal protection across different threat categories without requiring separate specialized systems.
Solution Approach 2:
The composite material system combines Kevlar fabric, resin saturation, and cushioning materials in a configuration that simultaneously addresses ballistic, electromagnetic, and thermal threats. The resin matrix provides electromagnetic shielding while the layered structure offers thermal insulation, adding multi-threat capabilities to the ballistic protection.
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 offers effective protection against ballistic impacts, extreme heat, flames, backface deformation from blasts, and electromagnetic pulse jamming while reducing weight and costs, providing a versatile and efficient armor solution.
Implementation Method 1
Insulating intumescing may also be used throughout the multiple layers of the invention to further increase fire protection
Implementation Method 2
one or more layers of woven Jute, or other forms of burlap which are stacked/layered or spun... Resin saturation is applied and pressure molding if warranted
Data Source
AI summary
The claimed invention differs from what currently exists as Kevlar core is encased by resinated Jute/burlap, with optional addition of one or more layers of resinated Kevlar, and/or Carbon Fiber for additional structural support. Insulation and barrier is inserted to overcome backface deformation and blast overpressure to the composite. Less the 0.2 mm aluminum sheeting is inserted to deflect electromagnetic pulse jamming. Entire composite is then coated with insulating intumescing or other class A fire resistant coating. This results in a Composite which becomes very strong with a reduction in raw material costs, that is not only resistant to projectiles, but is also resistant to acid, blast overpressure, backface deformation, electromagnetic pulse and direct flame in excess of 2,000 degrees Fahrenheit.