Composite Armor with Embedded Geometric Solids
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Solution Overview
Problem
Existing passive armor solutions are inadequate in effectively protecting against AP-type projectiles and small arms projectiles due to limitations in energy absorption and weight, which affects the mobility and versatility of protected vehicles.
Innovation Solution
A composite passive armor structure featuring geometric solids such as spheres or truncated pyramids embedded in a light alloy matrix, reinforced with high-strength stainless steel rods and brackets, which distorts and weakens projectile kinetic energy through a shock-absorbing mechanism, and is cast using elevated pressure to optimize protection and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heavy armor materials are used, then protection effectiveness against projectiles is improved, but vehicle mobility deteriorates
Solution Approach 1:
The patent employs a composite structure combining light alloy matrix with ceramic inserts (alumina, silica, bauxite) to achieve both lightweight properties and high protection effectiveness. The ceramic materials provide superior hardness and projectile resistance, while the light alloy matrix maintains low density and structural integrity, resolving the contradiction between protection effectiveness and weight.
Solution Approach 2:
The armor structure implements local quality enhancement by strategically placing ceramic inserts at specific locations within the light alloy matrix. The ceramic elements are positioned to intercept and neutralize projectile threats, while the surrounding light alloy provides structural support and mobility. This localized reinforcement achieves high protection where needed without compromising overall vehicle mobility.
2Reliability
If thicker armor plates are used, then protection against AP projectiles is improved, but fuel consumption increases
Solution Approach 1:
The composite structure of light alloy matrix with embedded ceramic inserts provides high protection against AP projectiles without requiring increased thickness. The ceramic materials offer superior ballistic resistance per unit volume, enabling effective protection with lighter, thinner armor sections that reduce overall vehicle weight and fuel consumption.
Solution Approach 2:
The patent changes the material parameters by substituting traditional heavy armor materials with a composite system featuring high-strength ceramic inserts. This parameter change in material composition and structure achieves equivalent or superior protection performance with reduced weight, thereby lowering fuel consumption for vehicle operation.
3Reliability
If more ceramic inserts are added, then projectile resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The ceramic inserts are pre-positioned within the light alloy matrix during the casting process. The mold design incorporates predetermined locations and orientations for ceramic inserts, allowing them to be embedded in regular patterns before the metal solidifies. This preliminary positioning action simplifies manufacturing by avoiding complex post-assembly operations while achieving optimal projectile resistance through systematic insert distribution.
Solution Approach 2:
The light alloy matrix serves multiple functions: it provides structural support, facilitates mobility, and acts as a binding medium for ceramic inserts. The casting process itself performs multiple roles: forming the matrix structure, positioning ceramic inserts, and creating the final composite armor piece. This multi-functionality reduces manufacturing complexity by consolidating several operations into unified processes.
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 provides effective protection against AP projectiles up to 12.6 mm, enhances vehicle mobility, and reduces fuel consumption by using a lightweight armor suitable for aircraft and watercraft applications.
Implementation Method 1
Then liquid metal is poured into the mould to fill the gaps and embed the inserts. After solidification of the metal, the ceramic inserts are anchored in the composite armour protection.
Implementation Method 2
The protruding part of geometric solids prevents the penetration of AP-type projectiles, projectile fragments, and small arms projectiles. The mere shape and very hard material of the geometric solids cause distortion in the projectile flight path, or ricochet and weakening of the projectile kinetic energy.
Implementation Method 3
The projectile striking against the exposed portion of the geometric solid pushes said geometric solid inside the matrix along the axis of the brackets in such a way that it causes both parting of the precut bracket walls to the outside, and a movement of the brackets to the inside of the matrix. The parting of the walls acts as a shock absorbing cushion for the geometric solid, while bracket movement to the inside of the matrix is controlled by the structure made of rods and a plate.
Data Source
Figure 1~2
AI summary
A composite passive armor protection comprises a structure, embedded in the light alloy matrix (1), wherein said structure is made of geometric solids (2), resting on brackets (3), passing through the holes in plate (4), wherein said brackets (3) have precuts in the walls located at a height above and below the plate (4), wherein in said precuts in the walls are secured rods (5) in such a way that they form a grid, wherein the geometric solids (2) are embedded in the light alloy matrix (1), preferably to a level above one half of their total height, and wherein the rods (5) are preferably fixed in such a way that their longitudinal axes coincide with the axes of the geometric solids (2).