C/SiC Armor With Oblique Holes For Weight Reduction
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Solution Overview
Problem
Conventional armor production methods, such as P900 armor, face challenges in reducing weight while maintaining performance due to limitations in hole design and punching/drilling techniques, which result in excessive waste and sharp edges, making it difficult to achieve significant weight reduction and efficient projectile disruption.
Innovation Solution
A process for producing ceramic composite materials with carbon fibers and silicon carbide (C/SiC) that incorporates obliquely set holes and a thin skin layer, formed through press molding and infiltration with silicon melts, to create a lightweight, high-performance armor with reduced waste and improved edge smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional punching or drilling techniques are used to create holes in armor plates, then holes can be formed for projectile disruption, but excessive material waste and sharp edges are produced
Solution Approach 1:
The invention forms holes during the press molding process itself, before the armor plate is completed. Press molding cores are used to create holes with smooth surfaces and no sharp edges, eliminating the need for subsequent punching or drilling operations and preventing material waste associated with those processes.
2Reliability
If multiple separate armor plates are used in a stacked configuration, then projectile disruption can be achieved, but the system becomes complex with multiple parts
Solution Approach 1:
The invention integrates multiple functional layers into a single monolithic armor plate structure. The press molding process combines the skin layer and core layer into one unified component with holes formed throughout, eliminating the need for separate stacked plates while maintaining projectile disruption capability through the integrated hole structure.
3Weight of moving object
If armor plates are made lighter by removing material, then weight reduction is achieved, but structural strength may be compromised
Solution Approach 1:
The invention creates a heterogeneous structure with a dense skin layer providing strength and a lighter core layer with holes providing weight reduction. The skin layer has different properties (higher density and strength) than the core layer, with each layer optimized for its specific function while working together as a unified structure.
4Object-affected harmful factors
If obliquely set holes are formed in armor plates, then kinetic energy absorption is improved, but manufacturing precision requirements increase
Solution Approach 1:
The oblique hole geometry is established during the press molding process itself, with the press molding cores pre-formed at the required oblique angles. This preliminary formation of holes with correct orientation eliminates the need for subsequent precision drilling or machining operations, making the manufacturing process more straightforward while ensuring consistent hole angles for optimal kinetic energy absorption.
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 resulting ceramic-based armor achieves weight reduction, reduced parts count, and lower system costs while maintaining high performance against projectile attacks, with obliquely set holes effectively absorbing kinetic energy and preventing projectile penetration.
Implementation Method 1
infiltrating the C/C body with liquid silicon, with at least partial reaction of the carbon present in the matrix of the C/C body with the silicon to form SiC
Implementation Method 2
densification of a porous fiber-reinforced carbon-containing shaped body to form a ceramic matrix, in particular by infiltration of the C/C body with liquid silicon
Data Source
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AI summary
A device and process of forming a defensive, ceramic based, applique armor for covering and protecting a substrate which may be exposed to attack by projectiles, the applique armor having a flat or curved armor plate formed of ceramic material and having a first surface and a second surface; wherein the ceramic material being formed of silicon carbide with carbon fibers (C/SiC) and the ceramic material has a plurality of holes on at least one of said surfaces; the holes having a diameter smaller than an anticipated bullet or ammunition projectile and the holes being set obliquely relative to at least one surface, whereby the device and process provide holes formed by press molding, boring, drilling, or combinations thereof.