Hollow Sphere Armor for Ballistic Energy Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current armor technologies are inadequate in effectively protecting vehicles and buildings from the impact of improvised explosive devices (IEDs) and ballistic projectiles, as they fail to dissipate the energy of incoming threats efficiently, leading to potential damage to the vehicle or structure.
Innovation Solution
The development of an armor system comprising energy-dispersion objects, such as hardened-shell hollow spheres filled with glass-filled nylon, arranged in predetermined configurations like hexagonal or square packs, which are held in place by lock mechanisms or polymers, designed to dissipate the energy of ballistic projectiles by spreading the impact over a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional armor materials (metal plates, ceramic tiles) are used to protect vehicles from ballistic projectiles and IEDs, then protective capability is provided, but weight increases significantly and energy dissipation efficiency is insufficient
Solution Approach 1:
The armor system segments the energy dissipation function into multiple independent hollow spheres distributed across the armor layer. Each sphere acts as an individual energy absorption unit that can be optimized independently, allowing the system to achieve superior protection with reduced overall weight compared to solid metal or ceramic armor of equivalent coverage.
Solution Approach 2:
The patent changes the physical parameters of the armor units by using hollow spheres with controlled wall thickness, material composition, and internal geometry rather than solid materials. This parameter optimization enables the spheres to dissipate projectile energy efficiently through controlled deformation and fragmentation while maintaining lightweight construction.
2Strength
If solid metal or ceramic armor materials are used, then strength and hardness are improved, but the ability to dissipate impact energy over a larger area is reduced
Solution Approach 1:
The armor system divides the impact energy dissipation function across multiple segmented hollow sphere units rather than relying on a single solid material layer. When a projectile impacts, each sphere independently absorbs and dissipates energy through controlled deformation, spreading the energy distribution over a larger area and preventing concentrated stress points that would occur with solid armor materials.
Solution Approach 2:
The patent employs composite construction within each hollow sphere, combining materials of different properties (e.g., metal shells with ceramic coatings or polymer fillers) to achieve both the strength needed for structural integrity and the energy dissipation characteristics required for effective armor performance. This composite approach allows simultaneous optimization of strength and energy dissipation.
3Reliability
If armor systems are designed for maximum protection, then reliability against threats is improved, but the complexity of the system increases
Solution Approach 1:
The armor system uses modular hollow sphere units that can be independently manufactured, tested, and replaced. This segmentation simplifies the overall system complexity by breaking down the protection function into standardized, interchangeable components rather than requiring a monolithic complex structure, while maintaining high reliability through redundant energy dissipation pathways across multiple units.
Solution Approach 2:
The hollow sphere design serves multiple functions simultaneously: it provides structural strength through its shell, dissipates impact energy through controlled deformation, reduces weight through its hollow construction, and can be easily replaced if damaged. This multi-functionality reduces the need for additional specialized components, thereby simplifying the overall system while enhancing reliability.
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
This armor system effectively disperses the energy of incoming threats, reducing pressure on any single point and minimizing damage to the vehicle or structure, while also being lightweight and modular for easy replacement and adjustment based on threat levels.
Implementation Method 1
designed to dissipate the energy of ballistic projectiles by spreading the impact over a larger area
Implementation Method 2
effectively disperses the energy of incoming threats, reducing pressure on any single point
Data Source
AI summary
An armor system that includes a first armor article that includes a plurality of energy-dispersion objects arranged in a predetermined configuration, wherein the plurality of energy-dispersion objects includes a plurality of hollow objects, and wherein at least some of the plurality of hollow objects are filled with an inner filler material; and a lock mechanism configured to hold the plurality of energy-dispersion objects in the predetermined configuration. A method for manufacturing an armor system, the armor system including a first armor article, the method including producing a plurality of hollow hemispheres; affixing pairs of the plurality of hemispheres to one another to form a first plurality of spheres; treating each one of the plurality of hemispheres with an anti-ballistic treatment; inserting a filler material into each one of the plurality of hemispheres; and locking the first plurality of spheres into a predetermined configuration.