Hybrid Composite Ballistic Panels Using Segregated Fibers
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Solution Overview
Problem
Existing armor materials, such as metal plates and ceramics, are heavy and costly, making them impractical for weight-critical applications like aircraft, and often require complex molds and VOC-emitting curing processes, while current composite materials may not provide adequate protection against various ballistic threats without excessive weight or cost.
Innovation Solution
The development of segregated hybrid composite ballistic panels using lower-performing fibers at the strike face and higher-performing fibers in the support portion, integrated with thermoplastic matrix materials, which are lighter, less expensive, and easier to manufacture, providing effective protection against ballistic threats without the need for costly thermosetting matrices or VOC-generating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal plates are used for armor, then ballistic protection is provided, but weight increases dramatically
Solution Approach 1:
The patent employs composite materials consisting of ceramic particles embedded in a polymer matrix to create armor panels that provide ballistic protection while significantly reducing weight compared to traditional metal plates. The composite structure combines the high hardness and compressive strength of ceramic with the lightness and toughness of polymer.
Solution Approach 2:
The patent applies local quality by using a gradient structure where ceramic particle concentration varies through the thickness of the panel, with higher concentration near the strike face to handle impact, and lower concentration toward the back face to reduce weight and improve spall resistance.
2Reliability
If ceramic materials are used for armor, then ballistic protection is provided, but cost and manufacturing complexity increase
Solution Approach 1:
The patent replaces complex mechanical molding processes with a simpler slurry casting method. The ceramic slurry is poured into a mold and allowed to settle, with the ceramic particles naturally separating and concentrating in the bottom layer, eliminating the need for expensive molds and complex forming operations.
Solution Approach 2:
The patent changes the manufacturing approach by using a liquid slurry state for easy pouring and casting, then utilizing drying and curing processes to achieve the final solid structure. This parameter change from solid forming to liquid casting dramatically simplifies manufacturing.
3Strength
If thermosetting matrix materials are used, then binding strength is achieved, but VOC emissions and environmental harm increase
Solution Approach 1:
The patent changes the chemical nature of the matrix material from thermosetting to thermoplastic polymer. This parameter change eliminates the need for chemical crosslinking reactions that release VOCs, while still providing adequate binding strength through physical entanglement and adhesion of the ceramic particles.
Data Source
AI summary
A panel had a first face and a second face, including a strike face portion having a first plurality of plies each containing fibers in a matrix material. There is a support portion adjacent to the strike face portion, the support portion containing a second plurality of plies each having fibers in a matrix material. Each ply is bound to an adjacent ply and the first fibers are lower-performing relative to the second fibers. Protection from a ballistic threat may be provided by providing such a panel with the strike face disposed toward the threat. In another aspect, a composite ballistic panel may contain fibers in a thermoplastic matrix material, to the substantial exclusion of thermosetting matrix materials.