Impedance Gradient Armor Appliqué for Blast Wave Reflection
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Solution Overview
Problem
Existing armor systems fail to effectively mitigate high-intensity impulses from blasts and projectiles due to reflection of shock and blast waves, which can cause significant harm to personnel and equipment.
Innovation Solution
A density gradient appliqué is created by dispersing filler particles in a fluid binder material, forming a non-homogeneous composition that is cast into a mold and hardened, resulting in an impedance gradient structure that matches the incoming shock and blast waves, minimizing reflection and maximizing energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a homogenous armor composition is used, then the manufacturing process is simple, but the impedance matching with incoming shock waves is poor causing high reflection
Solution Approach 1:
The patent applies local quality by creating a spatially varying filler particle distribution within the armor composition. The composition transitions from homogenous mixing to a graded structure where filler concentration varies continuously through the thickness, with higher concentration near the blast-facing surface and lower concentration near the rear surface. This gradient provides locally optimized impedance matching at each depth, reducing wave reflection while maintaining manufacturability through controlled particle settling during curing.
2Object-affected harmful factors
If a gradient structure is created to improve impedance matching, then wave reflection is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs preliminary action by pre-dispersing filler particles uniformly throughout the binder matrix before curing. The gradient structure is not created through complex post-processing or layer-by-layer assembly, but rather through controlled particle settling that occurs naturally during the curing process. This preliminary uniform dispersion followed by controlled segregation during curing simplifies the manufacturing process compared to alternative gradient formation methods.
Solution Approach 2:
The manufacturing process utilizes self-service by allowing the filler particles to self-organize into a gradient distribution through controlled settling during curing. Rather than requiring external intervention to create the gradient structure, the system uses the curing process itself to drive particle redistribution, with particles naturally settling to form the desired concentration gradient based on density differences and flow patterns during gelation.
3Object-affected harmful factors
If filler particles are concentrated at the surface, then impedance matching is improved, but the structural integrity may be compromised
Solution Approach 1:
The patent applies parameter changes by continuously varying the filler particle concentration parameter through the thickness of the armor composition. Rather than using discrete layers or surface coatings, the filler concentration transitions smoothly from high at the blast-facing surface to low at the rear surface. This continuous parameter variation optimizes impedance matching while distributing stress more evenly throughout the structure, preventing weak interfaces that would compromise structural integrity.
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 impedance gradient structure effectively reduces the intensity of reflected waves and minimizes kinetic energy and momentum transfer, demonstrating significant blast impulse and energy reduction in testing, with up to 54.3% energy reduction and 31.1% impulse reduction.
Implementation Method 1
causing a gradient of the filler particles to form in the composition such that the composition becomes non-homogenous
Implementation Method 2
hardening the binder material to trap the filler particles in the gradient
Implementation Method 3
the appliqué has an impedance increasing in a direction towards the armor plate... minimizing reflection and maximizing energy dissipation
Data Source
AI summary
An armor system includes an armor plate, and an appliqué affixed to an exterior of the armor plate, wherein the appliqué has a density increasing in a direction towards the armor plate and configured to minimize reflection of a blast wave from the armor plate. The coupling system comprises a binder material that surrounds filler particles configured to create an impedance gradient parallel to the impulse propagation direction.