Modular Armor Power Source Integration
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Solution Overview
Problem
Current wearable armor systems face challenges in providing both sufficient electrical power and adequate ballistics protection without adding excessive weight, as conventional batteries are bulky and offer limited protection when combined with soft armor, and using Small Arms Protective Insert plates increases weight concerns even further.
Innovation Solution
A modular armor system with a housing case made from fiber-reinforced composite materials, incorporating a frame with compartments for batteries and a control unit, and an external connector for power transmission, allowing for removable ballistic panels and flexible power distribution, enabling situation-specific configurations for both power and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional batteries are used to provide electrical power, then electrical energy capacity increases, but weight and volume increase significantly
Solution Approach 1:
The battery system is divided into multiple individual battery cells arranged in a modular array within the armor system. Each cell can be independently managed and replaced, allowing the electrical energy capacity to be scaled by adding or removing cells rather than using a single large heavy battery unit.
Solution Approach 2:
The battery cells serve multiple functions: they provide electrical power to worn equipment, act as structural components within the modular frame, and can be configured in different arrangements to provide both power and ballistic protection depending on the mission requirements.
2Use of energy by moving object
If conventional batteries are used, then electrical power is provided, but they are bulky and restrict body movement
Solution Approach 1:
The battery array is mounted on a flexible or adjustable support structure that can adapt to the wearer's body contours and movements. The modular design allows the battery configuration to be dynamically adjusted or repositioned to maintain comfort and freedom of movement while providing sufficient electrical power.
Solution Approach 2:
The battery cells are arranged in a thin, flexible array that can conform to the wearer's body shape. This flexible mounting approach reduces bulkiness and allows the power source to move with the wearer rather than restricting body movement.
3Volume of moving object
If soft armor packaging is used with conformal batteries, then space limitations are addressed, but ballistics protection is reduced
Solution Approach 1:
The armor system uses a modular frame structure that allows dynamic reconfiguration of protective elements. Ballistic protection panels can be added or removed from the frame depending on the threat level, enabling the system to provide adequate protection when needed while maintaining space efficiency during low-threat operations.
Solution Approach 2:
The system combines conformal batteries with composite armor materials in a layered configuration. The battery array is integrated with the armor structure using composite materials that provide both structural support and ballistic protection, maximizing space efficiency without sacrificing protection capabilities.
4Strength
If Small Arms Protective Insert plates are used with conformal batteries, then ballistics protection is improved, but carrying weight increases
Solution Approach 1:
The ballistic protection is segmented into multiple thin protective panels that can be distributed throughout the modular frame rather than using a single heavy plate. This segmentation reduces the concentrated weight while maintaining overall protection levels by strategically placing protective elements where they are most needed.
Solution Approach 2:
The modular frame structure serves dual purposes: it provides structural support for the battery array and simultaneously serves as a mounting system for ballistic protection panels. This multi-functionality eliminates the need for separate heavy plate carriers, reducing overall carrying weight while maintaining protection capabilities.
Data Source
AI summary
An apparatus for an armor system includes a housing case, an interior ballistic panel, a frame, a power source, and a control unit. The housing case includes a top shell and a bottom shell, where the top shell is removably secured to the bottom shell, forming a cavity. The interior ballistic panel is removably arranged within the cavity between the top shell and the bottom shell. The frame is arranged within the cavity between the top shell and the interior ballistic panel, the frame including a compartment. The power source is arranged within the compartment of the frame, and the control unit is communicatively connected to the power source to manage operation of the power source.