Modular Ballistic Panels With Encased Ceramic Plates
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Solution Overview
Problem
Existing ballistic-resistant ceramic plates are prone to fracturing and cracking during handling and use, limiting their suitability for combat and training scenarios, and require replacement after minimal damage, leading to inefficiencies and increased costs.
Innovation Solution
A ceramic plate system encased in a containment layer, comprising a fabric sheet and resin, which enhances ballistic resistance by preventing fracturing and cracking, and allows modular replacement of damaged panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic plates are used for ballistic protection, then ballistic resistance is improved, but the plates are prone to fracturing and cracking during handling and use
Solution Approach 1:
The patent uses composite materials by combining ceramic plates with a flexible containment layer made of fabric and resin. This composite structure allows the ceramic to provide ballistic resistance while the flexible containment layer prevents fracturing and cracking, resolving the contradiction between strength and reliability.
Solution Approach 2:
The patent applies a flexible containment layer (fabric and resin) around the ceramic plate. This flexible shell constrains the ceramic plate, preventing it from fracturing and cracking during handling and use, thereby improving reliability while maintaining ballistic resistance.
2Reliability
If ceramic plates are encased in containment layer, then resistance to fracturing is improved, but weight and volume increase
Solution Approach 1:
The patent uses a thin flexible containment layer made of fabric and resin instead of bulky rigid containers. This thin film provides the necessary constraint to prevent fracturing while minimizing additional weight and volume.
Solution Approach 2:
The containment layer is applied locally around the ceramic plate only where needed for constraint, rather than enclosing the entire assembly in a bulky structure. This localized application reduces unnecessary weight and volume while maintaining reliability.
3Reliability
If multiple ballistic panels are permanently integrated, then protection coverage is improved, but weight and volume increase
Solution Approach 1:
The patent divides the ballistic protection system into separate, modular panels that can be independently worn or removed. Each panel is self-contained with its own ceramic plate and containment layer, allowing selective deployment based on threat level, thus reducing total weight when full coverage is not needed.
Solution Approach 2:
The patent creates a dynamic armor system where panels can be added or removed based on operational requirements. The Velcro® fastening system allows rapid reconfiguration, enabling the wearer to adjust protection coverage dynamically rather than being constrained by a fixed permanent integration.
4Ease of repair
If ballistic panels are made modular and releasably engaged, then ease of replacement is improved, but connection reliability may be compromised
Solution Approach 1:
The patent uses Velcro® fastening systems as an intermediary connection mechanism between panels. This intermediary provides reliable engagement through strong adhesive bonding while maintaining ease of separation when needed, balancing connection reliability with ease of replacement.
Data Source
AI summary
Disclosed herein are embodiments of a releasably engagable system of ballistic-resistant panels including a first ballistic-resistant panel comprising a ceramic plate system, the first ballistic-resistant panel having opposing first ballistic-resistant panel front and back surfaces; and a second ballistic-resistant panel having opposing second ballistic-resistant panel front and back surfaces. Additionally, the embodiments of the releasably engagable systems of ballistic-resistant panels include at least one of fasteners, an adhesive coating, or a securement element, all of which function to releasably engage the second ballistic-resistant panel front surface with the first ballistic-resistant panel back surface in fixed adjacent relation to provide releasably engaged ballistic-resistant panels.