Modular Polymeric Armor Blocks for Lightweight Ballistic Protection
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Solution Overview
Problem
There is a need for lightweight, portable, and easily assembled armor that can effectively absorb and capture projectiles in hostile environments, while also being inexpensive and capable of constructing various structures, including those without armor protection.
Innovation Solution
The development of polymeric armor blocks made from high molecular weight polyethylene foam, which can be customized in thickness and layered for optimal projectile absorption, and designed to interlock for flexible structure assembly, allowing for the creation of both armored and non-armored structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional armor materials are used, then projectile stopping capability is achieved, but weight and portability are compromised
Solution Approach 1:
The patent changes the material parameters from traditional metal armor to polymeric foam materials with specific density ranges (0.05-0.5 g/cc). This parameter change enables the armor to achieve projectile stopping capability while significantly reducing weight, making it portable and suitable for field deployment.
Solution Approach 2:
The patent employs composite material structures combining polymeric foam layers with varying densities and thicknesses. This composite approach allows optimization of both protective performance and weight reduction, creating a lightweight armor that effectively stops projectiles through layered energy absorption mechanisms.
2Ease of operation
If armor is made modular and portable, then ease of transportation and assembly is improved, but structural complexity increases
Solution Approach 1:
The patent divides the armor system into modular blocks of standardized dimensions (e.g., 12x12x24 inches) that can be independently transported and assembled. This segmentation enables easy deployment in field conditions while maintaining structural integrity through standardized interlocking mechanisms.
Solution Approach 2:
The patent designs universal interlocking mechanisms that allow the same modular blocks to serve multiple functions - both as armored structures and as non-armored construction elements. This multi-functionality simplifies the overall system by reducing the need for specialized components.
3Weight of moving object
If polymeric foam material is used, then weight is reduced, but ballistic absorbing capability must be optimized
Solution Approach 1:
The patent applies local quality variations by using polymeric foam layers with different densities at different positions within the armor structure. Higher density foam is placed in regions requiring enhanced protection, while lower density foam is used where weight reduction is prioritized, optimizing the balance between weight and ballistic performance.
Solution Approach 2:
The patent addresses ballistic protection in multiple dimensions by stacking foam layers of varying thicknesses and densities. This dimensional approach allows the armor to absorb projectile energy through progressive deformation and energy dissipation across multiple layers, achieving reliable protection despite the lightweight material.
4Reliability
If multiple layers of material are used, then projectile absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies multi-layer manufacturing by specifying foam materials with standard density ranges (0.05-0.5 g/cc) that can be produced using conventional extrusion or injection molding processes. The standardized parameters enable consistent production of multiple layers that can be easily assembled through simple interlocking mechanisms.
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 polymeric armor blocks effectively stop a range of high-velocity projectiles and provide significant blast and shock wave protection, while allowing for easy transportation and assembly into various configurations, including walls and bunkers, and can be used in both armored and non-armored applications.
Implementation Method 1
a polymeric block could be constructed that would have excellent ballistic absorbing properties
Implementation Method 2
The material is preferably a polymeric foam material and can include one or more layers of such material
Implementation Method 3
High density, high molecular weight polyethylene is defined as high density polyethylene with molecular weights at or above the 106-107 Dalton range. It has been found that this material will become fluid and flow to some degree when struck by a high velocity projectile
Implementation Method 4
A high velocity projectile encountering the surface plane of a polymeric armor block made from high molecular weight polyethylene will penetrate the outer surface of the block and decelerate rapidly to a complete stop
Data Source
AI summary
A building block that can be assembled into structures without requiring special end or corner pieces. The block has top and bottom surfaces that contain a cooperating projection and slot for stacking the blocks. Two end surfaces and two side surfaces complete an enclosed volume. One side and one end surface has at least one interlocking male portion. The other side end surface has at least one cooperating slot portion into which the male portion fits to interlock the blocks.