Multi-Layer Vehicle Armor with Air Gap and Composite Core

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Solution Overview

Problem

Conventional materials used for vehicle construction, such as Rolled Homogeneous Armor (RHA) steel and aluminum, are not optimal for providing both structural support and ballistic protection while being lightweight, and fiber-reinforced plastics, although lightweight, are costly.

Innovation Solution

A multi-layer material comprising a hard metal layer, a composite layer with carbon and glass fibers, an air gap layer, and a polymeric honeycomb layer, which provides structural and ballistic protection while being significantly lighter than conventional solutions, achieving a weight savings of 40-50% without compromising protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional materials like RHA steel and aluminum are used for vehicle construction, then structural support and ballistic protection are provided, but the vehicle weight increases significantly

Engineering Contradiction:

Improveballistic protectionVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The armor system is divided into multiple functional layers: a hard metal layer (RHA steel) for initial projectile defeat, a polymeric foam core for blast pressure mitigation, and a ceramic outer layer for enhanced ballistic protection. Each layer performs a specific function, allowing the system to achieve superior protection with reduced overall thickness and weight compared to conventional homogeneous armor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs a composite structure combining dissimilar materials (metal, polymer, ceramic) with complementary properties. The hard metal provides structural integrity and spall resistance, the polymeric foam provides energy absorption and blast mitigation, and the ceramic layer provides hardness and projectile deflection. This multi-material composite approach achieves optimal balance between protection and weight.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If fiber-reinforced plastic materials are used, then vehicle weight is reduced, but the unit cost increases significantly

Engineering Contradiction:

Improvevehicle weightVSAvoidmanufacturing cost

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

Instead of using expensive fiber-reinforced plastics throughout the entire vehicle structure, the invention applies high-performance composite materials (carbon fiber, Kevlar) only in critical areas requiring enhanced ballistic protection, while using more cost-effective materials (RHA steel, polymeric foam) in non-critical structural areas. This localized application of premium materials reduces overall cost while maintaining necessary protection levels.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The polymeric foam core layer uses relatively inexpensive materials that can be easily manufactured and replaced if damaged, while the expensive ceramic and metal layers provide long-term durability and protection. The design allows the cheaper polymeric layer to absorb the brunt of blast pressures, protecting the more expensive outer layers from damage.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If ceramic tiles are applied to the outer surface for survivability enhancement, then ballistic protection is improved, but vehicle weight increases

Engineering Contradiction:

Improveballistic protectionVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The polymeric foam core acts as an intermediary layer between the ceramic outer layer and the vehicle structure. This foam layer absorbs blast pressures and reduces the transmission of shock waves to the vehicle interior, allowing the use of thinner ceramic tiles that would otherwise require heavier support structures. The foam mediates the interaction between the ceramic armor and the vehicle body, reducing overall system weight.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 multi-layer material effectively mitigates blast pressure and resists projectile penetration, offering a 50% weight reduction compared to conventional materials while maintaining equivalent ballistic protection, making it suitable for military and security vehicles.

Implementation Method 1

The multi-layer material effectively mitigates blast pressure and resists projectile penetration

Methodology Applied

Scientific EffectBlast pressure mitigation: Absorption (physical)

Implementation Method 2

The multi-layer material effectively mitigates blast pressure and resists projectile penetration

Methodology Applied

Scientific EffectProjectile penetration resistance: Impact Force

Data Source

PatentEP3081893B1Material for providing blast and projectile impact protection

Publication Date: 2018.12.12 CARTRIDGE LTD

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AI summary

We describe a vehicle, comprising: a vehicle body that mitigates blast pressure and resists projectile penetration, said vehicle body comprising a steel layer; a composite layer comprising carbon fiber and glass fiber, wherein said composite layer has a nonuniform fiber fraction; an innermost layer comprising ballistic material selected from the group consisting of aramid fibers, aromatic polyamide fibers and ultra-high molecular weight polyethylene; and an air gap layer disposed between said innermost layer and said composite layer, wherein said composite layer is disposed between said steel layer and said innermost layer.