Multi-phasic Ceramic Composite for Ballistic Armor

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Solution Overview

Problem

Conventional ceramic composite materials face issues with delamination, cracking, and dimensional stability due to their diverse nature, leading to suboptimal mechanical properties such as shock wave scattering in ballistic armor applications.

Innovation Solution

A multi-phasic ceramic composite with interlocked phases of silicon carbide and boron carbide, arranged in a 3-3 connectivity pattern, enhancing stability and mechanical properties through controlled phase boundaries and median minimum width, resulting in improved ballistic armor performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If diverse ceramic materials are used in multi-phase ceramic composite, then material properties can be optimized for specific applications, but delamination, cracking, and dimensional instability occur

Engineering Contradiction:

Improvematerial property optimizationVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a multi-phase ceramic composite structure where hard phases (silicon carbide, boron carbide) are embedded within a soft phase (glass matrix). This composite approach allows optimization of specific properties (hardness, shock resistance) while the glass matrix provides structural integrity and prevents delamination and cracking that plague conventional diverse ceramic composites.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent creates distinct phases with different properties distributed throughout the composite: hard, shock-resistant phases for ballistic protection and a softer glass matrix for structural stability. This local differentiation of material properties allows each phase to perform its specific function while contributing to overall composite reliability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional ceramic composite structures are used, then manufacturing is simpler, but shock wave scattering performance is suboptimal for ballistic armor

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidshock wave scattering

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent divides the ceramic composite into multiple distinct phases (hard phases and soft glass matrix) rather than using a homogeneous structure. This segmentation creates interfaces that scatter shock waves effectively, improving ballistic performance while maintaining a manufacturable composite structure through conventional ceramic processing techniques.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By combining materials with different acoustic impedances (hard ceramic phases and glass matrix), the patent creates a composite structure that naturally scatters shock waves. This composite approach improves ballistic protection performance without requiring complex manufacturing processes, as the phases can be integrated using standard ceramic composite fabrication methods.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If phase boundaries are not controlled in multi-phasic ceramic composite, then manufacturing is easier, but dimensional stability and mechanical properties deteriorate

Engineering Contradiction:

Improvephase boundary controlVSAvoiddimensional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent specifies controlled parameters for phase boundaries, including median minimum width measurements and connectivity patterns (such as 3-3 connectivity). By defining and controlling these geometric parameters, the patent achieves dimensional stability and improved mechanical properties while maintaining manufacturability through adjusted processing parameters.

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If heavier conventional materials are used for ballistic armor, then protection performance is adequate, but weight increases reducing mobility

Engineering Contradiction:

Improveballistic protectionVSAvoidarmor weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses a lightweight ceramic composite structure combining hard phases (silicon carbide, boron carbide) with a glass matrix, achieving ballistic protection performance comparable to heavier conventional armors. The composite structure provides high strength-to-weight ratio, reducing armor weight while maintaining adequate protection against ballistic threats.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11498874B2Multi-phasic ceramic composite

Publication Date: 2022.11.15 SAINT GOBAIN CERAMICS & PLASTICS INC

AI summary

A ceramic composite can include a first ceramic phase and a second ceramic phase. The first ceramic phase can include a silicon carbide. The second phase can include a boron carbide. In an embodiment, the silicon carbide in the first ceramic phase can have a grain size in a range of 0.8 to 200 microns. The first phase, the second phase, or both can further include a carbon. In another embodiment, at least one of the first ceramic phase and the second ceramic phase can have a median minimum width of at least 5 microns.