Perforated Metal Strike Face with Composite Backing for Ballistic Armor
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Solution Overview
Problem
Conventional ballistic armor systems are often too heavy, bulky, and expensive, with limited multi-hit performance, making them ineffective against high-velocity and high-caliber projectiles, and they can be vulnerable to cracking and exposure to environmental elements, which compromises their protective capabilities.
Innovation Solution
A lightweight armor system comprising a laminate composite material with a perforated metal or expanded metal strike face plate and a thin composite skin, designed to fracture and absorb projectiles, combined with an air space that can be filled with energy-absorbing foam, providing enhanced protection against a wide range of projectiles and fragments while meeting military standards for weight and size requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ceramic armor systems are used, then protection against high caliber artillery and projectiles is improved, but weight and bulk increase significantly
Solution Approach 1:
The patent employs a composite armor system consisting of a ceramic strike face (alumina or silica ceramic) bonded to a polymer resin backing layer. This composite structure combines the high strength and hardness of ceramic materials for projectile defeat with the lightweight and energy-absorbing properties of polymer resins, achieving effective protection against high-caliber projectiles while significantly reducing overall weight compared to conventional solid ceramic armor systems
Solution Approach 2:
The patent modifies the physical and chemical parameters of the armor materials by using specifically formulated polymer resins with controlled molecular weight, crosslinking density, and curing characteristics. These parameter changes optimize the balance between protection capability and weight, allowing the armor to defeat projectiles while maintaining reduced weight through precise control of material properties
2Strength
If conventional ceramic armor systems are used, then protection against projectiles is improved, but manufacturing cost increases
Solution Approach 1:
The patent utilizes commercially available, cost-effective polymer resins and ceramic materials that can be procured at reasonable prices. The bonding process and material selection are designed to minimize manufacturing complexity and cost, making the armor system economically viable for practical deployment while maintaining effective protection against high-caliber projectiles
Solution Approach 2:
The patent optimizes manufacturing parameters including curing temperature, bonding pressure, and material ratios to reduce production costs. By controlling these parameters, the system achieves consistent quality and protection performance while minimizing material waste and processing expenses, making the armor economically manufacturable
3Strength
If conventional ceramic armor systems are used, then initial protection is provided, but multi-hit performance is limited due to cracking
Solution Approach 1:
The patent incorporates a polymer resin backing layer that acts as a cushioning element behind the ceramic strike face. This backing layer absorbs and distributes the stress and cracking forces generated during projectile impact, preventing crack propagation that would compromise multi-hit performance. The polymer resin effectively cushions subsequent impacts even after the ceramic face has been damaged, maintaining protection capability across multiple hits
Solution Approach 2:
The composite structure of ceramic bonded to polymer resin creates a synergistic system where the ceramic provides initial projectile defeat and the polymer provides crack resistance and energy absorption for subsequent hits. This material combination specifically addresses multi-hit performance by allowing the polymer to accommodate and distribute stresses from multiple impacts without catastrophic failure
4Strength
If conventional ceramic armor systems are used, then protection is provided, but vulnerability to environmental elements increases due to cracking
Solution Approach 1:
The polymer resin backing layer serves as a protective barrier that cushions and isolates the ceramic strike face from environmental elements such as moisture, temperature extremes, and physical damage. Even when the ceramic cracks from projectile impact, the polymer backing prevents environmental penetration, maintaining protection capability and preventing degradation from environmental exposure across multiple hits
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 armor system effectively defeats high-velocity and high-caliber projectiles, including steel and tungsten carbide, with reduced deformation and destruction, and meets military standards for weight, size, and multi-hit capacity, while being relatively inexpensive and easy to manufacture.
Implementation Method 1
designed to fracture and absorb projectiles
Implementation Method 2
air space that can be filled with energy-absorbing foam
Implementation Method 3
designed to fracture and absorb projectiles
Implementation Method 4
perforated metal or expanded metal strike face plate
Data Source
AI summary
A lightweight ballistic armor system comprising at least one metal strike face plate, a laminate composite backing material secured to the at least one metal strike face plate and an optional air space provided between the metal strike face plate and the laminate composite backing material. The metal strike face plate or plates has a predetermined defined thickness and has a plurality of slotted holes set at an angle relative to the vertical orientation or axis of the metal strike face plate, or which are straight. The plurality of slotted holes is sufficiently small to prevent the passage of a projectile or fragment therethrough. The laminate composite backing material comprises at least one material selected from an aramid fiber material, S-glass, E-glass, polypropylene and UHMWPE, and is provided in combination with a polymer-based resin material. The optional air space provided between the metal strike face plate and the composite backing material has a depth in the range between 0-12 inches.