Pre-stressed Ceramic Armor via Thermal Expansion Bonding

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Solution Overview

Problem

Existing ceramic-based ballistic armor faces challenges in achieving multi-hit capabilities, weight reduction, and cost-effectiveness while maintaining effective ballistic performance, as current methods involve expensive manufacturing processes and weakened junctions in tile-connected inserts.

Innovation Solution

A pre-stressed ceramic-based antiballistic article is created by bonding a high thermal expansion material with a higher expansion coefficient to ceramic plates or tiles at elevated temperatures, inducing compression stress upon cooling, which is then encapsulated with a backing material and an outer shell for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic armor uses separate tiles connected together to achieve multi-hit capability, then the armor can withstand multiple hits, but the manufacturing cost increases and the junctions become weakened points

Engineering Contradiction:

Improvemulti-hit capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention divides the ceramic armor into multiple separate tiles that are connected together to form a panel. Each tile can independently absorb impact, providing multi-hit capability while allowing standardized manufacturing of individual tiles that are then assembled into panels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines multiple ceramic tiles with a backing material and connects them together using a standardized connection system. This merging of components creates a composite structure that maintains the advantages of individual tiles while providing collective protection and simplified assembly.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If ceramic armor uses separate tiles connected together to achieve multi-hit capability, then the armor can withstand multiple hits, but the junctions become weakened points from a ballistic point of view

Engineering Contradiction:

Improvemulti-hit capabilityVSAvoidjunction strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention applies different material properties and structural characteristics to different parts of the armor system. The junction areas between tiles are specifically designed with reinforced connection mechanisms and optimized backing material attachment to maintain uniform ballistic performance across the entire panel, eliminating weak points at the connections.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If ceramic armor uses monolithic plates to reduce manufacturing complexity, then the manufacturing process is simplified, but multi-hit capability cannot be achieved

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmulti-hit capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

4Strength

If ceramic armor increases thickness to improve ballistic performance, then the stopping power increases, but the weight and thickness of the armor increase

Engineering Contradiction:

Improveballistic performanceVSAvoidarmor weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The invention uses a composite structure combining ceramic tiles with a specialized backing material. This composite design allows the ceramic to provide hard protection while the backing material absorbs residual energy, achieving high ballistic performance with reduced overall thickness and weight compared to solid ceramic or solid steel alternatives.

Inventive Principle:

Principle #40Composite materials

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 solution provides increased multi-hit capability, reduced weight, lower material costs, and decreased spall and debris ejection angles, resulting in improved durability and ballistic protection with a thinner, lighter design.

Implementation Method 1

bonding a high thermal expansion material having a much higher expansion coefficient than the ceramic material, to the ceramic plate/tile at elevated temperature

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

Upon cooling, the thermal expansion material contracts, exerting compression stress on the ceramic plate/tile

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS9696122B2Antiballistic article and method of producing same

Publication Date: 2017.07.04 IMI SYST LTD

AI summary

A light weight pre-stressed antiballistic article including a monolith ceramic plate/tile bonded to a thin lightweight thermal expansion material with an adhesive, characterized, in that the thermal expansion material has a thermal expansion coefficient at least 50% higher than the ceramic plate/tile, and the thermal expansion material is bonded to either the front face, back face or both faces of the ceramic plate/tile at a bonding temperature of between 50° C. and 250° C. with adhesive and subsequently cooled, whereby upon cooling, the bonded thermal expansion material contracts to a greater extent than the ceramic plate/tile, exerting compression stress on the ceramic plate/tile.