Seam Protected Ceramic Armor Arrays

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Solution Overview

Problem

Existing vehicle armor assemblies with ceramic tiles encapsulated in metal face vulnerabilities due to gaps between tiles and material incompatibilities, leading to potential penetration by ballistic projectiles and manufacturing challenges caused by material reactions and thermal expansion differences.

Innovation Solution

The development of seam protected encapsulated arrays of solid ceramic elements, where ceramic elements are arranged adjacent to each other and encapsulated in a metal alloy with a seam protector and barrier layer to prevent penetration and material interaction, using techniques like investment casting to ensure robust ballistic protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If ceramic tiles are encapsulated in metal to form armor assemblies, then ballistic protection is improved, but gaps between tiles create vulnerable seams that reduce protection

Engineering Contradiction:

Improveballistic protectionVSAvoidseam vulnerability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A seam protector material is introduced as an intermediary substance that fills the gaps between adjacent ceramic tiles during encapsulation. This seam protector prevents ballistic projectiles from penetrating through the seams between tiles, thereby eliminating the vulnerable gaps while maintaining the overall armor structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If ceramic tiles and metal are used together in armor assemblies, then protective performance is improved, but material reactions during manufacturing compromise both materials

Engineering Contradiction:

Improveprotective performanceVSAvoidmanufacturing feasibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

A barrier layer is introduced as an intermediary between the ceramic tiles and the metal encapsulant. This barrier layer prevents direct contact and chemical reactions between the ceramic and metal materials during the casting process, allowing both materials to maintain their desired properties without compromising each other.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If ceramic tiles and metal are used together in armor assemblies, then protective performance is improved, but different thermal expansion rates create cracks and voids

Engineering Contradiction:

Improveprotective performanceVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The barrier layer serves as a buffer between ceramic tiles and metal encapsulant, accommodating the different coefficients of thermal expansion. This intermediary layer prevents the formation of cracks and voids that would otherwise occur due to differential expansion and contraction during cooling, thereby maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If seam protectors are added to protect vulnerable seams, then ballistic protection is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveballistic protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The seam protector is integrated into the encapsulation process itself, where the same molten metal that encapsulates the ceramic tiles also fills the gaps between adjacent tiles to form the seam protectors. This merging of functions eliminates the need for separate seam protector components and reduces manufacturing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molten metal encapsulant serves multiple functions simultaneously: it encapsulates the ceramic tiles, fills the gaps between tiles to create seam protectors, and provides the outer protective layer. This multi-functionality reduces the number of separate components and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhances the resistance of armor assemblies to ballistic impacts by protecting vulnerable seams and preventing material reactions, thereby improving the overall performance and manufacturing feasibility of the armor assemblies.

Implementation Method 1

a seam protector may be pre-cast or pre-machined from the other base metal. The other base metal may be cast around the array of ceramic elements and the seam protector

Methodology Applied

Scientific EffectCasting: Melting

Implementation Method 2

the ceramic tiles and the metal may have different coefficients of thermal expansion, and may expand or contract at different rates

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8967230B2Seam protected encapsulated array

Publication Date: 2015.03.03 SPOKANE IND INC

AI summary

Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seams and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seams and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.