Segmented Body Armor Panel for Slash Protection
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Solution Overview
Problem
Existing body armor solutions for slash threats are either too expensive, heavy, and cumbersome, making them uncomfortable and difficult to conceal, while also lacking optimal air and moisture permeability.
Innovation Solution
A body armor panel design featuring two primary layers with spaced solid elements and a third 'button' layer, providing a flexible and lightweight structure with excellent permeability, using cold-rolled stainless steel elements that offer high slash resistance without continuous gaps for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid panels made from ceramic or steel are used to provide slash protection, then protection effectiveness is improved, but weight and cost increase significantly
Solution Approach 1:
The armor panel is segmented into multiple layers with spaced solid elements rather than continuous solid panels. The first layer has solid elements spaced apart to form gaps, the second layer has solid elements positioned to bridge gaps from the first layer, and the third layer has solid elements positioned to bridge remaining gaps. This segmentation provides slash protection while significantly reducing weight compared to solid ceramic or steel panels.
2Adaptability or versatility
If multi-threat armor systems with large metal or ceramic plates are used, then protection against multiple threats is improved, but flexibility and concealability deteriorate
Solution Approach 1:
The armor panel provides localized protection only where slash threats are most likely to occur, rather than covering the entire body with heavy armor. The solid elements are strategically positioned in layers to protect critical areas while leaving other areas more flexible and concealable. This local quality approach maintains multi-threat protection capability while improving overall flexibility and wearability.
3Reliability
If chain mail is used for slash protection, then protection effectiveness is improved, but weight, manufacturing cost, and texture roughness increase
Solution Approach 1:
The armor uses spaced solid elements in multiple layers instead of interconnected metal rings. This segmentation approach achieves similar slash protection to chain mail but with significantly reduced manufacturing complexity and cost. The solid elements can be independently positioned and attached to the backing sheet, eliminating the need for complex ring interconnection processes.
4Reliability
If continuous solid panels are used, then slash protection is improved, but air and moisture permeability deteriorate, causing chafing and overheating
Solution Approach 1:
The armor panel uses a porous structure with spaced solid elements that create gaps and allow air and moisture penetration. The first layer has solid elements spaced apart forming gaps, the second layer has solid elements positioned to bridge some gaps, and the third layer has solid elements positioned to bridge remaining gaps. This porous structure provides slash protection while maintaining breathability and reducing chafing and overheating.
Data Source
AI summary
A slash-protecting panel is affordable, comfortable, flexible, light, and concealable, while providing at least 80N HOSDB slash protection. A plurality of solid elements are aligned on upper and lower backing sheets in rows and columns separated by continuous gaps between 25% and 95% as wide as the solid elements, the upper elements being centered above the gap intersections of the lower elements, leaving isolated gap “islands” uncovered but no continuous gaps. Embodiments further include a third layer with smaller “button” solid elements arranged behind the gap islands, leaving no gaps. The solid elements can be ceramic or metal, and the backing sheets can be ballistic fabric, or any convenient woven, non-woven, or warp knit. Solid elements can be attached to the sheets by rivets or adhesives, or held in pockets. Embodiments include an inner and/or an outer covering layer of a knit or similar fabric for added comfort.