Segmented Ceramic Ballistic Armor for Multi-Impact Resistance
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Solution Overview
Problem
Current body armor is either heavy and ineffective against multiple ballistic impacts, or lightweight but unable to stop higher-velocity projectiles, and lacks durability and comfort.
Innovation Solution
A multi-layer body armor design featuring a strike face of Tac-Tex or polyester, a ceramic plate formed from bonded ceramic tiles, aramid layers, a rigid polyethylene backing, and additional layers for impact absorption and dispersion, with a foam layer and fabric band for comfort and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal body armor is used, then impact resistance is improved, but weight increases significantly
Solution Approach 1:
The patent employs a composite structure combining ceramic tiles (alumina or boron carbide) with polymer matrix materials. The ceramic provides high hardness and ballistic resistance, while the polymer matrix binds the tiles and absorbs impact energy. This composite approach achieves metal-level protection with reduced weight, as ceramics and polymers have lower density than traditional metal armors while maintaining or exceeding their protective capabilities.
2Weight of moving object
If Kevlar body armor is used, then weight is reduced and flexibility is improved, but effectiveness against multiple impacts deteriorates
Solution Approach 1:
The ceramic armor plate is segmented into multiple individual tiles rather than using a single monolithic piece. When struck by a projectile, only the impacted tile fractures and absorbs the energy, while surrounding tiles remain intact and functional. This segmentation allows the armor to sustain multiple impacts, as damaged tiles can be individually replaced without compromising the entire armor system. The polymer matrix between tiles provides additional layers that can absorb subsequent impacts.
3Strength
If traditional body armor is used, then protection is provided, but comfort and ease of wear deteriorate
Solution Approach 1:
The patent incorporates flexible polymer matrix materials between the ceramic tiles and as backing layers. These polymers provide flexibility and conformability, allowing the rigid ceramic armor to be worn comfortably against the body. The flexible layers also help distribute impact forces and reduce pressure points, improving wearability while maintaining protective capabilities.
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 is lightweight, durable, and capable of sustaining multiple ballistic impacts while stopping high-velocity projectiles, with the ceramic tiles breaking apart to maintain effectiveness and the design being comfortable and cost-effective to produce.
Implementation Method 1
the ceramic tiles breaking apart to maintain effectiveness
Implementation Method 2
bonded together using an adhesive binder
Implementation Method 3
These layers are hot pressed together with an adhesive to form a single unitary rigid piece
Data Source
AI summary
Multi-impact multi-layer body armor is presented. A first layer is a single layer of front covering material. A second layer, is a ballistic ceramic plate formed of a plurality of curved smaller ceramic tiles that are bonded together using a structural adhesive. A third layer formed of one or a plurality of aramid layers such as Kevlar® XP. A fourth layer formed of a rigid backing plate, formed of ultra-high molecular weight polyethylene such as Spectra Shield®. A fifth layer is a single layer of rear covering material. Thus, an improved body armor is presented which is inexpensive to produce, light, durable and can sustain multiple impacts.