Stressed Skin Vehicle Armor with Boronized Steel Tiles
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Solution Overview
Problem
Conventional vehicle armor systems are heavy and costly, compromising mobility and survivability due to excessive weight, while existing solutions fail to effectively protect against both blast and projectile threats efficiently.
Innovation Solution
A lightweight vehicle armor system featuring a stressed skin construction with thin, boronized, case-hardened steel tiles overlying a dense particle-filled elastomer layer, providing a hardened exterior and energy-absorbing interior for impact distribution and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional armored skin materials are used to provide protection, then occupant and vehicle system survivability is improved, but vehicle weight increases disproportionately
Solution Approach 1:
The patent employs a composite armor system consisting of a stressed skin aluminum alloy body panel, a particle-filled elastomer layer, and a thin boronized case-hardened steel tile layer. This composite structure combines the lightweight properties of aluminum alloy with the energy-absorbing characteristics of particle-filled elastomer and the protective hardness of boronized steel, achieving effective armor protection with reduced overall weight compared to conventional solid steel or ceramic armor systems
Solution Approach 2:
The steel tiles are applied selectively to specific high-threat areas of the vehicle body where projectile and blast threats are most likely to occur, rather than covering the entire vehicle. The boronized case-hardening process also applies local quality by creating a hard outer layer on the steel tiles while maintaining a tougher, more ductile inner structure, optimizing protection where needed while minimizing overall weight
2Reliability
If armor protection level is increased, then probability of kill (Pk) reduction is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameters by using a thin layer of boronized case-hardened steel instead of thick conventional steel or ceramic tiles. The boronization process creates a hard surface layer with optimized thickness and hardness parameters, while the particle-filled elastomer layer provides additional protection at low cost. This parameter optimization achieves effective Pk reduction without the prohibitive costs of conventional thick ceramic or solid steel armor systems
Solution Approach 2:
The steel tiles can be individually replaced if damaged, rather than requiring replacement of entire expensive ceramic armor panels. The modular tile design allows for cost-effective maintenance and repair, reducing long-term manufacturing and operational costs
3Strength
If thin steel tiles with hardened surface are used, then projectile protection is improved, but energy absorption capability worsens
Solution Approach 1:
The boronized case-hardening process creates a localized hard outer layer on the steel tiles that provides superior projectile resistance, while the inner portion of the steel tile and the particle-filled elastomer layer maintain toughness and ductility for effective impact energy absorption. This gradient structure optimizes both protection and energy management
Solution Approach 2:
The combination of hard boronized steel surface with the tougher particle-filled elastomer and non-hardened steel interior creates a composite structure that manages projectile impact by first resisting penetration through the hard outer layer, then absorbing and distributing impact energy through the intermediate elastomer layer and ductile inner steel structure
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 system effectively reduces weight and cost while enhancing occupant and vehicle survivability by distributing impact energy laterally, offering improved protection against both blast and projectile threats without compromising mobility.
Implementation Method 1
thin, boronized, case-hardened steel tiles
Implementation Method 2
dense particle-filled elastomer layer, providing a hardened exterior and energy-absorbing interior
Data Source
AI summary
Vehicle armor includes a body panel of the vehicle having a stressed skin construction with an inside surface and an outside surface. A liner overlies the inside surface of the body panel and a particle-filled elastomer overlies the outside surface of the body panel. Thin, single-layer steel tiles overlie the elastomer layer, with the tiles each having a hardened outer side and a non-hardened inner side.