Textured Monolithic Armor Element for Lower Surface Density
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Solution Overview
Problem
Existing armor technologies face challenges in achieving high ballistic performance with low surface density, particularly for large surface areas, leading to excessive weight and inefficiencies in protecting vehicles and personnel from armor-piercing projectiles.
Innovation Solution
A monolithic armor element with a textured impact surface, comprising a sintered material with specific grain structures and a rear energy-dissipating coating, designed to deflect and absorb projectile energy effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a monolithic ceramic armor element with large surface area is used, then the number of joints is reduced, but the weight and surface density increase significantly
Solution Approach 1:
The patent applies local quality by creating a non-uniform thickness distribution in the monolithic ceramic armor element. The impact face features localized thickening in specific zones (such as around expected impact points or in a gradient pattern) while maintaining thinner regions in other areas. This allows the armor to concentrate material where it is most needed for ballistic protection while reducing material in less critical areas, thereby lowering overall surface density without compromising protection effectiveness.
2Reliability
If the impact surface is textured to increase contact area, then ballistic performance improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating the texture directly into the mold cavity during the manufacturing process. The mold includes pre-formed texturing elements (such as ribs, protrusions, or patterned surfaces) that transfer the desired surface geometry to the ceramic armor element during forming. This approach eliminates the need for subsequent texturing operations or assembly of separate textured components, thereby improving ballistic performance while avoiding increased manufacturing complexity.
3Reliability
If mosaic assembly of ceramic pieces is used, then multi-shot resistance is improved, but assembly time and cost increase
Solution Approach 1:
The patent applies merging by combining multiple ceramic pieces into a single monolithic structure. Instead of assembling separate ceramic tiles or segments that require joints and alignment, the invention forms one integrated ceramic component with varying thickness. This merging eliminates the assembly process entirely, reducing production time and cost while maintaining or improving multi-shot resistance through the continuous monolithic structure and strategic thickness distribution.
4Ease of manufacture
If uniform thickness is used throughout the armor element, then manufacturing is simplified, but ballistic performance against large projectiles is insufficient
Solution Approach 1:
The patent applies local quality by varying the thickness of the ceramic armor element at different locations. The impact face features localized thickening in specific zones (such as around expected impact points or in a gradient pattern) while maintaining thinner regions in other areas. This allows the armor to concentrate material where it is most needed for ballistic protection while reducing material in less critical areas, thereby lowering overall surface density without compromising protection effectiveness.
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 textured design enhances ballistic performance by increasing initial contact area without substantial material increase, effectively deflecting and absorbing projectile energy, thus reducing weight and improving protection.
Implementation Method 1
said body is made of a sintered material
Implementation Method 2
at least a portion of said impact face of said body is textured, in such a way that... the average thickness Esm... is greater than 50%, and less than 95% of the average thickness of said body
Implementation Method 3
said body may be provided on its inner face (or face opposite the impact face) with a rear energy-dissipating coating
Data Source
Figure 1~2j
Figure 3~4
Figure 5~6
AI summary
Screening element in the form of a monolithic sintered member which has an external face and an opposite internal face, the surface of the faces being greater than 100 cm2 and the mean thickness Em between the faces being greater than 4 mm, the member being characterised in that at least a portion of the external face is textured so that Ai decreases from the internal face from a value of i greater than at least 50, A75 ≥ 0.2 × A0 and A95 < 0.9 × A0, 0.03 × A0 < A95 < 0.5 × A0 and A100 < 0.1 × A0, Ai being the area occupied only by the material in a plane i with an internal section with respect to the intermediate thickness Ei and i corresponding, as a percentage, to the fraction of the mean thickness Em in the plane i.