Layered Vehicle Armour with Air Gap and Composite Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle armor solutions that provide protection against explosively formed projectiles (EFP) are excessively thick, leading to weight and bulk issues that impede vehicle speed and maneuverability, and are vulnerable to damage from small arms fire and minor collisions.
Innovation Solution
A layered armor assembly comprising an outer fiber-reinforced composite protective layer, an outer ceramic armor layer, an inner fiber-reinforced composite support layer, an air gap for deflection, an inner segmented ceramic armor layer, and a high energy-absorbing layer, configured to minimize thickness while maximizing protection and resilience against EFPs and minor impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If ceramic armor is used to reduce weight, then weight is reduced, but the armor becomes vulnerable to damage from minor collisions
Solution Approach 1:
The patent uses a composite structure combining ceramic armor layers with fiber-reinforced polymer matrix layers. The ceramic provides ballistic protection while the polymer matrix provides toughness and collision resistance. This composite approach allows the armor to maintain low weight while gaining resilience to minor collisions through the ductile polymer phase that can absorb impact energy without shattering like pure ceramic would.
2Speed
If armor thickness is reduced to improve speed and maneuverability, then vehicle speed and maneuverability improve, but protection effectiveness decreases
Solution Approach 1:
The multi-layer composite structure combines materials with complementary properties: ceramic layers for EFP fragmentation and ballistics, fiber-reinforced polymers for energy absorption and structural integrity. This allows thinner overall armor thickness while maintaining protection effectiveness through the synergistic interaction of different materials that address different threat mechanisms simultaneously.
Solution Approach 2:
The armor is divided into multiple functional layers with specific thicknesses optimized for their respective roles. The segmented ceramic tiles (50-150mm dimensions) with spacing create a structure that fragments EFPs effectively, while each layer contributes to overall protection without requiring excessive total thickness. The air gaps between ceramic tiles further enhance EFP disruption while minimizing material usage.
3Reliability
If steel armor is used to protect against collisions, then collision resistance improves, but weight increases significantly
Solution Approach 1:
The fiber-reinforced polymer matrix layers serve as the collision-resistant component, replacing heavy steel for this specific function. The polymer matrix with embedded fibers provides toughness and ductility that allow it to absorb collision energy through deformation rather than brittle fracture. This composite approach achieves adequate collision resistance at a fraction of the weight of traditional steel armor, with the polymer matrix acting as the primary collision mitigation layer.
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 reduces the overall thickness of the armor while maintaining effective protection against EFPs and small arms fire, enhancing vehicle maneuverability and resilience to minor impacts and collisions, while minimizing weight and bulk.
Implementation Method 1
an air gap of between 1mm and 10mm to allow for deflection of the outer armour pack
Implementation Method 2
a high energy absorbing layer of at least 25mm thickness configured to mitigate the effect of residual fragments defeating the outer and inner armour packs
Implementation Method 3
an outermost outer fibre reinforced composite protective layer configured to protect the outer ceramic armour layer against minor impacts
Data Source
Figure 1
Figure 2
AI summary
Vehicle armour comprises an assembly of:- • a) an outer armour pack (A) comprising:- • i) an outermost outer fibre reinforced composite protective layer (1) of at least 1mm thickness; • ii) an outer ceramic armour layer (2) to protect against small arms and provide initial fragmentation of a penetrator; and • iii) an inner fibre reinforced composite support layer (3) to absorb residual energy from small arms; the outermost outer fibre reinforced composite protective layer being configured to protect the outer ceramic armour layer against minor impacts; • b) an air gap (B) of between 1mm and 10mm to allow for deflection of the outer armour pack; • c) an inner armour pack (C) comprising; • i) an outer fibre reinforced composite protective layer (5) of at least 0.5mm thickness; • ii) an inner segmented ceramic armour layer (6) configured to provide the majority of protection against a penetrator; • iii) an innermost inner fibre reinforced composite layer (7) of at least 10mm thickness; the outer fibre reinforced composite protective layer being configured to protect the inner segmented ceramic armour layer against damage during handling or maintenance of the armour • d) a high energy absorbing layer (D) of at least 25mm thickness configured to mitigate the effect of residual fragments defeating the outer and inner armour packs. the assembly being configured to be mounted in spaced relationship to the hull (11) of a vehicle.