U.S. patent application number 10/511781 was filed with the patent office on 2006-03-30 for armor system.
Invention is credited to James J M Henry.
Application Number | 20060065111 10/511781 |
Document ID | / |
Family ID | 29251076 |
Filed Date | 2006-03-30 |
United States Patent
Application |
20060065111 |
Kind Code |
A1 |
Henry; James J M |
March 30, 2006 |
Armor system
Abstract
An armor system is provided having an outer case of woven or
unidirectional fibers filled with one or more protective materials.
The outer case includes a pressure sensitive adhesive bonded to one
side for quick and easy application to a body to be protected. The
protective materials may include ceramic material which may be in
the form of ceramic tile sheets, loose ceramic balls, or perforated
tiles, multiple layers of woven or unidirectional cloth, and steel
mesh. These materials may be used alone or in any combination. A
tensioned energy layer and/or a self-healing layer may be provided
to fill a void created by a projectile.
Inventors: |
Henry; James J M;
(Wilsonville, OR) |
Correspondence
Address: |
KOLISCH HARTWELL, P.C.
200 PACIFIC BUILDING
520 SW YAMHILL STREET
PORTLAND
OR
97204
US
|
Family ID: |
29251076 |
Appl. No.: |
10/511781 |
Filed: |
April 17, 2003 |
PCT Filed: |
April 17, 2003 |
PCT NO: |
PCT/US03/12233 |
371 Date: |
October 19, 2005 |
Current U.S.
Class: |
89/36.02 |
Current CPC
Class: |
F41H 5/0492 20130101;
F41H 5/0428 20130101 |
Class at
Publication: |
089/036.02 |
International
Class: |
F41H 5/02 20060101
F41H005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 17, 2002 |
US |
60373755 |
Claims
1. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of protective material, and a securing layer bonded
to at least one of the front side or the backside of the outer case
for attaching the armor unit to the body to be protected.
2. The armor system of claim 1, wherein the securing layer
comprises an adhesive layer includes a pressure sensitive adhesive
and a removable release liner that exposes the pressure sensitive
adhesive when the release liner is removed.
3. The armor system of claim 1, further including a securing layer
bonded to the front side of the outer case and the backside of the
outer case.
4. The armor system of claim 3, wherein the securing layer
comprises an adhesive layer includes a pressure sensitive adhesive
and a removable release liner that exposes the pressure sensitive
adhesive when the release liner is removed.
5. The armor system of claim 1, wherein the outer case includes
layers of protective material that includes at least one initial
impact layer, at least one layer of steel mesh, and at least one
energy-absorbing material layer.
6. The armor system of claim 5, wherein the initial impact layer
includes at least one layer of woven glass or plastic fibers.
7. The armor system of claim 6, wherein the woven glass or plastic
fibers is one of Spectra.TM., Kevlar.TM., or Dyneema.TM..
8. The armor system of claim 5, wherein the at least one energy
absorbing material layer includes ceramic material.
9. The armor system of claim 8, wherein the ceramic material
includes ceramic files.
10. The armor system of claim 9, wherein the ceramic tiles are
perforated with a plurality of holes.
11. The armor system of claim 5, wherein the at least one energy
absorbing material layer includes loose discrete elements randomly
located in the outer case.
12. The armor system of claim 11, wherein the loose discrete
elements include ceramic balls.
13. The armor system of claim 1., wherein the armor unit includes a
self-healing layer to fill a void formed by a projectile.
14. The armor system of claim 13, further including at least one
layer of ceramic material and at least one layer of tensioned
spring material.
15. The armor system of claim 13, wherein the self-healing layer
includes an agent that expands and hardens when exposed to air.
16. The armor system of claim 15, wherein the self-healing layer
includes packets filled with foam that expands and hardens when
exposed to air.
17. The armor system of claim 10, wherein the at least one energy
absorbing material layer includes plural bags of loose discrete
elements.
18. The armor system of claim 17, wherein the loose discrete
elements include ceramic balls.
19. The armor system of claim 13, further including a layer of
ceramic material and at least one layer of glass or plastic
composite material.
20. The armor system of claim 19, wherein the at least one layer of
woven glass or plastic fibers is one of Spectra.TM., Kevlar.TM., or
Dyneema.TM..
21. The armor system of claim 19, wherein the layer of ceramic
material includes at least one layer of ceramic tile and further
including a tensioned energy layer.
22. The armor system of claim 21, wherein the at least one layer of
ceramic tile includes at least one of hexagonal tiles, square
tiles, rectangular tiles, and perforated tiles with plural holes
formed therein.
23. The armor system of claim 21, wherein the tensioned energy
layer includes tubes of glass or plastic including plural ceramic
balls under compression by at least one spring.
24. The armor system of claim 23, wherein each tube includes a
spring located at each end of the tube to apply a compression force
to the ceramic balls.
25. The armor system of claim 21, wherein the tensioned energy
layer includes at least one glass or plastic tube including plural
ceramic balls and an end cap located at each end of the tube to
release energy upon impact.
26. The armor system of claim 21, wherein the tensioned energy
layer includes at least one glass or plastic tube including plural
ceramic balls, springs located at each end thereof, and an end cap
located at each end of the tube to release energy upon impact.
27. The armor system of claim 1, further including a high strength
woven adhesive tape applied to at least one side of the at least
one layer of protective material.
28. The armor system of claim 1, further including a high strength
woven adhesive tape applied to both sides of the at least one layer
of protective material.
29. The armor system of claim 1, wherein one layer of protective
material includes a layer of ceramic material with a high strength
metal bonded thereto.
30. The armor system of claim 1, wherein one layer of protective
material includes a layer of perforated ceramic tiles with holes
formed therein.
31. The armor system of claim 31, further including a polymer
material filling the holes in the ceramic tile.
32. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of self-healing material to fill a void formed by a
projectile, and an adhesive layer bonded to at least one of the
front side or the backside of the outer case for adhering the armor
unit to the body to be protected.
33. The armor system of claim 32, wherein the self-healing material
includes packets filled with an agent that expands and hardens when
exposed to air.
34. The armor system of claim 33, wherein the agent is foam.
35. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of perforated ceramic tiles having holes formed
therein, and an adhesive layer bonded to at least one of the front
side or the backside of the outer case for adhering the armor unit
to the body to be protected.
36. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of protective material with a high strength woven
tape applied to at least one side thereof, and an adhesive layer
bonded to at least one of the front side or the backside of the
outer case for adhering the armor unit to the body to be
protected.
37. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of self-healing material to fill a void formed by a
projectile.
38. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of perforated ceramic tiles having holes formed
therein.
39. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one layer of protective material with a high strength woven
tape applied to at least one side thereof.
40. The armor system of claim 1, wherein the outer case is made of
one of Kevlar.RTM. and Dyneema.RTM..
41. An armor system for protecting a vehicle, comprising: a vehicle
having a body to be protected, at least one armor unit having an
outer case with a front side and a backside forming an interior,
the interior of the outer case including at least one layer of
protective material, and an adhesive securing layer bonded to at
least one of the front side or the backside of the outer case for
attaching the armor unit to the vehicle.
42. An armor system for protecting a body, comprising: at least one
armor unit having an outer case with a front side and a backside
forming an interior, the interior of the outer case including at
least one tensioned energy layer including plural discrete elements
under tension that are released upon impact to repopulate a void
created by the projectile.
43. A method of protecting a body, comprising: providing at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of protective material, and providing
a securing layer bonded to at least one of the front side or the
backside of the outer case for attaching the armor unit to the body
to be protected.
44. A method of protecting a body, comprising: providing at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of self-healing material to fill a
void formed by a projectile, and providing an adhesive layer bonded
to at least one of the front side or the backside of the outer case
for adhering the armor unit to the body to be protected.
45. A method of protecting a body, comprising: providing at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of perforated ceramic tiles having
holes formed therein, and providing an adhesive layer bonded to at
least one of the front side or the backside of the outer case for
adhering the armor unit to the body to be protected.
46. A method of protecting a body, comprising: protecting at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of protective material with a high
strength woven tape applied to at least one side thereof, and
protecting an adhesive layer bonded to at least one of the front
side or the backside of the outer case for adhering the armor unit
to the body to be protected.
47. A method of protecting a body, comprising: providing at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of self-healing material to fill a
void formed by a projectile.
48. A method of protecting a body, comprising: providing at least
one armor unit having an outer case with a front side and a
backside forming an interior, the interior of the outer case
including at least one layer of perforated ceramic tiles having
holes formed therein.
Description
[0001] This invention claims the benefit of co-pending U.S.
Provisional Application No. 60/373,755, entitled "Armor System",
filed Apr. 17, 2002, the entire disclosure of which is hereby
incorporated by reference as if set forth in its entirety for all
purposes.
TECHNICAL FIELD
[0002] The present invention is directed to armor systems and more
particularly to an armor system that can be quickly and easily
applied to an animate or inanimate body to be protected.
BACKGROUND OF THE INVENTION
[0003] Many and various types of armor systems are known for
shielding personnel, vehicles, and equipment from injury and/or
damage from projectiles. Such armor systems are typically used in
military environments to protect military personnel as well as
military equipment such as, for example, aircraft, tanks, ships,
and other vehicles. Armor systems are also used in law enforcement
and other environments in which protection from armor piercing
projectiles or other type of ballistic missiles is desired.
[0004] Armor can be made of various materials depending on what is
to be protected and the level of threat or danger. For example,
some armor is used in or with clothing to protect the body of
military or law enforcement personnel. Such armor is typically a
soft body armor of multiple plies of aramid and/or polyethylene
cloth and is used with or incorporated into clothing such as, for
example, body vests. Another type of armor is a rigid laminated
fiberglass used to protect solid structures such as armored cars,
bank teller windows, and police structures. Yet another type of
armor is special alloy steel, aluminum, or ceramic plate, which may
be used in combination with other materials for military
applications. Ceramic materials in various forms are also used as
armor.
[0005] In some applications the armor is incorporated into the
structure that is to be protected. Such applications may include
military vehicles, armored vehicles, and structures for cashiers or
security personnel. Since the armor must be incorporated into these
structures it is not possible to quickly and easily provide armor
for protection for structures or bodies that do not have "built-in"
armor.
[0006] Some armor systems do employ some means of attaching the
armor system to the body or structure to be protected. For example,
some armor systems may be attached to a body or structure with
fasteners such as bolts or screws. Other armor systems may utilize
glue to adhere the armor to the body. However, this usually
requires the application of a liquid glue to the armor and/or the
body to which the armor is being attached. This increases the time
and cost of applying the armor. Furthermore, such glues are costly,
inconvenient to apply, and may be hazardous due to fumes or other
hazardous chemicals involved. Also, such liquid glues require
storage, which further increases costs especially if a special
storage facility is required.
[0007] Some armor systems use a magnet to attach the armor to a
body. However, magnetic armor systems are limited in use to
metallic bodies and structures and are not suitable for some
applications.
[0008] Another problem encountered with prior art armor systems is
weight. Some armor systems employ thick steel plates. However, the
weight of the steel plates makes such armor systems undesirable.
Furthermore, with the development of armor piercing projectiles the
thickness of the steel plates used in armor systems has increased
which further increases the cost and weight of the armor system and
decreases its ability to conform to some surfaces.
[0009] In order to provide a more lightweight armor, some systems
have employed forms of ceramic material that have had some effect
against projectiles. For example, ceramic tiles have been used to
dissipate the kinetic energy of projectiles. In some armor systems,
the ceramic tiles are arranged in a specific pattern and attached
to a backing material such as nylon to form a ceramic tile sheet.
The ceramic tiles may have a variety of shapes such as, for
example, a square or octagonal shape. However, upon impact the
ceramic tiles shatter creating voids and dangerous fragments. In
order to be effective, the ceramic tiles must be arranged with a
minimum spacing between them. The spacing provides room for the
ceramic tiles to expand as they crack and/or shatter to absorb the
energy of the projectile. This precise spacing of the ceramic tiles
is time consuming and adds to the cost of manufacture of the armor
system. Furthermore, if the spacing is not right the armor system
may not be effective. In other armor systems, single or multiple
ceramic tiles may be employed at one or more locations within the
armor system. However, as with the ceramic sheets, the ceramic
tiles may shatter creating dangerous fragments.
[0010] One solution to the problem of the creation of ceramic
fragments is to combine the ceramic sheet or sheets with thick
sheets or layers of glass or plastic cloth to absorb the shattered
ceramic pieces. Such cloth is typically a woven ballistic cloth,
such as Kevlar.RTM. and Spectra.RTM. film.
[0011] Even though such armor systems have proven effective the
weight is still more than is desirable. Additionally, the cost of
the ceramic tiles is expensive.
[0012] Another problem encountered with prior armor systems is
their inability to conform to some surfaces. It is desirable that
the armor system be flexible so that it can conform to a variety of
bodies to be protected. For example, such armor systems are
desirable for use as body suits for military or law enforcement
personnel as well as for vehicles and other objects. It is
preferable that the armor system be adaptable to any of such
uses.
[0013] Another problem with prior armor systems is that any
projectiles that penetrate the armor system create voids in the
armor system leaving the body to be protected vulnerable to damage
from additional projectiles. Additionally, such voids subject the
body to be protected from other types of damage. For example, in
marine environments a void created by a projectile may allow water
to penetrate and damage the body to be protected. Such voids may
also allow nuclear, chemical, or biological agents to penetrate the
through the armor system.
[0014] Examples of prior art ceramic armor systems include U.S.
Pat. Nos. 3,924,038, 4,911,061, and 5,705,764, the subject matter
of which is incorporated herein by reference.
[0015] However, none of the prior art discloses an armor system
that can be quickly and easily applied to a body or structure.
SUMMARY OF THE INVENTION
[0016] The foregoing problems are overcome and other advantages are
provided by an armor system that can be quickly and easily applied
to a body to be protected and that provides a high degree of
protection from a projectile.
[0017] In certain embodiments, the present invention provides an
armor system that is flexible and can conform to a variety of
shapes and surfaces.
[0018] The present invention provides an armor system that can be
quickly and easily applied to a body or object to be protected. The
armor system preferably includes one or more armor units that
include a pressure sensitive adhesive such as, for example, a "peel
and stick" adhesive to adhere the armor system to the body to be
protected. The pressure sensitive adhesive adheres to most surfaces
and adheres extremely well to high-energy surfaces such metal,
wood, concrete, glass, or other smooth surfaces. The pressure
sensitive adhesive can be formed on either the backside of the
armor system for application to an outer surface of the body or
structure or can be formed on the front side of the armor system
for application to an inner surface of the body or structure.
Alternatively, the pressure sensitive adhesive can be formed on
both the front and back side of the armor system for an even wider
range of applications.
[0019] The present invention may also provide an armor system that
includes layers of different protective materials that can be
arranged in various combinations depending on factors such as, for
example, the level of threat, cost, weight, and environment of
use.
[0020] The armor units may include an outer case that can be filled
with layers of different protective materials either alone or in
various combinations depending on factors such as threat level,
weight, cost, and conformability. One of the preferred layers may
be a ceramic layer that may in various forms of ceramic including
ceramic plates, sheets of ceramic tiles, or loose ceramic spheres
or balls. Other layers of protective materials may include multiple
layers of woven or unidirectional cloth and a steel mesh layer.
[0021] In one possible embodiment, the ceramic layer includes loose
ceramic filler material that randomly fills the outer case. The
ceramic filler material is preferably in the form of ceramic balls
or spheres but may be in any desired shape. The ceramic balls may
have substantially uniform diameters or may have various diameters.
Additionally, the ceramic filler material may be encapsulated
within a resin matrix instead being a loose fill. The ceramic balls
are combined with at least one layer of steel mesh and plural
layers of woven ballistic cloth.
[0022] In another possible embodiment, the armor unit includes a
self-healing layer in which the void left by the projectile is
filled and the armor unit is sealed to prevent the protective
materials from spilling out of the outer case. In one arrangement
of the self-healing embodiment, the armor unit includes plural bags
of loose ceramic fill combined with a tensioned steel spring and a
layer of foam packets each of which include foam that expands and
hardens when exposed to air. When the armor unit is pierced by a
projectile the foam expands into the void left by the projectile
and hardens preventing the loose ceramic fill from spilling out of
the outer case. In another embodiment, the armor unit includes a
layer of tubes filled with ceramic material located adjacent a
layer of foam packets. Each tube includes springs located at each
end to place the ceramic material under compression and explosive
end caps at each end. When the tube is shattered by a projectile
the ceramic material is forced by the springs into the void created
by the projectile. Since the foam packets is the first layer to
encounter the projectile at least one of the foam packets is
ruptured by the projectile so that the foam is exposed to air and
expands hardens to prevent the ceramic material from spilling out
of the outer case.
[0023] The self-healing armor unit may include various layers of
strengthening material for added protection. A high strength woven
adhesive tape material is provided that can be adhered to one or
both sides of one of the protective layers such as, for example,
one or more of the layers of ceramic or tensioned steel spring.
Another strengthening material that may be bonded to one of the
layers may be a high strength metal layer.
[0024] The present invention further provides a lighter weight
ceramic layer that includes perforated ceramic tiles. Each ceramic
tile includes plural holes that reduce the weight of the ceramic
tile but allows the ceramic tile to retain its strength properties.
In one embodiment, the holes are filled with a polymer material
capable of bonding a high strength protective material, such as,
for example, a metal plate to the ceramic tile.
[0025] The present invention provides an armor system that is
lightweight and that can be quickly and easily applied to many
bodies and vehicles. The armor system is preferably flexible so
that it can be easily applied to either flat or non-flat areas on
military or law enforcement personnel, vehicles, critical systems
such as, for example, oil and gas pipelines, and other objects
where protection from weapons or explosives are required. One
example of such use is the application of the flexible armor system
to surfaces of helicopter fuselages to protect pilots and critical
flight systems.
[0026] The present invention provides a light flexible armor that
easily conforms to different surfaces and shapes, that adheres
aggressively to a variety of curved or flat surfaces, and that is
capable of stopping numerous types of threats.
[0027] The foregoing embodiments and features are for illustrative
purposes and are not intended to be limiting, persons skilled in
the art being capable of appreciating other embodiments from the
scope and spirit of the foregoing teachings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of one embodiment of an armor
system unit with multiple layers of protective material.
[0029] FIG. 2 is a partial view of a hexagonal ceramic tiles.
[0030] FIG. 3 is a partial view of a layer of ceramic tile
squares.
[0031] FIG. 4 is a partial view of a layer of perforated ceramic
tiles.
[0032] FIG. 5 is a partial view of a layer of triangular shaped
ceramic tiles.
[0033] FIG. 6 a perspective view of another embodiment of an armor
system unit with a loose fill ceramic layer.
[0034] FIG. 7 is a partial perspective view showing a self-healing
armor unit with an expandable foam layer.
[0035] FIG. 8 is a partial view of a tensioned steel spring.
[0036] FIG. 9 is a view of a punctured expandable foam packet.
[0037] FIG. 10 is a view of a single layer of expandable foam
packets.
[0038] FIG. 11 is a view of a double layer of expandable foam
packets.
[0039] FIG. 12 is a view showing a self-healing armor unit with
ceramic filled tubes.
[0040] FIG. 13 is a view of a ceramic filled tube.
[0041] FIG. 14 is a view of a ceramic filled tube with one end
shown in an exploded condition.
[0042] FIG. 15 is a view of a ceramic filled tube shown ruptured at
a center portion.
[0043] FIG. 16 is a view of another embodiment of a self-healing
armor unit.
[0044] FIG. 17 is a view of another embodiment of a self-healing
armor unit with ceramic filled tubes positioned with their ends
facing outwardly.
[0045] FIG. 18 is a view of an armor unit with a steel spring layer
strengthened with a high strength woven adhesive tape.
[0046] FIG. 19 is a view of a protective layer of ceramic filled
tubes and tensioned steel spring strengthened with a high strength
woven adhesive tape.
[0047] FIG. 20 is a view of a protective layer of hexagonal ceramic
tiles strengthened with a high strength woven adhesive tape.
[0048] FIG. 21 is a view of a protective layer of square ceramic
tiles strengthened with a high strength woven adhesive tape.
[0049] FIG. 22 is a view of a protective layer of perforated
ceramic tiles strengthened with a high strength woven adhesive
tape.
[0050] FIG. 23 is a view of a protective layer of ceramic and high
strength metal.
[0051] FIG. 24 is a view of a perforated ceramic tile with a
polymer fill in the holes.
[0052] FIG. 25 is a view of a protective layer of aluminum,
ceramic, and glass composite.
DETAILED DESCRIPTION
[0053] In certain embodiments, the armor system of the present
invention provides an armor that can be quickly and easily applied
to a body to be protected and adapted to a variety of situations
depending on the level of threat and the level of protection
needed. The armor system may include plural armor units that
include an outer case that can be filled with a variety of
protective materials either alone or in combination with other
protective materials. The type and combination of materials that
are enclosed within the outer case depend on several factors such
as, for example, the level of threat and protection that is needed
against the threat, the weight of the armor system, the need for
the armor system to conform to the body to which it is to protects,
and the cost of the armor system.
[0054] FIG. 1 shows an armor unit 10, one or more of which make up
the armor system of the present invention. Although only one armor
unit 10 is shown it is understood that many more armor units 10 may
be used depending on the application or body to be protected. For
example, the armor system may be used in a wide variety of
applications such as, for example, to protect people, cars,
buildings, or naval craft. The number of armor units 10 used
depends on the size of the area to be protected. Each armor unit 10
includes an outer case 12 that encloses one or more protective
materials 14. Outer case 12 may be formed in any suitable manner.
However, as shown in FIG. 1, outer case 10 is preferably made of
first and second sheets of material 16 and 18 located adjacent each
other with their outer edges aligned and stitched or sewn together
preferably with a ballistic thread along a seam 20 to form
sidewalls 22. Although the outer edges of first and second sheets
16 and 18 are shown as being sewn they could be secured in any
other suitable manner. First sheet 16 comprises a front side 24
that faces an incoming bullet, missile, or other projectile. Second
sheet 18 comprises a backside 26 that lies adjacent to the body to
be protected. FIG. 1 shows one side of outer case 12 as being open
but this is merely for illustrative purposes to reveal protective
material layers 14. Normally, all edges of outer case 12 are sewn
or stitched closed. Further, outer case 12 can be made of any
material suitable for containing protective material layers 14 but
is preferably made of a ballistic cloth of woven fibers such as,
for example, glass rovings or fibers. Plastic fibers such as, for
example, polyethylene plastic may also be used. Examples of
suitable plastic fiber material of woven or unidirectional
ballistic fibers such as, for example, Kevlar.TM., manufactured by
Hexcel Schwebel, of Anderson, S.C. and Dyneema.TM., manufactured by
DSM High Performance Fibers, of Greenville, N.C.
[0055] In order to quickly and easily apply armor unit 10 to a body
or structure outer case 10 includes a pre-applied securing layer on
any portion thereof such as, for example, on one or both sides of
outer case 10. The securing layer may be either a heat sensitive or
a pressure sensitive securing layer. One example of a pre-applied
pressure sensitive securing layer is Velcro.RTM. or any other
securing layer that can mate with a complementary surface on the
body to be protected. Preferably, the securing layer is a
pre-applied adhesive on a side allowing that side to be applied to
the body or structure. The pressure sensitive adhesive is
preferably a "peel and stick" type of adhesive in which a release
liner is peeled away to expose the adhesive, which is then applied
to a surface of the body or structure to be protected. As shown in
FIG. 1, armor unit 10 includes a "peel and stick" adhesive layer 28
attached to backside 26 so that armor unit 10 can be quickly and
easily adhered to a body to be protected. Adhesive layer 28
includes a thin film with a pressure sensitive adhesive bonded
thereto. Any type of very strong pressure sensitive adhesive may be
used. One example of such a pressure sensitive adhesive is
Scotchcal.TM. Film 3662-10 manufactured by 3M Corporation of
Minneapolis, Minn. A release liner 30 covers the adhesive so that
it maintains its tack until it is ready for use. Adhesive layer 28
is bonded to outer case 12 with a strong flexible adhesive bonding
layer 32 such as, for example, a two-part liquid bonding agent such
as, for example, a polyurethane resin. Examples of such adhesive
resin are Z-7050 polyurethane compound and Z-8050-10 polyurethane
compound manufactured by Development Associates, Inc. of North
Kingston, R.I. After bonding layer 32 has been applied to outer
case 12, adhesive layer 28 is attached thereto and pressure,
preferably about 100 lbs./ft..sup.2, is applied for a period of
time to allow adhesive layer 28 to bond to outer case 12. Outer
case 12 is preferably porous so that the liquid bonding agent seeps
through outer case 12 and bonds with the adjacent layer of
protective material.
[0056] FIG. 1 shows adhesive layer 28 on backside 26 so that armor
unit 10 can be attached to an outer surface of a body to be
protected. However, adhesive layer 28 may be attached to front side
24 so that it can be adhered to an inner surface of a body to be
protected. Alternatively, an adhesive layer 28 may be adhered to
both front side 24 and backside 26 for an even wider range of
application. However, it should be understood that regardless of
whether armor unit 10 is adhered to an outer surface or an inner
surface of a body to be protected the layers of protective
materials 14 are arranged so that a particular desired layer of
protective material is the first to encounter a bullet or
projectile. When armor unit 10 is ready to be adhered to a body
release liner 30 is peeled away to expose adhesive layer 28, which
is then applied to the body.
[0057] Referring to FIG. 1, outer case 12 encloses a combination of
protective materials 14 some of which may be used alone or in
combination depending on certain factors discussed above such as,
for example, the threat level and the amount of protection needed
against the threat. The armor system shown in FIG. 1 is merely an
example of types and combinations of protective materials 14
enclosed within the outer case 12. In the embodiment shown in FIG.
1, outer case 12 of armor unit 10 encloses three layers of
protective material. In this example, an initial impact layer is
located directly adjacent front side 24 to absorb the energy of the
projectile. The initial impact layer is shown to include multiple
layers 34 of woven or unidirectional ballistic cloth intended to be
the first protective layer to encounter a projectile to absorb the
energy of the projectile. Cloth layers 34 may be of the same
material as outer case 12 which may be woven glass fibers or woven
plastic fibers such as, for example, Spectra.TM., manufactured by
Hexcel Schwebel, of Anderson, S.C., Kevlar.TM., or Dyneema.TM.. The
embodiment shown in FIG. 1 is shown using fifty layers of
903-Spectra.TM. woven fabric. If it is important to have a very
lightweight armor, the initial impact layer may comprise
unidirectional fiber cloth such as, for example, Spectra Shield.TM.
film manufactured by Hexce! Schwebel, of Anderson, S.C. The
unidirectional fiber layer may be used with or without other
protective layers such as, for example, ceramic layers as discussed
below. In another embodiment, the initial impact layer can be a
layer of hard material such as, for example, ceramic 38 discussed
below to absorb the energy of the projectile and to deform and/or
break it up. This is preferable when protecting against threats
from high velocity projectiles.
[0058] An optional protective second layer is located adjacent the
initial impact layer to further absorb the energy of the
projectile. The optional protective second layer is shown to
include a steel mesh layer 36 which may be used to further break up
and absorb the kinetic energy of a projectile. The most effective
location for steel mesh layer 36 is directly behind cloth layers
34. However, steel mesh layer 36 could be placed in other
locations. In one example, steel mesh layer 36 comprises
25.times.110 woven wire mesh of 0.015 in. (mesh
thickness).times.0.0105 in. (wire diameter) formed in a Plain Dutch
weave. A third energy-absorbing layer of firm or hard material is
provided to further absorb the energy of the projectile and to
break it up. The energy-absorbing layer preferably includes a
ceramic 38. The ceramic material used in ceramic layer 38 may be
any type of ceramic such as, for example, an aluminum oxide, a
silicon carbide, or a boron carbide. For example, the ceramic
material may have an alumina content of between about 85 to about
99 percent to provide an aggregate of extreme hardness having a
great resistance to fracture because of its very high compressive
strength. For example, suitable ceramic materials are available
from CoorsTek of Golden, Colo. or other manufacturers such as, for
example, Fujimi America, Inc. of Portland, Oreg. In addition, the
energy-absorbing layer may be other hard materials such as, for
example, polymer compositions including a woven high-density
polyethylene, glass or vitreous-like materials, metals including
tungsten wire or mesh-based elements, and other substances with
similar impact-resistant and/or energy-absorbing properties.
[0059] The energy-absorbing layer may be in any number of forms and
may include, for example, at least one and preferably a plurality
of single ceramic plates 40 enclosed within the outer case 12 and
having a thickness sufficient to provide protection depending on
need.
[0060] An alternative energy-absorbing layer may include, for
example, one or more multi-tile sheets 42 (FIGS. 2-5) composed of
plural ceramic tiles attached to a glass fiber cloth base sheet 43
by a resin material. The ceramic tiles may be formed in a variety
of shapes. For example, as seen in FIGS. 2-5, sheet 42 may include
hexagonal-shaped ceramic tiles 44 (FIG. 2) such as, for example, a
one-quarter inch ceramic hex mesh armor of the type manufactured by
CoorsTek of Golden, Colo., or rectangular-shaped tiles 46 (FIG. 3).
The flexibility of hexagonal-shaped ceramic tiles 44 make them
particularly useful for protecting vehicles. Rectangular-shaped
tiles 46 are particularly useful for protecting buildings. When
weight is a concern and/or extra strength is needed sheet 42 may
include perforated tiles 48 (FIG. 4). Perforated tiles 48 include
holes 50 drilled or otherwise formed therein at spaced intervals.
For example, holes 50 may have a diameter of preferably no greater
than about 3/16 inches (or between 4 and 5 mm) spaced about 1 cm
center-to-center. Perforated tiles 48 are lighter in weight than
solid ceramic tiles and provide a stronger tile that is less prone
to shattering upon impact. Triangular shaped tiles 51 are shown in
FIG. 5.
[0061] The ceramic tiles shown in FIGS. 2-5 may be arranged in an
abutting relationship or in a spaced relationship. For example, the
ceramic tiles may be spaced between 0.03 to 0.05 inches on all
sides. The spacing between the ceramic tiles typically depends upon
the selected tile thickness for a particular application. The
spacing of between 0.03 to 0.05 inches gives the ceramic tile sheet
an inherent tendency to give or recoil somewhat under impact.
Triangular shaped tiles 51 have significant flexibility and are
preferably adapted for use with human body armor.
[0062] The ceramic tiles or other energy-absorbing tiles or
elements may have different dimensions depending on the
application. For example, ceramic tiles for use with body armor
preferably have a thickness of about 3.1750 mm in order to provide
flexibility. Ceramic tiles with greater dimensions may be employed
when the threat level is higher and/or flexibility is less of an
issue. An example of ceramic tile dimensions for use in a higher
threat level include ceramic tiles having a width of about 50 mm, a
length of about 50 mm, and a thickness of between about 3 and 20
mm. Alternatively, ceramic tiles may have a width of about 100 mm,
a length of about 150 mm, and a thickness of between 4 and 50 mm
may be used for even higher threat level. For greater protection,
ceramic tiles may have a width of about 11.4 mm, a length of about
228 mm, and a thickness of between about 6 and 50 mm. These
represent examples of ceramic tile dimensions and the invention is
not limited to these specific examples. The brittle nature of the
ceramic tiles may cause them to shatter upon contact with
projectiles or flying fragments. This shattering of the ceramic
tiles at least partially absorbs the kinetic energy of the
projectile and also fragments the incoming projectile.
Additionally, cloth layers 34 help absorb the impact of the
projectile and also catch or contain ceramic pieces as they shatter
due to the impact.
[0063] Flexibility for a layer can be varied by sizing energy
absorbing materials into small tiles which can be of various shapes
and sizes as seen most clearly in FIGS. 2-5.
[0064] In another embodiment seen in FIG. 6, the energy-absorbing
layer includes loose discrete elements. The discrete elements may
be of any suitable material and any size and shape. The discrete
elements are shown in FIG. 6 as being in the form of a plurality of
ceramic balls or spheres 52. Ceramic balls 52 may have a uniform
diameter or the diameters may vary. In one example, ceramic balls
52 have a diameter ranging from between 5 mm to 20 mm. Preferably,
ceramic balls 52 are loose and are not arranged in any particular
orientation but randomly fill outer case 12 to be as dense as
possible. However, ceramic balls 52 may alternatively be embedded
in a matrix of, for example, polyurethane. Armor units 10 having
loose ceramic fill are particularly useful for protecting
buildings.
[0065] A self-healing armor unit 11 is shown in FIG. 7 in which
outer case 12 includes an energy-absorbing layer shown as
individual encasements 54 filled with loose discrete ceramic
elements such as, for example, ceramic balls 52 discussed above.
Encasements 54 are preferably made of the same material as outer
case 12 and can be of any suitable size. A tensioned spring 56
(FIG. 8) such as, for example, a high carbon steel spring, is
located adjacent encasements 54 and provides a force tending to
keep or hold encasements 54 in place and provides a further
protective layer. However, spring 56 is brittle and will shatter
upon impact by a projectile allowing the projectile to possibly
rupture an encasement 54. In order to prevent ceramic balls 52 from
spilling out of outer case 12 after a projectile has penetrated
outer case 12 a self-healing initial impact layer is provided in
the form of a layer of expansion packets 58 filled with an
expandable agent such as, for example, an expandable foam. One
suitable type of expandable foam is Thixo-Foam, manufactured by
Todol Products of Natick, Mass. Another suitable expandable foam is
Liquid Foam, manufactured by U.S. Composites of West Palm Beach,
Fla. The layer of expansion packets 58 is located immediately
adjacent front side 24 so that expansion packets 58 are the first
layer to encounter a projectile. Expansion packets 58 may be
suitably sized and shaped to be, for example, either 2 in. by 2 in.
square packets or 4 in. by 4 in. square packets and are filled with
a foam that, when exposed to air, expands and hardens forming a
foam barrier 59 as seen in FIG. 9.
[0066] Expansion packets 58 may be provided in a single layer (FIG.
10) or a double layer (FIG. 11). In one possible embodiment, an
expansion packet 58 is punctured by a projectile so that air
contacts the foam causing it to expand and fill the void left by
the projectile. Hardened foam barrier 59 prevents ceramic balls 52
from spilling out of outer case 12 should the projectile pierce
spring 56 and bags 54. Preferably, the foam is dyed to be the same
color as outer case 12 to camouflage any penetration by a
projectile. Armor unit 11 may include a securing layer on both
sides of outer case 12 and is shown with a "peel and stick"
adhesive layer 28 with release liner 30 is applied to both front
side 24 and backside 26 of armor unit 11. However, adhesive layer
28 may be applied only to either front side 24 or backside 26
depending on need. The self-healing armor unit 11 is particularly
useful in marine environments because the expanded and hardened
foam fills and seals punctures forming a substantially airtight
barrier. Other useful applications for self-healing armor unit 11
is in nuclear, biological, or chemical warfare environments because
the expanded and hardened foam could prevent such hazardous agents
from seeping into, for example, a vehicle.
[0067] FIG. 12 shows another embodiment of a self-healing armor
unit 11 in which outer case 12 includes a securing layer on at
least one outer side shown here as an adhesive layer 28 with
release liner 30. Outer case 12 contains plural energy-absorbing
layers shown here as multiple layers ballistic cloth 34 and ceramic
layer 38 which may include any of the ceramic tiles discussed
above. Outer case 12 further includes a tensioned energy layer
including plural discrete elements under tension that are released
upon impact to repopulate the void created by the projectile. The
tensioned energy layer is shown to include a layer of ceramic
filled glass or plastic tubes 60. As seen in FIG. 13, each tube 60
is filled with a plurality of ceramic balls 52 held under
compression by springs 62 located at each end thereof When a
projectile ruptures a tube 60, springs 62 force balls 52 into the
void formed by the projectile. Alternatively, each tube 60 may
include an end cap 64 located at each end thereof that releases
energy upon impact by a projectile to instantaneously propel
ceramic balls 52 into the void created by the projectile. End caps
64 may be in any suitable form such as, for example, compressed gas
or an explosive. In the embodiment shown in FIG. 12, each tube 60
includes both springs 62 and end caps 64. End caps 64 are shown in
FIG. 12 as an explosive end cap similar to percussive caps found in
bullets and which explode upon impact by a projectile. FIG. 14
shows tube 60 in an exploded condition after one of end caps 64
having been struck by a projectile. After end cap 64 explodes, the
force of the explosion and the force of one of springs 62 forces
ceramic balls 52 out of tube 60 to fill the void left by the
projectile. FIG. 15 shows tube 60 in an exploded condition after
having been struck in the center by a projectile. In this example,
both springs 62 force ceramic balls 52 out to fill the void left by
the projectile. As further seen in FIG. 12, a layer of expansion
packets 58 is located immediately adjacent the layer of tubes 60
and is the initial impact layer that encounters a projectile to
prevent ceramic balls 52 from spilling out from outer case 12.
[0068] FIG. 16 shows an alternative arrangement of protective
layers including an energy-absorbing layer of plural encasements 54
with discrete energy-absorbing elements such as, for example,
ceramic balls 52, tensioned spring 56, energy tensioned layer such
as, for example, ceramic filled tubes 60, and an initial impact
layer of expansion packets 58. This alternative arrangement
provides a lighter weight armor unit 11.
[0069] In order to counter the force of an incoming projectile,
self-healing armor unit 11 shown in FIG. 17 includes an
energy-absorbing layer such as, for example, ceramic 38 and a
tensioned energy layer of, for example, tubes 60 that are oriented
with their lengths extending between ceramic layer 38 and front
side 24 of outer case 12. When a tube 60 is struck by a projectile
ceramic balls 52 located within tubes 60 are forced outward in a
direction substantially against the direction of force of the
projectile. An initial impact layer of expansion packets 58 is
located immediately adjacent tubes 60 to prevent ceramic balls 52
from spilling out of outer case 12.
[0070] FIG. 18 shows a lighter weight armor unit 13 that includes
an energy-absorbing layer such as, for example, encasements 54 of
ceramic balls 52 and an optional protective second layer such as,
for example, tensioned spring 56. In this embodiment, tensioned
spring 56 is strengthened by a high strength woven adhesive tape
66. One example of such high strength tape 66 is 3M 3662-10
Scothcal.TM., manufactured by 3M Corporation, in St. Paul, Minn.
High strength tape 66 is shown applied to both sides of tensioned
spring 56. However, high strength tape 66 may be applied to only
one side of tensioned spring 56. This embodiment is advantageous
for use in the protection of buildings as it is light-weight and
easily conformable to various surfaces. Additionally, high strength
tape 66 provides a higher level of protection.
[0071] FIG. 19 shows an alternative protective layer that may be
included in outer case 12 in which the tensioned energy layer of,
for example, ceramic filled tubes 60 and tensioned spring 56 are
located adjacent each other with high strength tape 66 applied to
both sides. This protective layer can be placed in any desired
position within outer case 12 and combined with any of the
protective layers previously discussed.
[0072] FIGS. 20-22 shown various examples of an energy-absorbing
layer with high strength tape 66 applied to each side thereof. For
example, multi-tile sheets 42 may include hex tiles 44 (FIG. 20),
solid rectangular tiles 46 (FIG. 21), or perforated tiles 48 (FIG.
22). High strength tape 64 provides a higher degree of protection
from a projectile and additionally prevents shattering of the
ceramic tiles. The multi-tile sheets 42 with high strength tape 66
may be used in any of the previously discussed arrangement of
protective materials either as the only ceramic layer or combined
with other ceramic or non-ceramic layers.
[0073] FIG. 23 shows an alternative protective layer in which a
high strength metal layer 68 such as, for example, titanium is
bonded to an energy-absorbing layer such as, for example, ceramic
38. Any type of high strength bonding agent may be used to adhere
metal layer 68 to ceramic layer 38. Examples include epoxy resin,
cement, or dental adhesives. In addition to providing extra
protection, metal layer 68 helps prevent shattering of ceramic
layer 38.
[0074] FIG. 24 shows an embodiment of perforated tile 70 having a
fill 72 in each hole 74. Fill 72 may be a polymer such as, for
example, the Z-7050 polyurethane compound discussed above. Fill 72
flows just past the surfaces of tile 70 and serves as a bonding
agent to adhere strengthening materials such as, for example, metal
plate 68.
[0075] FIG. 25 shows another protective energy-absorbing layer that
may be included in outer case 12. This energy-absorbing layer is
shown to include three layers of material bonded together.
Specifically, a layer of aluminum 80 is bonded to a layer of
ceramic 82, which is then bonded to a layer of glass or plastic
composite material 84 such as, for example, a ballistic panel
manufactured by Oak Ridge Plastics, of Ripon, Wis. This bonded
protective layer is particularly useful in marine environments and
may be used in place of protective layers that include woven
materials that degrade in water or very wet environments.
[0076] It should be understood that the foregoing description is
only illustrative of the invention. Various alternatives and
modifications can be devised by those skilled in the art without
departing from the invention. Accordingly, the present invention is
intended to embrace all such alternatives, modifications, and
variances which fall within the scope of the appended claims.
* * * * *