U.S. patent application number 12/237615 was filed with the patent office on 2010-04-29 for lightweight composite armor.
This patent application is currently assigned to MKP Structural Design Associates, Inc.. Invention is credited to Zheng-Dong Ma.
Application Number | 20100101402 12/237615 |
Document ID | / |
Family ID | 42078091 |
Filed Date | 2010-04-29 |
United States Patent
Application |
20100101402 |
Kind Code |
A1 |
Ma; Zheng-Dong |
April 29, 2010 |
LIGHTWEIGHT COMPOSITE ARMOR
Abstract
Improved composite armor designs uses optimally shaped ceramic
pellets, a specific stacking geometry and a web system for
patterning the pellets, improving manufacturability, and providing
additional structural reinforcement. Lightweight, composite
ballistic armor according to the invention may comprise an array of
ceramic pellets, each pellet having a front surface, a back surface
and a longitudinal centerline, and wherein the front surface of
each pellet is intentionally convex. The front surface of each
pellet may be hemispherical, in which case the cross-section of the
pellet taken perpendicular to the centerline may be oval-shaped.
Alternatively, the front surface of each pellet may be elliptical,
in which case the cross-section of the pellet taken perpendicular
to the centerline may be circular. In the preferred embodiment, the
back surface of each pellet is formed at the same angle relative to
its centerline, with the pellets being arranged with the flat
surfaces lying in a plane. The pellets may be arranged in a square
matrix, or may be arranged in a hexagonally close-packed matrix.
The array of pellets may be embedded in a hardened matrix material,
and/or tied together with netting material.
Inventors: |
Ma; Zheng-Dong; (Ann Arbor,
MI) |
Correspondence
Address: |
GIFFORD, KRASS, SPRINKLE,ANDERSON & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Assignee: |
MKP Structural Design Associates,
Inc.
|
Family ID: |
42078091 |
Appl. No.: |
12/237615 |
Filed: |
September 25, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11187378 |
Jul 22, 2005 |
7490539 |
|
|
12237615 |
|
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Current U.S.
Class: |
89/36.02 ;
89/903; 89/906; 89/908; 89/917 |
Current CPC
Class: |
F41H 5/0492 20130101;
F41H 5/013 20130101 |
Class at
Publication: |
89/36.02 ;
89/903; 89/917; 89/906; 89/908 |
International
Class: |
F41H 5/04 20060101
F41H005/04; F41H 5/02 20060101 F41H005/02 |
Goverment Interests
GOVERNMENT SUPPORT
[0002] This invention was made with government support under
Contract No. W56 HZV-05-C-0098, entered into with the United States
Army Tank-Automotive Research, Development and Engineering Center
(TARDEC). The Government may have certain rights in the invention.
Claims
1. Lightweight, composite ballistic armor, comprising: an array of
ceramic pellets, each pellet having a front surface, a back surface
and a longitudinal centerline; and wherein: the front surface of
each pellet is intentionally convex; the front and back surfaces of
the pellets define parallel, spaced-apart front and back planes,
and the longitudinal centerlines of the pellets are parallel to one
another and angled relative to the front and back planes at an
angle other 90 degrees.
2. The lightweight, composite ballistic armor of claim 1, wherein
the front surface of each pellet is hemispherical.
3. The lightweight, composite ballistic armor of claim 1, wherein:
the front surface of each pellet is hemispherical; and the
cross-section of the pellet taken perpendicular to the centerline
is oval-shaped.
4. The lightweight, composite ballistic armor of claim 1, wherein
the front surface of each pellet is elliptical.
5. The lightweight, composite ballistic armor of claim 1, wherein:
the front surface of each pellet is elliptical; and the
cross-section of the pellet taken perpendicular to the centerline
is circular.
6. The lightweight, composite ballistic armor of claim 1, wherein:
the back surface of each pellet is substantially flat; and the
pellets are arranged with the flat surfaces in a flat back
plane.
7. The lightweight, composite ballistic armor of claim 1, wherein
the pellets are arranged in a square matrix.
8. The lightweight, composite ballistic armor of claim 1, wherein
the pellets are arranged in a hexagonally close-packed matrix.
9. The lightweight, composite ballistic armor of claim 1, wherein
the array of pellets are embedded in a hardened thermoset or
thermoplastic polymer matrix material.
10. The lightweight, composite ballistic armor of claim 1, wherein:
the array of pellets are tied together with fibrous netting
material; and the tied pellets are embedded in a hardened
matrix.
11. The lightweight, composite ballistic armor of claim 1, wherein:
the array of pellets are tied together with fibrous netting
material; and the tied pellets are embedded in a hardened matrix;
and the matrix is strengthened with a nano-clay component.
12. The lightweight, composite ballistic armor of claim 1, wherein
the array of pellets are embedded in a hardened matrix material
forming a plurality of front plates, and further including: a
flexible, web-based support structure; and a plurality of tiles
attached to the support structure, each tile including a front
plate disposed on one side of the support structure, a back plate
disposed on the other side of the support structure, and one or
more fasteners for joining each front plate to a corresponding back
plate through the support structure.
13. The lightweight, composite ballistic armor of claim 12, wherein
each back plate is a composite structure including opposing panels
filled with a resin impregnated matrix.
14. The lightweight, composite ballistic armor of claim 12, wherein
the back and front plates are co-extensive.
15. The lightweight, composite ballistic armor of claim 12, wherein
the web-based support structure can bend along lines between the
tiles, resulting in a hinged sheet that can be draped over a
vehicle or other thing to be protected.
16. The lightweight, composite ballistic armor of claim 12, wherein
the ceramic pellets are bound together with a network of cables
embedded in the hardened matrix material.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/187,378, filed Jul. 22, 2005, the entire
content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0003] This invention relates generally to ballistic armor and, in
particular, to a lightweight composite ballistic armor for military
and tactical vehicles and armored civilian vehicles as well as
buildings protecting people, machinery, supplies and fuel.
BACKGROUND OF THE INVENTION
[0004] The terrorist attacks of Sep. 11, 2001 in New York City and
Washington, D.C., and the current war in Iraq, have heightened the
need for ballistic armor. Military vehicles, in particular, are
vulnerable to higher-potency weapons such as rocket-launched
grenades and other projectiles. Military personnel want
lightweight, fast and maneuverable vehicles, but they also want
vehicle occupants to be fully protected. Ballistic steel armor
plates, while relatively inexpensive, add thousands of pounds to a
vehicle, many of which were not designed to carry such loads. This
has resulted in numerous engine and transmission failures as well
as problems with vehicle suspensions and brakes. The additional
weight reduces fuel efficiency and makes it impossible to carry
additional personnel in the vehicle in case of emergency. For these
reasons, designers are beginning to adopt more lightweight
composite armor across the board for military and tactical
vehicles.
[0005] Various lightweight armor designs are now becoming
commercially available. Cellular Materials International, Inc. of
Charlottesville, Va. offers a product called Microtruss.TM., a
periodic cellular material designed to absorb a larger amount of
energy than solid material of equal mass. When a blast hits the
face of the sandwich panel, the face plate will stretch and wrinkle
followed by the propagation of the impulse force into the core. The
core will then buckle and collapse, absorbing the maximum kinetic
energy of the blast. The back face plate takes the remaining blast
pressure towards the end of the blast event where the intensity of
the impulse force is considerably reduced. Thus, the periodic
structure maximizes the absorption of the impulse energy created by
the blast and distributes or diffuses the intensity of the force,
leading to protection of the assets behind the sandwich
structures.
[0006] Designs using ceramic pellets are also evolving. U.S. Pat.
No. 6,203,908 is directed to a composite armor for absorbing and
dissipating kinetic energy from high velocity projectiles. The
armor comprises a panel having a layer of a plurality of high
density ceramic bodies, the bodies having a specific gravity of at
least 2 and being made of a material selected from the group
consisting of ceramic material which does not contain aluminum
oxide and ceramic material having an aluminum oxide content of not
more than 80%. Each of the bodies is substantially cylindrical in
shape, with at least one convexly curved end face, and each of the
bodies having a major axis substantially perpendicular to the axis
of its respective curved end face, wherein the ratio D/R between
the diameter D of each of the cylindrical bodies and the radius R
of curvature of the respectively convexly curved end face of each
of the bodies is at least 0.64:1, and wherein the bodies are
arranged in a plurality of adjacent rows and columns, the major
axis of the bodies being in substantially parallel orientation with
each other and substantially perpendicular to an adjacent surface
of the panel.
[0007] Ballistic armor utilizing ceramic components is also
commercially available. ARES Protection, Le Bourg 38270,
Primarette, France offers a product called LIBA, which stands for
light improved ballistic armor. The armor is a system consisting of
one or more layer(s) of spherical ceramic pellets glued with (or
without) a backing material and embedded in a polyurethane matrix
LIBA is for body and vehicle protection applications, especially to
stop AP ammunitions. LIBA is developed for protection against WC
bullets and hollow charges.
[0008] Despite these advances, the need remains for an improved,
more optimized lightweight composite armor for military and
tactical vehicles and other applications.
SUMMARY OF THE INVENTION
[0009] The present invention improves upon existing composite armor
designs through the use of optimally shaped ceramic pellets and a
three-dimensional fiber network system for patterning the pellets,
improving manufacturability, and providing additional structural
reinforcement. The result is lightweight, composite hybrid
structures for ballistic protection particularly suited to tactical
ground vehicles. Due to the flexibility of the system, however, the
armor can also be used, with minimum modifications, to protect
commercial vehicles. The armor system can be further extended for
other usages, for example, in a chair-based armor system to protect
driver and passengers, or attached to office walls, ceilings,
floors and exterior structures to protect officers, or even as
personal armor.
[0010] To further deflect an incoming projectile and defeat
penetration, pellets with convex crowns may be used according to
embodiments of the invention. Such lightweight, composite ballistic
armor, comprises an array of ceramic pellets, each pellet having a
front surface, a back surface and a longitudinal centerline, and
wherein the front surface of each pellet is intentionally convex.
The front surface of each pellet may be hemispherical, in which
case the cross-section of the pellet taken perpendicular to the
centerline may be oval-shaped. Alternatively, the front surface of
each pellet may be elliptical, in which case the cross-section of
the pellet taken perpendicular to the centerline may be
circular.
[0011] In the preferred embodiment, the back surface of each pellet
is formed at the same angle relative to its centerline, with the
pellets being arranged with the flat surfaces lying in a plane. The
pellets may be arranged in a square matrix, or may be arranged in a
hexagonally close-packed matrix. To improve stability in normal use
(under vibration loads, impact energy absorption and
manufacturability), the array of pellets may be embedded in a
hardened polymer or metal matrix material, and/or tied together
with a fiber network.
[0012] Arrays of pellets may be embedded in a hardened polymer or
metal matrix material to form a single front plate. One or more of
these front plates may be attached to a single back plate. The
system may further include a flexible net-like, support structure
with a plurality of armor tiles attached to the support structure,
each tile including one or more front plates disposed on one side
of the support structure, a back plate disposed on the other side
of the support structure, and one or more fasteners for joining
each front plate to a corresponding back plate through the support
structure. An alternative embodiment has the support structure
behind the back plate. Each back plate may itself be a composite
structure including opposing panels filled with a resin impregnated
matrix. The back and front plates may be co-extensive, and the
web-based support structure may be bendable along lines between the
tiles, resulting in a hinged sheet that can be draped over a
vehicle or other thing to be protected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A shows composite armor characteristics and vehicular
installation positions;
[0014] FIG. 1B shows different construction alternatives according
to the invention;
[0015] FIG. 2 shows two alternative patterns according to the
invention;
[0016] FIG. 3A shows pellets and fiber network structures inside
the ceramic based face plate;
[0017] FIG. 3B shows the fiber net structure aligned with the
pellets to provide reinforcement;
[0018] FIG. 4 shows a back plate using bolts;
[0019] FIG. 5 shows groove and clip-on mechanisms;
[0020] FIG. 6 shows a metallic wire fastener;
[0021] FIG. 7 shows a concept for ceramic layer with improved
performances;
[0022] FIG. 8 shows impact force acting on the back plate;
[0023] FIG. 9A illustrates ceramic cylinders;
[0024] FIG. 9B illustrates a cable network;
[0025] FIG. 9C illustrates a matrix;
[0026] FIG. 10 illustrates a design with ceramic pellets and a
cable network;
[0027] FIG. 11 shows a composite armor unit including a web-based
supporting structure and pellet array;
[0028] FIG. 12 illustrates the use of angle-cut cylindrical ceramic
pellets;
[0029] FIG. 13A shows a pellet according to the invention cut at an
angle of 60 degrees;
[0030] FIG. 13B shows a pellet according to the invention cut at
and angle of 67.5 degrees and having a hemispherical crown;
[0031] FIG. 13C shows a pellet according to the invention cut at
and angle of 67.5 degrees and having a partial elliptical
crown;
[0032] FIG. 13D shows a pellet according to the invention cut at an
angle of 67.5 degrees and having a half elliptical crown;
[0033] FIG. 14A depicts a square-packed array of dome-crowned
pellets; and
[0034] FIG. 14B depicts a hexagonal close-packed array of
dome-crowned pellets.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Basic armor configuration (100) according to the invention
is illustrated in FIG. 1A. FIG. 1B shows different construction
alternatives. Each include three major modules: 1) a functionally
oriented material (FOM) tile (102) as the front plate, 2) a
Bio-mimetic Tendon-Reinforced (BTR) back plate 104, and 3)
supporting structure 106 using a fabric web. Various alternative
embodiments are available in each case. As described in further
detail below, the front plate may use pellets arranged in a regular
structure (110), of the pellets may use a designed shape (112). In
the preferred embodiment, the back plate may be constructed using
any of the forms disclosed in co-pending U.S. patent application
Ser. No. 11/023,923, the entire content of which is incorporated
herein by reference. Other embodiments include the use of a solid
plate of aluminum or other suitable metal or polymer material. The
front and back plates may be joined with a clip mechanism (114), or
other disclosed alternatives may be used. In the preferred
embodiment, the front and back plates are co-extensive, and
arranged in an array shown at 100 facilitating easier replacement.
If the resulting "blanket" is draped over the front or side of a
vehicle, an optional bullet-resistant window (120) may be
provided.
[0036] The front plate is preferably composed of ceramic pellets
arranged in a periodic pattern designed for improving the ballistic
resistance, especially in the presence of multiple hits. The
pellets may be contained in a single-layered or three-dimensional
metal or fiber network filled by thermoset or thermoplastic polymer
material. The polymer may be further improved by use of nano clay
to improve resistance to crack propagation. The ceramic pellet will
have an optimally designed shape, which enhances the transferring
of impact load onto surrounding pellets. This feature results in
desired compress stress among the pellets, which reduces the crack
propagation and improves the out-of-plane impact resistance
performance.
[0037] The ceramic pellets in the tile are seated in a fabric
network, and are molded with the selected thermoset or
thermoplastic polymer material. The polymer material functions as
impact absorber and position keeper of the pellets and may have
nano-clay particles molded in to further improve resistance to
crack propagation. The fabric network in the ceramic layer has two
major functions: one is to keep the pellets in a desired
arrangement and the other is to reinforce the ceramic layer during
the ballistic impact.
[0038] The back plate features ultra-light weight and outstanding
out-of-plane stiffness/strength. It is designed to have improved
bending stiffness and strength for optimizing the armor
performance. The back plate, combined with one or more face plates,
is referred to herein as an Armor Tile.
[0039] The fabric net is designed to hold the armor tiles (ceramic
layer and back plate) in place and form an integrated armor kit
that can fill into various vehicle contours. The optimally designed
supporting structure also provides the advanced features of low
cost and ease of installation, replacement, and repair.
The Front Plate
[0040] Each layer of ceramic pellets provides improved ballistic
performance under conditions of single and multiple hits in several
ways: Crack propagation is limited at the boundary of each
individual pellet; An individual crack must propagate through the
fabric web and thermoset or thermoplastic polymer matrix; The
inclined angle of the stacked pellets will tend to rotate the
incoming projectile and reduce the damage to the underlying target;
The domed geometry of the individual pellets will further deflect
and redirect the incoming projectiles away from the target. In one
embodiment, commercially available ceramic pellets are used;
however, in the preferred embodiments pellets of purpose-designed
shapes are used.
[0041] There are two kinds of ceramic pellets with simple shapes
that are commercially available, including spherical and
cylindrical versions. These pellets are used in manufacturing
industry as grinding media in size-reduction mills of various
types. We have identified pellets made from Alumina (A1203) with
the purity of 93%, 96.5% and 99.5%. Other candidate materials
include Alumina with higher purity, Zirconia-Toughened Alumina,
Yttria (Y203) Partially Stabilized Zirconia.
[0042] There are two patterns for the ceramic pellet layering,
namely, the square and honeycomb arrangements 202, 204 as shown in
FIG. 2. In the preferred embodiment the ceramic pellets are packed
in a hexagonal close-paced arraignment (also known as a honeycomb).
A lower-density, square packing is possible and may have advantages
if the thermoset or thermoplastic matrix and fabric layers require
additional spacing for optimal performance, or lower weight. It is
also desirable to improve the in-plane and out-plane bending
stiffness and strength of the simple ceramic layer. To achieve this
goal, a single or multi-layer fabric net structure is used as the
pellet holder during fabrication. This fabric net provides
structural reinforcement, providing resistance to tensile loads and
flexural stiffness. The compound structure of the ceramic pellets
and the fabric net are further molded in a thermoset or
thermoplastic matrix. One single-layered net design with honeycomb
pattern is shown in FIGS. 3A and 3B.
[0043] From FIG. 3B, it is seen that the fabric net structures will
serve to align the ceramic pellets and hold them in place during
the manufacturing process. After the thermoset or thermoplastic
matrix is cured with the ceramic pellets, the net structures will
provide reinforcement in resisting tensile stress, which is one
weakness of a layer comprised of only ceramic pellets and the
matrix. The net structure can also be three dimensional, which
could provide additional reinforcement to the whole composite. The
material selected for fabricating the web will be a high-strength
fiber such as para-aramid synthetic fiber.
[0044] The matrix material holds the ceramic pellets together and
absorbs the vibration and impact energy under normal working
conditions, so that the armor will not change configuration or be
damaged in normal loading conditions (such a driving a vehicle).
Under ballistic impact, it is expect the matrix material will not
be strong enough to defeat of the projectiles. However, it is
expected that the matrix material have the capabilities to absorb
significant amounts of the impact energy and prevent collateral
damage to surrounding pellets. A thermoset or thermoplastic
material is applicable to this purpose, depending upon cost,
manufacturability, and reparability.
The Back Plate
[0045] In the preferred embodiment, the back plate employs the
patent-pending BTR material concept, which features ultra-light
weight and outstanding out-of-plane stiffness/strength. The ceramic
face plates may be connected to the back plates using bolts (FIG.
4), clip designs (FIG. 5), or metal wire/cable. (FIG. 6) The
supporting structure (net structure) is clamped between the ceramic
face plate and back plate, as shown in FIGS. 4 to 6.
Effectiveness
[0046] The ballistic impact on a homogeneous ceramic layer leads to
damage through mechanisms that are different in different stages of
the penetration. At initial impact, the high hardness of ceramic
materials helps to flatten the projectile tip. The damage to the
ceramic is localized at this stage to a relatively confined area
under the projectile as only compressive forces are in effect. In
the second phase, propagation of the reflective wave (tensile wave)
causes material damage at the back of the ceramic layer because
ceramics are weak in tension. At this point the damage zone is like
shaped like a mushroom. Then cracks initiate from the root of the
mushroom because of the bending of the ceramic layer. At the same
time, the cap of mushroom becomes larger, expanding inside the
ceramics with a certain angle (.about.60 degrees) relative to the
axis of the mushroom. Finally, the mushroom cap cracks, causing
fragmentation of the ceramic layer and the debris is kept in place
to stop the projectile with the help of back plate. This process
continues until the back plate fails. Homogenous, traditional,
ceramic materials are hard and brittle. The high hardness
contributes to flatten the nose part of the incoming projectiles,
which increases the forces to stop the projectiles. The brittle
properties of ceramics are not good for sustained defeating of
projectiles, however, the damage zone forms due to this helps to
distribute the impact force over a larger area. Another effect of
brittleness of ceramic material is the long cracks usually expand
from the point of impact due to bending. It is believed that these
long cracks, creating small pieces of ceramic material, reduce the
penetration resistance of the armor because there is limited
in-plane constraint to keep the ceramic in place. Loss of mass
through ejection of material permits in further penetration of the
projectile.
[0047] As mentioned in the previous section, there are many
mechanisms which help to improve the ballistic performance of
armor. There are also many other mechanisms which compromise the
overall performances. The goal is to promote the "good" mechanisms,
and suppress "bad" ones. We identified good mechanisms as: [0048]
A) Hardness of ceramic to flatten the tip of projectile at the
initial stage of impact; [0049] B) Transference of impact force to
surrounding and supporting materials; [0050] C) Constraints of
material to prevent material "flee" from the impact zone; [0051] D)
Other aspects to defeat projectile by involving more materials in
the impact zone; and bad mechanisms as: [0052] E) Long cracks
propagation; [0053] F) Large damage zone.
[0054] Based upon these observations, the ceramic layer will
preferably include ceramic pellets to form a mosaic as opposed to
an entire piece of ceramic material. With this approach, the
following advantages should be realized:
[0055] A) The hard pellets will be able to flatten the tip of the
projectile;
[0056] B) The special geometry of the pellets will be able to
transfer the impact force (in form of compressive stress) to
surrounding pellets as far as possible;
[0057] C) Special shape of the surrounding pellets helps to hold
the material in the impact zone;
[0058] D) If the projectiles can be designed to change the
penetration angle of the bullet, the armor will be much more
effective. Therefore, the bigger the angle change is, the better
the armor performances will be;
[0059] E) Boundaries between the pellets help to stop the
propagation of cracks;
[0060] F) Damage will be restricted in a limited range due to the
fact that long cracks can be stopped from its initiating stage.
[0061] G) Damage will be further restricted to a limited range due
to the fact that long cracks in the polymer matrix can be stopped
from further propagation due to the presence of nano-clay particles
in the matrix.
[0062] The ceramic layer design can be seen as an effort to promote
the above features by optimally configuring the basic components in
the ceramic layer. FIG. 7 illustrates an example concept of the
ceramic mosaic. In this concept, the ceramic pellets have a
particular geometry, which helps to transfer impact load to
surrounding pellets. The transfer of force to surrounding tiles
will be in form of compressive stress, which is favorable for
ceramic materials. Because the boundary of tiles restrains the
propagation of cracks, the design will have better multi-hit
performance. The pellets are molded in thermoset or thermoplastic
polymer materials, which functions as impact absorber and keep the
tiles in place. The design will have better dynamic performances
because of the thermoset or thermoplastic material used.
[0063] Using this approach, the projectile penetration angle can be
deflected due to the asymmetric design of the ceramic pellets. The
angle deflection, although it is small, greatly improve the chance
of defeating the projectile. Because a face plate composed of
ceramic blocks will lack tension and bending strength, an optimized
cable network will be included in the ceramic layer for
reinforcement during normal work conditions and under ballistic
impact. Thematrix will be selected to absorb the shock wave and
prevent ceramic damage in normal work conditions and under
ballistic impact. Other important concerns include
manufacturability and cost.
[0064] As discussed above, the back plate should have large bending
stiffness to prevent excessive bending of ceramic layer, the
bending is an undesired deformation for the ceramic layer. At the
same time, back plate should have large bending strength to hold
the damage ceramic material in place to continue to stop the
projectile. At the same time, the back plate should be able to
collect debris from projectiles and ceramic layer and to stop them
from penetration. Thus, the force acting on the back plate will be
a distributed force, depicted in FIG. 8.
The Support Structure
[0065] The supporting structure is the structure between the armor
kits and vehicle structures. It provides the benefit of easy
installation, and also can be designed to improve the ballistic
function of armor kits. Traditionally, armor kits are bolted on the
structures for which they provide protection. If this traditional
method is applied, there is an additional task to fit the geometry
of the armor kit to the back structures. Therefore, we proposed an
alternative method to mount the armor kits with an additional
supporting structure. This supporting structure will provide
additional benefits, such as easy to install, replace and
repair.
[0066] At least two alternative supporting structures are possible.
The first is a net structure that the armor kits are attached to,
as shown in FIGS. 4-6. The benefit of this design will be
lightweight and easy to install on different kinds of surfaces. The
second one is made of fabric cloths, such as a para-aramid fiber,
which has arrays of pockets that the armor tiles can be inserted
in. This concept is similar to the body armor except a large number
of armor inserts will be used.
[0067] In terms of materials, different kinds of materials are
combined to defeat the projectile effectively. Ceramic pellets or
cylinders function to damage and to rotate the projectiles.
Optimized cable network provides reinforcement when tension and
bending loads exist on the armor plate. Matrix material functions
to absorb shock waves and to keep the structural integrity. FIGS.
9A-9C illustrates an armor design with ceramic cylinders, cable
network, and matrix.
[0068] We have identified polycarbonate as a suitable matrix
material. Aluminum is another suitable material. Para-aramid fiber
is preferable as the cable material in the face plate and back
plate because para-aramid fiber is widely used in body armor and
has superior ballistic performances.
[0069] FIG. 10 shows a ceramic pellet layout and a holding net
designed for the face plate. This prototype face plate has a total
volume of 272.8 cm3, total weight of 832 g, and density of 3.05
g/cm3, which is 60% lighter than steel (7.8 g/cm3), 19% lighter
than homogeneous ceramic (3.8 g/cm3), and only 10% heavier than
aluminum (2.7 g/cm3). FIG. 11 shows a composite armor unit
including a web-based supporting structure and pellet array.
[0070] FIG. 12 illustrates the use of angle-cut cylindrical ceramic
pellets. From experimental results, it was found that two
structural layers with 1/4'' hemp stuffers, 1/16'' para-aramid
fiber ropes, 12 layers of woven para-aramid fiber, and Epoxy matrix
has the best performance in terms of bending stiffness. Although an
angle of 45 degrees is indicated, it will be apparent to those of
skill that other angles are possible. For example, FIG. 13A shows a
pellet according to the invention having an angle of 60 degrees. In
the embodiment shown, the cross section is 16.2 mm and the height
is 12 mm.
[0071] To further deflect an incoming projectile and defeat
penetration, pellets with convex crowns may be used, as shown in
FIGS. 13B-D. While angled pellets have the ability to turn the
projectile, domed pellets have the ability to deflect and turn
projectiles, thereby enhancing effectiveness.
[0072] FIG. 13B illustrates the use of a round crown having a
radius of 10 mm. If the center of the hemisphere lies on a line 902
perpendicular to the back surface 904 of the pellet, the cross
section (A-A) taken perpendicular to the longitudinal centerline
906 of the pellet may be oval shaped. In the embodiment shown, with
an angle of 67.5 degrees, "a" measures 15.6 mm and "b" measures
14.4 mm. The invention is not limited in the regard, however, as
angles other than 67.5 degrees may be used, which would alter the
dimensions of "a" and "b." In the case where the angle of the
pellet is 90 degrees, "a" and "b" would be equal.
[0073] In the dome-crowned embodiments of the invention, the
convexity need not be hemispherical or symmetrical about an axis.
FIG. 13C depicts a crown that is partially elliptical, whereas FIG.
13D shows a crown that is half-elliptic, both allowing for a
circular cross section (A-A). As with the other embodiments of this
invention, the dome-crowned pellets may be square-packed, as shown
in FIG. 14A, or hexagonally close-packed as shown in FIG. 14B.
[0074] Once packed, the pellets are embedded in epoxy or other
matrix material, with or without netting. The packed pellets may be
made into tiles, with or without back plates through a flexible
support structure. The multi-layer structure of FIG. 12 may also be
used with the dome-crowned pellets, in which case the outer-facing
array of pellets would include the domed surfaces, whereas the
inner array would have pellets with flat, parallel surface. The
angle of the inner array and that of the outer array need not be
the same.
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