U.S. patent application number 12/760413 was filed with the patent office on 2011-07-14 for armor assembly including multiple armor plates.
Invention is credited to Young-Hwa Kim.
Application Number | 20110168003 12/760413 |
Document ID | / |
Family ID | 42982844 |
Filed Date | 2011-07-14 |
United States Patent
Application |
20110168003 |
Kind Code |
A1 |
Kim; Young-Hwa |
July 14, 2011 |
ARMOR ASSEMBLY INCLUDING MULTIPLE ARMOR PLATES
Abstract
In some example, the disclosure provides armor assembly designs
utilizing multiple solid armor plates and one or more coupling
elements, such as, e.g., high-strength ropes, to couple the solid
armor plates to each other. For example, the solid armor plates may
be attached to one another and held in position via high-strength
ropes for form a discontinuous armor layer. The armor assemblies
may include multiple layer arrangements of the solid armor plates
that provide substantially complete coverage of a surface when the
multiple discontinuous layers are combined. Ropes or other coupling
elements may be used to horizontally connect plates together within
the same discontinuous layer of armor plates and ropes may also be
used to vertically connect plates in different armor layers. In
some example, the armor assembly may be highly flexible and
breathable to provide body armor that may be comfortably worn. In
some examples, armor assemblies may be adapted for use as vehicle
armor or other armor applications.
Inventors: |
Kim; Young-Hwa; (Hudson,
WI) |
Family ID: |
42982844 |
Appl. No.: |
12/760413 |
Filed: |
April 14, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61212657 |
Apr 14, 2009 |
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61214103 |
Apr 20, 2009 |
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61216100 |
May 13, 2009 |
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Current U.S.
Class: |
89/36.02 ;
89/903; 89/904; 89/906; 89/907; 89/908; 89/910 |
Current CPC
Class: |
F41H 1/02 20130101 |
Class at
Publication: |
89/36.02 ;
89/903; 89/904; 89/906; 89/908; 89/907; 89/910 |
International
Class: |
F41H 5/04 20060101
F41H005/04; F41H 5/02 20060101 F41H005/02 |
Claims
1. An armor assembly comprising: a plurality of armor plates; and
at least one coupling element that couples the plurality of armor
plates to each other, wherein the plurality of armor plates are
coupled to each other via the at least one coupling element at
discrete locations on each armor plate to form a discontinuous
armor layer.
2. The armor assembly of claim 1, wherein the plurality of plates
forming the discontinuous layer includes a first plurality of
plates forming a first discontinuous layer and a second plurality
of plates forming a second discontinuous layer overlaying at least
a portion of the first discontinuous layer.
3. The armor assembly of claim 2, wherein the first plurality of
plates define a first gap portion in the first discontinuous layer,
wherein the second plurality of plates forming the second
discontinuous layer overlays at least a portion of the first gap
portion.
4. The armor assembly of claim 2, wherein the plurality of plates
forming the discontinuous layer includes a third plurality of
plates forming a third discontinuous layer overlaying at least a
portion of the second discontinuous layer.
5. The armor assembly of claim 4, wherein the second plurality of
plates define a second gap portion in the second discontinuous
layer, wherein the third plurality of plates forming the third
discontinuous layer overlays at least a portion of the second gap
portion.
6. The armor assembly of claim 5, wherein the first, second, and
third discontinuous layers combine to form a continuous layer with
substantially no gaps extending through the continuous layer along
a substantially linear path.
7. The armor assembly of claim 2, wherein the first plurality of
plates of the first discontinuous layer and the second plurality of
plates of the second discontinuous layer are mechanically coupled
to each other via the at least one rope.
8. The armor assembly of claim 1, wherein the plurality of armor
plates comprising one or more of aramid, polyethylene, ceramic,
carbon nanotubes, or metallic alloy.
9. The armor assembly of claim 1, wherein the at least one coupling
element comprises one or more of aramid, polyethylene, nylon, or
metallic wire.
10. The armor assembly of claim 1, wherein each of the plurality of
armor plates includes at least one coupling aperture, wherein the
at least one rope extends through the at least one coupling
aperture of the plurality of plates to mechanically couple the
plurality of plates to each other.
11. The armor assembly of claim 1, wherein each of the plurality of
armor plates includes a plurality of coupling apertures dispersed
around a perimeter of the armor plate.
12. The armor assembly of claim 1, wherein the armor assembly may
substantially conform to a surface having a radius of curvature
greater than 30 mm.
13. The armor assembly of claim 1, wherein the plurality of armor
plates comprise a ceramic material and the at least one coupling
elements comprise polyethylene or aramid fiber ropes.
14. The armor assembly of claim 1, wherein the plurality of armor
plates comprise multiple layers, wherein respective layers include
unidirectional fibers held together in a binder.
15. The armor assembly of claim 14, wherein the unidirectional
fibers comprise polyethylene or aramid.
16. The armor assembly of claim 1, wherein a thickness the first
plurality of plates is between approximately 2 mm and approximately
30 mm.
17. The armor assembly of claim 1, wherein the armor assembly may
substantially conform to a surface having a radius of curvature
less than 300 mm.
18. An armor assembly comprising: a first discontinuous armor layer
including of a first plurality of armor plates; a second
discontinuous armor layer including of a second plurality of armor
plates; a third discontinuous layer armor including of a third
plurality of armor plates; and at least one coupling element that
couples the first, second, and third plurality of armor plates to
each other to form at least a portion of the armor assembly.
19. The armor assembly of claim 18, wherein the first, second, and
third plurality of armor plates are coupled to each other via the
at least one coupling element at discrete locations on respective
armor plates.
20. The armor assembly of claim 18, wherein the second
discontinuous layer is between the first and third discontinuous
layers.
21. The armor assembly of claim 18, wherein the second plurality of
armor plates covers less than about 60 percent of a total area
covered by the armor assembly and the third plurality of armor
plates covers less than about 40 percent of the total area covered
by the armor assembly.
22. The armor assembly of claim 18, wherein the second plurality of
plates covers gaps between the first plurality of plates, and the
third plurality of plates covers gaps extending through the first
and second plurality of plates.
23. The armor assembly of claim 18, wherein the first, second and
third discontinuous layers are adjacent to each other and are
positioned relative to each other such that no gap exists in the
armor layers defining a substantially linear path through all of
the discontinuous layers.
24. The armor assembly of claim 18, wherein at least one of the
first, second, and third plurality of armor plates forming the
first, second and third arrays of armor plates have a shape that is
non-identical from the other of the first, second, and third
plurality plates.
25. The armor assembly of claim 24, wherein the at least one
coupling element traverses substantially vertically through the
first and second discontinuous layers armor plates to connect the
first and second plurality of plates together, and wherein the at
least one coupling element traverses substantially vertically
through the second and third discontinuous layers of armor plates
to connect the second and third plurality of plates together.
26. The armor assembly of claim 18, wherein the first, second, and
third discontinuous armor layers define one or more continuous
pathways configured to allow air flow through the armor
assembly.
27. A method comprising coupling a plurality of armor plates to
each other via at least one coupling element, wherein the plurality
of armor plates are coupled to each other via the at least one
coupling element at discrete locations on each armor plate to form
a discontinuous armor layer.
28. The method of claim 27, wherein the plurality of armor plates
comprise a first, second, and third plurality of armor plates, and
the discontinuous armor layer comprises first, second, and third
discontinuous armor layers, wherein coupling the plurality of armor
plates to each other via at least one coupling element comprising
coupling the first, second, and third plurality of armor plates to
each other via the at least one coupling element to form the first,
second, and third discontinuous armor layers, and wherein the first
armor layer includes the first plurality of armor plates, the
second armor layer includes the second plurality of armor plates,
and the third armor layer includes the third plurality of armor
plates.
29. The method of claim 27, wherein first, second, and third
discontinuous layers combine to form a continuous layer with
substantially no gaps extending through the continuous layer along
a substantially linear path.
Description
[0001] This application also claims the benefit of U.S. Provisional
Application No. 61/212,657, filed Apr. 14, 2009. This application
also claims the benefit of U.S. Provisional Application No.
61/214,103, filed Apr. 20, 2009. This application also claims the
benefit of U.S. Provisional Application No. 61/216,100, filed May
13, 2009. The entire content of each of these provisional
applications is incorporated herein by reference.
TECHNICAL FIELD
[0002] The disclosure relates to protective materials that can be
used as body armor against ballistic threats or knife threats.
BACKGROUND
[0003] In some examples, flexible body armor designs utilize many
layers of fabric formed of high-tensile strength yarns. While such
materials can be effective at stopping hand gun rounds, the
flexible body armor may be uncomfortable to the wearer. Factors
contributing to discomfort to the wearer may include lack of
breathability, weight, and/or stiffness of the body armor.
SUMMARY
[0004] In general, the disclosure relates to armor assemblies
including a plurality of protective armor plates coupled to one
another by via ropes or other coupling elements. The protective
armor plates may be arranged adjacent to one another to form a
discontinuous armor layer. Armor plates adjacent to one another may
be directly coupled to one another via ropes or other coupling
elements throughout the assembly such that substantially all armor
plates in the assembly are coupled to all other plates either
directly or indirectly. A gap portion in the discontinuous layer
may be defined by adjacent neighboring plates. The discontinuous
layer formed plurality of coupled armor plates may provide an armor
assembly that provide protection against, for example,
firearm-fired projectiles, shrapnel from explosions, and/or
weapons-grade knives over the areas covered by armor plates and
while also provide a degree of flexibility and breathability via
the gaps between the armor plates.
[0005] In some examples, multiple discontinuous layers each formed
via a plurality of armor plates connected to each other via ropes
or other coupling elements are formed. Adjacent layers may overly
one another such that the armor plates of one layer cover at least
a portion of the gap portions of an adjacent layer. In this manner,
the multiple discontinuous layers may provide for increased
coverage area of armor plates relative to the gap areas in the
assembly while also providing flexibility and breathability for the
armor assembly. In one embodiment, a series of three or more
discontinuous layers each formed of a plurality of armor plates
coupled to each other via rope or other coupling element form an
armor assembly in which substantially no gaps extend through all
layers of the armor assembly along a substantially linear path,
thereby providing armor protection over substantially the entire
surface of the armor assembly while maintaining flexibility and/or
breathability of the armor assembly.
[0006] In one embodiment, the disclosure is directed to an armor
assembly comprising a plurality of armor plates; and at least one
coupling element that couples the plurality of armor plates to each
other, wherein the plurality of armor plates are coupled to each
other via the at least one coupling element at discrete locations
on each armor plate to form a discontinuous armor layer.
[0007] In another embodiment, the disclosure is directed to an
armor assembly comprising a first discontinuous armor layer
including of a first plurality of armor plates; a second
discontinuous armor layer including of a second plurality of armor
plates; a third discontinuous layer armor including of a third
plurality of armor plates; and at least one coupling element that
couples the first, second, and third plurality of armor plates to
each other to form at least a portion of the armor assembly.
[0008] In another embodiment, the disclosure is directed to a
method comprising coupling a plurality of armor plates to each
other via at least one coupling element, wherein the plurality of
armor plates are coupled to each other via the at least one
coupling element at discrete locations on each armor plate to form
a discontinuous armor layer.
[0009] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIGS. 1A and 1B are conceptual diagrams illustrating, from a
plan view, a portion of an example armor assembly including a
plurality of example armor plates connected to each other via
example coupling elements.
[0011] FIG. 2 is a conceptual diagram illustrating an example armor
plate from the assembly of FIGS. 1A and 1B.
[0012] FIG. 3 is a conceptual diagram illustrating two example
armor plates coupled to one another from a plan view.
[0013] FIG. 4 is a conceptual diagram illustrating a
cross-sectional view the assembly of FIG. 1A along line A-A.
[0014] FIG. 5 is a conceptual diagram illustrating, from a plan
view, an example assembly including example first and second
discontinuous layers each formed of example armor plates.
[0015] FIG. 6 is another conceptual diagram illustrating, from a
plan view, an example assembly including example first and second
discontinuous layers each formed of example armor plates.
[0016] FIG. 7 is a conceptual diagram illustrating an example
assembly including example first and second discontinuous layers
from a side view.
[0017] FIGS. 8A and 8B are conceptual diagrams illustrating an
example armor plate.
[0018] FIGS. 9A and 9B are conceptual diagrams illustrating another
example armor plate.
[0019] FIGS. 10A and 10B are conceptual diagrams illustrating an
example assembly including three example armor plates coupled to
each other.
[0020] FIG. 11 is a conceptual diagram illustrating another example
assembly including three example armor plates coupled to each
other.
[0021] FIGS. 12A and 12B are conceptual diagrams illustrating an
example armor plate.
[0022] FIG. 13 is a conceptual diagram illustrating an example
assembly including the example armor plate of FIGS. 12A and
12B.
[0023] FIG. 14 is a conceptual diagram illustrating air flow
through the example assembly of FIG. 13.
[0024] FIGS. 15A and 15B are conceptual diagrams illustrating an
example process for forming an example armor plate.
[0025] FIGS. 16 and 17 are conceptual diagrams illustrating example
armor plates.
[0026] FIGS. 18A-E are conceptual diagrams illustrating an example
armor plate from various viewpoints.
[0027] FIG. 19 is a conceptual diagram illustrating three example
armor plates coupled to each other.
[0028] FIGS. 20A-D are conceptual diagrams illustrating an example
armor plate from various viewpoints.
[0029] FIGS. 21A-D are conceptual diagrams illustrating an example
assembly including multiple example discontinuous layers formed of
example armor plates.
[0030] FIGS. 22A-C are conceptual diagrams illustrating another
example assembly including multiple example discontinuous layers
formed of example armor plates.
[0031] FIGS. 23A-C are conceptual diagrams illustrating another
example armor plate from various viewpoints.
[0032] FIGS. 24A and 24B are conceptual diagrams illustrating
another example armor plate.
[0033] FIG. 25 is a conceptual diagram illustrating an example
portion of an example armor assembly.
[0034] FIG. 26 is a conceptual diagram illustrating an example
portion of another example armor assembly.
[0035] FIG. 27 is a conceptual diagram illustrating an example
portion of another example armor assembly.
[0036] FIG. 28 is a conceptual diagram illustrating an example
portion of another example armor assembly.
[0037] FIGS. 29A-C are conceptual diagrams illustrating various
example discontinuous armor layers on an example portion of another
example armor assembly.
[0038] FIGS. 30A and 30B are conceptual diagrams illustrating
various example discontinuous armor layers on an example portion of
another example armor assembly.
[0039] FIG. 31 is a conceptual diagram illustrating an example
portion of example armor assemblies from a cross-sectional
view.
[0040] FIGS. 32-34 are conceptual diagrams of example isolated hole
covers.
[0041] FIGS. 35 and 36 are conceptual diagrams illustrating an
example portion of example armor assemblies from cross-sectional
views.
[0042] FIG. 37 is a conceptual diagram of an example isolated hole
cover.
[0043] FIG. 38 is a conceptual diagram of an example ring from the
example isolated hole cover of FIG. 37.
[0044] FIGS. 39A and 39B are conceptual diagrams illustrating the
example impact of a bullet at a portion of an example armor
assembly.
[0045] FIGS. 40A and 40B are conceptual diagrams illustrating the
example impact of a bullet at a portion of another example armor
assembly.
DETAILED DESCRIPTION
[0046] In general, the disclosure relates to armor assemblies
including a plurality of protective armor plates coupled to one
another by ropes or other coupling elements. The protective armor
plates may be arranged adjacent to one another and along
substantially the same plane to form a discontinuous armor layer.
Armor plates adjacent to one another may be directly coupled to one
another via ropes or other coupling elements throughout the
assembly such that substantially all armor plates in the assembly
are coupled to all other plates either directly or indirectly. A
gap extending through the discontinuous layer may be defined by
adjacent neighboring plates. As will be described further below,
the discontinuous layer formed of a plurality of coupled armor
plates may provide an armor assembly that provide protection
against, for example, projectiles from firearms, shrapnel from
explosions, and/or weapons-grade knives over the areas covered by
armor plates and while also providing a degree of flexibility and
breathability via the gaps between the armor plates.
[0047] In some examples, multiple discontinuous layers each formed
via a plurality of armor plates connected to each other via ropes
or other coupling elements are formed. The ropes or other coupling
elements may attach adjacent plates in the same layer and/or
adjacent plates in adjacent layers. Adjacent layers may overly one
another such that the armor plates of one layer cover at least a
portion of the gap portions of the neighboring layer. In this
manner, the multiple discontinuous layers may provide for increased
coverage area of armor plates relative to the gap areas in the
assembly while also providing flexibility and breathability for the
armor assembly.
[0048] In one embodiment, a series of three or more discontinuous
layers each formed of a plurality of armor plates coupled to each
other via rope or other coupling element form an armor assembly in
which substantially no gaps extend through all layers of the armor
assembly along a substantially linear path, thereby providing armor
protection over substantially the entire surface of the armor
assembly. Such an armor assembly may maintain a desired degree of
flexibility and/or breathability, e.g., as compared to a single,
relatively inflexible large armor plate having approximately the
same size of the armor assembly and/or a body armor article formed
of multiple layers of woven fabric.
[0049] Some multiple layer woven fabric-based body armor assemblies
stop bullet penetration by arresting or capturing the bullet with
yarns directly in front of the bullet at the site of impact. The
energy required to straighten these strands of fabric and to
displace them from the plane of the fabric acts to dissipate the
energy of the bullet. Woven fabric based-assemblies also spread the
incoming energy to strands of fabric in the layers below the
impacted surface. Upon impact, the bullet is also plastically
deformed by the fabric resistance, helping to distribute the force
over a larger area and engaging more strands of fabric in the lower
layers. However, due to the relatively high density of the woven
fabric, such body armor may provide only a minimal amount of
breathability through the fabric.
[0050] Conversely, example armor assemblies such as those described
in this disclosure may include solid armor plates having an area
larger than the bullet cross section at impact for the dissipation
of the bullet's energy. At the same time, the ropes or other
coupling elements connecting the armor plates provide a mechanism
for beneficially spreading the incoming energy over a larger area,
which may ultimately reduce the pressure applied on the inner
surface of the protective armor structure to a sub-lethal
level.
[0051] For sharp objects, such as knifes and ice picks, multiple
layer woven fabric-based body armor tends to perform poorly because
the point of the sharp object "slips" between the strands of the
fabric such that the woven fabric based-body armor does not supply
adequate resistance to stop the penetration of the sharp object.
Unlike that of woven fabric material, the solid armor plates of an
armor assembly may prevent the penetration of the point and may
also engage the resistance of the neighboring plates via the
connecting ropes. The armor plate material can be selected such
that the armor assembly provides protection against bullets,
shrapnel, and/or knife threats.
[0052] In some example armor assemblies of this disclosure, because
there are gaps between the solid armor plates which are coupled
together via ropes or other coupling elements, there is a
relatively large volume of empty space in the assembly structure
corresponding to the gaps between adjacent guard plates. This gap
space may provide increased breathability and allow for bulk
air-flow through the armor assembly as well as also allow moisture
to travel through armor assembly. In addition to providing suitable
breathability, the armor assembly may be flexible and supple
because the solid, discrete plates may be coupled together via a
flexible coupling element, such as, a flexible rope. In contrast
with multi-layer woven fabric-based body armor, some embodiments of
the armor assemblies described in this disclosure effectively
separate the functions of penetration resistance via protective
plates and the spreading of the impact energy to the neighboring
structure via the coupling elements used to couple the armor plates
together. Therefore, the embodiments of the body armor assembly can
be made lighter than some multilayer woven fabric-based armor body
armors. In some embodiments, armor assemblies of the disclosure are
more comfortable to wear compared to that of multiple layer woven
fabric-based body armor assemblies since embodiment of armor
assemblies described herein may be more flexible, lighter in weight
and configured to provide for a suitable level of air flow through
the assembly.
[0053] FIGS. 1A and 1B are conceptual diagrams illustrating, from a
plan view, a portion of example armor assembly 10 including a
plurality of example armor plates 12a-12i (collectively referred to
as armor plates 12) coupled to each other via coupling element 14.
FIG. 1B illustrates a magnified view of plates 12a, 12b, 12d, and
12e. For ease of illustration, only coupling elements 14 used to
directly connect adjacent edges of plates 12a, 12b, 12d, and 12e
are shown in FIG. 1B.
[0054] Armor assembly 10 may provide protection against, e.g.,
projectiles from firearms, shrapnel from explosions, and/or
weapons-grade knives. In some examples, such an assembly may be
worn adjacent to portions of the body of a person to function as
body armor. In other examples, assembly 10 can also be designed for
use as vehicle armor that protects against, for example, improvised
explosive devices. However, other uses for assembly 10 are
contemplated, especially uses in which assembly 10 is utilized to
provide protection from ballistic threats.
[0055] As shown in FIGS. 1A and 1B, armor plates 12 are arranged
and coupled to one another via coupling element 14 in assembly 10
to form a discontinuous layer of armor material. Adjacent edges of
neighboring plates 12 define gap region 18 which forms a void space
that extends through the discontinuous layer formed by plates 12
and coupling element 14. In this manner, armor plates 12 and
coupling element 14 may be characterized as forming a discontinuous
armor layer having discrete armor plates rather than a continuous
armor layer without any gaps or other breaks in the armor layer.
The configuration of plates 12 as a discontinuous armor layer
allows for assembly 10 to exhibit greater flexibility than an armor
assembly including only a single armor plate formed of a continuous
armor layer even in cases in which the composition of the armor
plates for each assembly is substantially the same.
[0056] Coupling element 14 mechanically couples adjacent plates 12
to one another at discrete locations on the perimeter of plates 12.
All plates 12 in assembly are connected or attached to one another
via coupling element 14, whether it be directly (e.g., in the case
of two individual plates that are directly adjacent to one another)
or indirectly (e.g., in the case of two individual plates that are
separated by one or more intervening plates). Coupling element 14
in assembly 10 may be a single continuous coupling element or a
plurality of individual coupling elements. In one example, coupling
element 14 may include one or more ropes that attached adjacent
plates 12 in assembly 10 to one another. As will be described
further below, coupling elements 14 may additionally or
alternatively connect one or more of plates 12 to armor plate(s)
from one or more adjacent discontinuous armor layers overlying the
discontinuous layer formed by plates 12. In this manner, coupling
element 14 may connect two or more armor plates 12 within the same
discontinuous armor layer (referred to at some points herein as
horizontal attachment) and/or to connect one or more armor plates
12 to one or more armor plates in one or more adjacent
discontinuous armor layers (referred to herein at some points as
vertical attachment).
[0057] Coupling element 14 may allow for some degree of movement of
plates 12 relative to another while still providing for attachment
to one another. In such a configuration, in the case of a ballistic
impact, one or more individual plates 12 may act to arrest an
immediate penetration of the impacting object (e.g., a firearm
fired bullet), and the impact force may be quickly spread to a much
larger area via the composite assembly of coupling elements 14 and
plates 12 allowing the non-destructive dissipation of the initial
energy. Because the coupling elements 14 allow plates 12 to move
relative to each other, assembly 10 may be flexible compared to a
single continuous armor layer formed of substantially the same
material as plates 12. Further, the spacing between plates 12,
armor assembly 10 allows for the bulk flow of air through assembly
10 (e.g., from the bottom surface to the top surface). As such, in
some embodiments, assembly 10 may be a relatively flexible,
breathable armor that is comfortable to wear.
[0058] Unlike that of an arrangement in which multiple armor plates
are attached to the surface of the same woven fabric substrate to
be fixed relative to each other, coupling element 14 attaches to
each of plates 12a-i at discrete locations dispersed about the
perimeter of each plate rather than forming a continuous fabric
layer that spans across gaps 18 separating plates at substantially
all locations along the perimeter of adjacent plates. In this
manner, air flow through gaps 18 is not impeded by the coupling
elements, or at least not impeded to the degree that would present
with a continuous woven fabric substrate.
[0059] In the examples of FIGS. 1A, 1B, 2, and 3, each individual
plates 12 includes a plurality of apertures 16 (only a single
aperture is labeled in FIGS. 1A, 1B, 2, and 3) extending through
the thickness of plate from the top surface to the bottom surface.
To directly connect two or more plates to one another, coupling
element 14 may be extended through at least one aperture 16 of each
individual armor plates 12 and may then secured (e.g., tied or
otherwise anchored) within the respective apertures 16. To increase
the strength of the attachment between plates 12 in assembly 10,
the number of apertures may be increased to increase number of
distinct points on the perimeter of each plates engaged with
coupling element 14. In FIG. 1B coupling element 14 diagonally
couples all four corners of plates 12a-d.
[0060] As shown in FIGS. 1A, 1B, 2, and 3, each armor plate 12 may
include a plurality of apertures 16 dispersed around the perimeter
of each plate on substantially all sides. Coupling element 14 may
be extended through one or more of apertures from each plate to
attach plates 12 together. Coupling element 14 may extend only
through a single aperture for two plates to form a loop that secure
the two plates at the discrete locations of the respective
apertures. In some examples, coupling element 14 may spiral or
otherwise extend through a plurality of apertures in each of
multiple individual plates to connect plates 12 to each other.
Apertures 16 may be aligned in a row maintaining a substantially
uniform distance from the edge of plates 12. In FIG. 3, plates 12a
and 12b include a plurality of apertures at varying distances from
the edge of plates 12a, 12b to form multiple rows of apertures.
[0061] In one embodiment, two-dimensionally arrayed armor plates
are tied together using stranded fibers by looping the fibers
through holes in the plates. As described below, coupling element
14 may be wire, string, yarn, rope or other elongated,
substantially one-dimensional structure. In one embodiment,
braided-strand ropes are used. The ropes can extend across the
width of the plate in a spiral from one hole to the next and one or
many ropes can be used in each hole. By spiraling from hole to
hole, a single rope can be used to connect multiple pairs of plates
together. Alternatively, a single rope can tie a single pair of
plates together with multiple passes through each hole. The number
of ropes and the thickness of the ropes can be adjusted to give the
optimal performance on a per weight basis.
[0062] Other techniques for connecting plates 12 to one another via
coupling elements 14 are contemplated. For example, coupling
elements 14, such as ropes, may be embedded into two more of plates
12 at discrete locations about the perimeter of two or more
adjacent plates to attach the plates together. In other examples,
ropes (or other coupling elements) may be threaded through one or
more apertures extending through the length of the plate (e.g., a
direction substantially orthogonal to the major surface of plates
12) with knots or other obstructions in the ropes to restrict to
the movement of the individual armor plates along the length of
rope. In some examples, plates 12 may be adhered to a rope net that
acts to attach plates 12a-i to each other.
[0063] FIG. 2 is a conceptual diagram illustrating example armor
plate 12e from the assembly of FIGS. 1A and 1B. As shown FIG. 2,
armor plate 12e includes eighteen individual apertures 16 evenly
dispersed about the perimeter of plate 12e. Each aperture 16
extends through armor plate 12e from the top surface to the bottom
surface, and coupling element 14 extends through aperture 16 as
well as another aperture in a neighboring plate (not shown in FIG.
2) of assembly 10 to connect armor plate 12e to at least one other
armor plate of assembly 10.
[0064] Solid armor plate 12e can be made from any high strength
hard or reasonably hard material. Hard ceramics such as boron
carbide or other lightweight ceramics may be used. Less hard, but
still rigid, composite materials can also be used. Advanced
composites comprising carbon nanotubes, other nano-particles or
micro-particles could also be used for the plate material. Layers
of polyethylene (e.g. Dyneema.RTM. or Spectra.RTM.) or aramid (e.g.
Kevlar.RTM.) can be hardened through the choice of binder used to
hold the layers together and these hardened layers can form the
plate material. In one embodiment Dyneema.RTM. HB50, which
comprises multiple layers of unidirectional polyethylene yarns held
together with a binder, is used as the plate material. In other
examples, multiple layers of unidirectional aramid fibers may be
held together with a binder to form plates 12.
[0065] Suitable binder materials may include polymer resin
materials that provide for a suitable resin matrix. In some
examples, the binder resin matrix should transfer the stress load
maximally to stronger ultra high molecular weight polyethylene
(UHMWPE) fibers. The overall bond at the fiber-matrix interface is
an aggregate of any chemical bonds formed, dipole-attraction bonds
such as van der Waals and hydrogen bonding, and mechanical bonds
such as interlocking. As the composite material bends after the
time of impact, the primary stress the material experiences are
tensional (i.e. stretching), except for the localized area in the
immediate vicinity of the impact point, which primarily experience
compression forces. In order to transfer the maximum amount of
stress load from the weaker matrix to the stronger fiber, the
integrity of the overall fiber-binder matrix bond has to be
maintained as long as possible while both materials are being
stretched and deformed under tension.
[0066] If both materials experience the same level of strain
displacement while they are stretched and deformed under tension,
the much higher Young's modulus of the fibers means that it will
bear the higher percentage of stress load, thus achieving the
intended goal of transferring as much load as possible from the
weaker matrix to the stronger fibers. Therefore it is desirable for
the matrix material's elongation at break to be higher than the
fiber, to ensure that the matrix is able to survive the same degree
of strain as the fiber before it fractures. In addition, the
Young's modulus of the matrix should also be considerably lower
than the fiber. The very high loading rate of a high-velocity
bullet also may cause materials to behave more glass-like than they
would under normal static load or low-velocity impact conditions.
Thus, a polymer for the matrix may be sufficiently ductile and soft
rather than stiff and brittle in order to avoid fracturing.
[0067] Example binder materials may include thermoplastics, such
as, e.g., polyester, polyamides (i.e. nylon), polyvinyls,
polyolefins, and polyurethane, elastomeric block copolymers such as
polyisoprene-polyethylene-butylene-polystyrene block copolymers or
polytyrene-polyisoprene-polystyrene block copolymers, and/or
thermosets, such as, e.g., toughened or ductile epoxies or
phenolics, unsaturated polyesters, and vinyl esters.
[0068] Metallic alloys are another category of material that can be
used in constructing the solid plates. In some examples, the metal
alloy may exhibit at least greater than 40% elongation at break. If
the elongation at break is appreciably lower than this, the metal
does not have enough ductility to plastically deform to a large
degree, the main method of energy dissipation, without fracturing.
Example metal alloys may include 302 stainless steel, 304 stainless
steel, Gall-Tough.RTM. toughened stainless steel, Haynes.RTM. 25
and 188 metal alloys, Allvac.RTM. nickel superalloys, and/or
Beryllium copper alloys.
[0069] In choosing materials for the plate material of body armor,
materials having a relatively high degree high degree of toughness
per weight may be preferred. The toughness of a material is
associated with the amount of energy that a material can absorb
before fracturing. Toughness can be measured as the area under a
material's stress-strain curve. Toughness can also depend on the
rate of change of the applied stress. Thus, the rate of change of
the energy applied by the threat may also an important
consideration when designing an armor system and selecting material
for forming armor plates and/or coupling elements.
[0070] The choice of materials for the various armor plates
described in this disclosure, such as, e.g., plates 12 and armor
plates forming other discontinuous layers of one or more armor
assemblies described herein, may be determined by the threat that
the armor assembly is desired to protect against. For example, for
knife stab body armors, the material chosen can exceed a certain
minimum hardness threshold--if the material is too soft, the
hardened steel knife blade penetrates too deeply, e.g., to pass the
NIJ Stab Body Armor requirements. On a per weight basis, nylon 6/6,
ballistic grade polycarbonate (Lexan.RTM.), nylon 6/6 reinforced
with S-fiberglass and Garolite can be effective for such
protection. For ballistic body armors designed to protect up to NIJ
Level IIIA, plates made from laminations of UHMWPE and/or aramid
fibers can be effective. Because the tips of bullets specified for
NIJ Level IIIA and below are composed of softer metals such as lead
or copper alloys that deform relatively easily, the low hardness of
UHMWPE and aramid materials does not hinder their performance in
stopping these projectiles. However for NIJ Level III bullets that
employ a significantly harder steel tip, or NIJ Level IV
armor-piercing bullets that can employ very hard, high-density
metal tips such as tungsten carbide or depleted uranium, the
hardness of the plate material plays a much larger role and softer
UHMWPE and aramid materials may be less effective as such materials
may be selected for NIJ Level IIIA and below applications.
[0071] In some examples, for cases such as NIJ Ballistics Level
III, IV as described above, or NIJ Stab Body Armor, where the
hardness of the plate material plays an important role, ceramic
materials can be effective. The function of these ceramic plates is
to maximally deform and blunt the harder metal bullet tips of NIJ
Level III or IV, or the sharp, hardened steel tip of the NIJ Stab
Body Armor P & S-Class test knife blades, in order to minimize
the penetration depth into the supporting material layer (i.e.
polymers and/or metals) underneath the outer ceramic layer. For
high speed shrapnel or rifles at NIJ Level IV, plates composed of
very hard ceramics such as boron carbide or silicon carbide, or
ceramic plates combined with UHMWPE or aramid laminations can be
effective. For the coupling element material, which will be
described further below, UHMWPE and aramid fibers provide very high
tensile strengths, e.g., between about 3000 and about 3500 MPa
(10.sup.6 Pascals). The aramids offer superior high temperature
performance but may be susceptible to degradation from UV exposure
and water damage. The UHMWPE have good UV and water resistance but
may lose tensile strength at temperatures above 70.degree. C.
[0072] In an embodiment that may be capable of stopping handgun
rounds up to NIJ Level IIIA, Dyneema.RTM. HB50 plates may be used.
In an embodiment for stopping knife stab threats, relatively thin
ceramic plates may be used. In an embodiment for stopping NIJ Level
III and Level IV rifle rounds relatively thick ceramic plates may
be used. Combinations of these materials can also be used. Other
materials for armor plates 12 are contemplated.
[0073] In one embodiment, the size of each individual plate 12 is
between about 1 inch and about 4 inches measured across the top
surface at the maximum dimension of the plate. The actual size of
the solid pate can be selected based on the curvature of the area
the armor is intended to protect, e.g., greater curvature may
require small armor plates to provide for increased flexible of the
assembly. In some embodiments, individual plate size can be less
than about 1 inch and in other embodiments it can be greater than
about 4 inches. In an embodiment where the armor may be used for
the protection of a vehicle, the size of the individual solid armor
plates may be between about 3 inches and about 12 inches. In other
embodiments, the plate size may be greater than about 12
inches.
[0074] Within an assembly of armor plates, each plate may have
substantially the same size as each other. Alternatively, the size
of individual plates as well as plate thickness may vary at
different portions of armor assembly 10. Similarly, the pattern
arrangement and shape of plates 12 may also vary within an armor
assembly. In general, the shape of an armor plate refers to the
2-dimensional shape of the armor plate from a plan view
substantially orthogonal to the top or bottom surface of the armor
plate. For example, in the portion of assembly 10 shown in FIGS. 1A
and 1B, armor plates 12 have a square shape and are arranged in a
3.times.3 grid. In other examples, armor plates 12 may exhibit two
or more shapes and may be arranged in one or more patterns within
assembly 10.
[0075] In some examples, depending on the material of armor plates,
a relatively small gap may be present between adjacent plates. For
example, when using Dyneema HB50 for armor plates, very little gap
space may be needed for the overall armor assembly to have
sufficient flexibility to conform to the curvature of a person's
chest/torso region. Therefore, in such an example, the pattern of
the armor plates within such an armor assembly may not as
significant compared to assemblies including armor plates made of
different materials. Because the Dyneema HB50 material is soft and
easily deformable, there is a good degree of freedom in the overall
assembly's flexural, torsional and shear movements even when
adjacent plates are touching in their resting positions.
[0076] In some examples, for stiff, rigid armor materials such as
metal, any pattern may be selected so long as long the radius of
curvature of the overall armor assembly is small enough to conform
to a desired surface, e.g., to a person's chest/torso region. The
radius of curvature may refer to the curvature of the armor
assembly in a "lock up" position of the overall assembly, i.e. when
the armor plates no longer are free to move because the plates have
been bent and extended as far as the coupling elements and
interference between neighboring plates allow.
[0077] Design factors such as plate size, shape, thickness, and
pattern may be selected for various portions to provide varying
properties for different portions of armor assembly 10. For
examples, such factors may be selected to provide for first portion
of assembly 10 that is more flexible than a second portion of
assembly 10. Similarly, such factors may be selected to provide for
varying degrees of breathability as well as protection from
ballistic threats throughout armor assembly 10. In the case of
assembly 10 configured for use as body armor, portions of assembly
10 may be designed to be more flexible at portions corresponding to
curved body features and less flexible for portions corresponding
to portions of a body having a relatively flat surface. The level
of protection provided by assembly 10 may be increased for portions
designed to protect more vital portion of a body compared to that
of less vital portions of a body.
[0078] Coupling element 14 may be formed of any suitable material
having the strength to couple plates 12 of assembly 10 to one
another as well as transfer force from a localized impact
throughout armor assembly 14. Coupling element 14 may be relatively
flexible to allow plates 12 to move relative to one another. For
ease of description, in some cases, coupling element 14 may be
referred to as rope 14. However, other suitable materials and/or
structures are contemplated for coupling element 14. Suitable
material may include fibers strands, yarns and ropes. In some
example, coupling element 14 may include one or more ropes, such
as, e.g., braided-strand ropes. It has been found that some ropes
are effective in transmitting the initial stress from an impact to
the surrounding structure. The ropes can be constructed from any
types of fibers, such as those used for fisherman's nets or ropes
used for parachutes or for mountain climbing. In some embodiments,
aramid, or high molecular weight polyethylene, such as Dyneema.RTM.
or Spectra.RTM., may be utilized for the rope material. Other
embodiments use nylon or blends of nylon, polyethylene and/or
aramid. Combinations of any conventional or new rope materials can
be used. The ropes can comprise braided yarns or other fiber
structures. In one preferred embodiment, ropes having a braided
helical structure are used. Ropes with braided helical structures
may have the ability to deform and absorb energy more so than
simple yarns or wires due at least in part to the braided
structure.
[0079] Alternatively or additionally, coupling element 14 may be
formed of one or more wire strands. Similar to that described for
the material used to form armor plates, example metals may exhibit
sufficient elongation at break and ductility in order to avoid
fracturing/rupturing. The same example metals listed above for
metal alloy armor plates may also be used as example metal alloy
materials for coupling elements. As above, metallic alloy wire may
exhibit a braided helical structures. In some examples,
Dyneema/Spectra/Kevlar may be preferred over metal ropes/wires
because of strength-to-weight advantage of the non-metallic
materials, as examples metal alloys may significantly add to the
overall weight relative to some non-metallic options. In some
example, armor plates and coupling elements may be composed of
identical or substantially similar materials rather than dissimilar
materials to avoid potential problems caused by mismatches in
mechanical impedance and modulus.
[0080] FIG. 3 is a conceptual diagram illustrating two example
armor plates 12a and 12b of an armor assembly that are coupled to
one another via example coupling elements 14 from a plan view. For
ease of illustration, coupling elements 14 are shown only for the
two adjacent edges of plates 12a, 12b. Armor plates 12a, 12b may be
substantially the same or similar to that of plates 12a-i shown in
FIG. 1A. A plurality of apertures 14 extending through armor plates
are dispersed at discrete locations about the perimeter of plates
12a, 12b. However, unlike that of plates 12a-i shown in FIGS. 1A
and B, apertures 16 are located adjacent the edge of plates 12a and
12b at varying distances to form two separate rows of apertures 16.
Such a configuration may be provide for additional connections
between armor plates 12a, 12b via coupling element 14 to increase
the overall connection strength between plate 12a and plate 12b. In
other examples, apertures may be aligned in a single row around the
perimeter, e.g., as shown in FIG. 1A, or may include more than two
rows, e.g., three rows, of apertures dispersed around the perimeter
of individual armor plates in assembly 10.
[0081] FIG. 4 is a conceptual diagram illustrating a
cross-sectional view the assembly of FIG. 1A along line A-A. As
shown, armor plates 12g-i are coupled to each other via ropes 14
which extend through apertures formed in each plate. The top and
bottom surface of each of plates 12g-i are arranged along
substantially the same plane and plates 12g-i form a discontinuous
layer of armor material when assembly 10 is laid flat. However, the
plane of the discontinuous layer may vary, e.g., when assembly 10
bent around curved surface, as a result of flexibility of assembly
10 on a global level (e.g. multi-plate perspective). In some
examples, even if individual plates 12 of assembly 10 are
relatively rigid plates, the arrangement of plates 12 and ropes 14
in assembly 10 over a portion that includes multiple plates may
allow armor assembly 10 to bend such that assembly 10 roughly
follows the contour of a curved surface. For examples, in some
embodiments, assembly 10, as well as other example armor assemblies
described herein, may be configured such that at least a portion of
armor assembly 10 may substantially conform to a flat surface as
well as bend to substantially conform to a curved surface. As
described above, the flexibility of an armor assembly may be
described in terms of radius of curvature for the armor assembly at
"lock-up." Such radius of curvature generally refer the radius of
curvature when the armor plates of an armor assembly are no longer
are free to move because the plates have been bent and extended as
far as the coupling elements and interference between neighboring
plates allow. At such a point, the armor assembly cannot be bent
further due to the configuration of the armor plates, gaps, and
coupling elements, for example, without plastically deforming or
otherwise permanently deforming the armor assembly. For example,
for ceramic-based armor plates, after such a point, one or more
ceramic plates may fracture. As another example, for metal-based
armor plates, after such a point, one or more metal plates may be
permanently deformed. Additionally or alternatively, the coupling
elements of an armor assembly may permanently yield, e.g., ropes
may become permanently stretched. In some examples, assembly 10, as
well as other example armor assemblies of this disclosure, may
exhibit a radius of curvature less than approximately 300 mm, such
as, for example, a radius of curvature between approximately 100 mm
and approximately 200 mm. In some examples, the radius of curvature
may be less than approximately 30 mm. Moreover, in some examples,
assembly 10, as well as other example armor assemblies of this
disclosure, may have some maximum curvature, e.g., due to minimum
effective plate size, maximum gap distance between plates, and/or
other factors, which can be expressed in terms of a minimum radius
of curvature. For example, in some cases, for assembly 10, as well
as other example armor assemblies of this disclosure, the radius of
curvature may be greater than approximately 30 mm, such as, e.g.,
greater than approximately 100 mm. In some examples, an armor
assembly may also be able to conform to a substantially flat
surface as well conform to a curved surface consistent with the
example radius of curvature values described above. Alternatively,
an example armor assembly may be configured to have a maximum
radius of curvature in which case the armor assembly may not be
laid flat but may still be bent to a smaller radius of curvature
values.
[0082] In FIG. 4, armor plates 12g-i are shown as having
substantially the same thickness as one another. In some examples,
plates 12g-i may have a thickness between about 2 mm to about 30
mm, such as, e.g., about 2 mm to about 15 mm or about 4 mm to about
10 mm. In some examples, plates 12g-i have a thickness of at least
6 mm. Such example thicknesses may be applicable for a variety of
armor plate compositions, including, e.g., HB50 Dyneema. Different
thickness may be selected based on the composition of the armor
plates and may be varied based on the level of protection desired
to be provided by armor assembly 10. Plate thicknesses other than
those described are contemplated. Such example thicknesses may be
applicable for one or more of the plates described in this
disclosure.
[0083] As shown in FIG. 4, each of armor plates 12g-i is formed of
a single layer, which may be formed of one or more of the materials
described above. In other example, each of armor plates 12g-i may
be multiple layer structures. The thickness and composition of the
layers of each armor plate may be selected to provide desired
properties. Each of armor plates 12g-i may be formed of multiple
layers having substantially the same composition. In other
examples, plates 12g-i may be formed of multiple layers, where at
least two layers have different compositions. In one embodiment,
armor plates with a multiple layer structures may include an armor
material base layer coated with a different material optimized for
sound dampening characteristics to minimize sound when the plates
hit and rub against each other. In another example, a multiple
layer armor plate may include a Dyneema plate with a ceramic layer
on top since the hard ceramic may effectively blunt a bullet or
other projective before it engages the Dyneema layer. Another
example multiple layer armor plate may include a metal plate with a
ceramic layer on top. In some example, an intermediate layer can
also be used in cases where there is a mechanical impedance
mismatch between two dissimilar layers. Bridging the difference in
mechanical impedance values will improve the energy transmission
from the layer that is first impacted by the bullet to layers
underneath
[0084] The edges of adjacent plates 12g-i define gaps 18. Gaps 18
between neighboring armor plates 12 (e.g., plates 12h and 12i in
FIG. 4) may extend from the top surface to the bottom surface of
the discontinuous layer formed via armor plates 12 in armor
assembly 10. In some examples, gaps 18 may extend through the
discontinuous layer formed via plates 12 along a substantially
linear path. Increasing the distance between neighboring armor
plates 12 may increase the size of gap 18. In some examples, gaps
18 may have a width (i.e., the distance between the edges of
adjacent plates defining the gap) between approximately 2 mm to
approximately 10 mm, such as, e.g., approximately 5 mm to
approximately 7 mm. Gaps width may be substantially uniform
throughout armor assembly 10 or may vary from plate to plates or
region to region, e.g., due to different pattern and/or plate shape
in armor assembly 10). In some examples, the average width of gaps
18 over one or more regions of armor assembly 10 may be expressed
as gap density calculated as the overall gap surface area for a
particular portion of assembly 10 divided by the overall area of
the assembly 10 in that portion (i.e., plate surface area plus gap
surface area). In some examples, the gap density of assembly 10 may
range from approximately 5% to approximately 30% such as, e.g.,
approximately 10% to approximately 20%.
[0085] The gap density of assembly 10 may be selected based on the
overall level of protection, breathability, and/or flexibility
desired for an armor assembly. For example, as the gap density of
assembly 10 is increased, the overall flexibility and/or
breathability of armor assembly 10 may also be increased. However,
while increasing the overall density of gaps 18 (i.e., gap space
within the overall area of assembly 10) may increase the
flexibility and/or breathability of armor assembly, the increase in
the gap area in assembly 10 may also decrease the relative level of
protection provided by assembly 10. In general, gaps 18 between
neighboring plates 12 in assembly 10 represent weak portions within
the assembly that may be susceptible to ballistic threats or knife
threats. Accordingly, in some examples, it may be desirable to
minimize the gap space of a plate while maintaining at a minimum
threshold level of breathability and/or flexibility. However, for a
single discontinuous armor layer, such as that shown in FIG. 1A,
gaps may be present to at least some extent between individual
armor plates 12 in the discontinuous armor layer of armor assembly
10 to provide flexibility and/or breathability.
[0086] In accordance with some example of the disclosure, an armor
assembly may include multiple discontinuous layers of armor layers,
such as, e.g., the discontinuous armor layer formed of plates 12
and coupling elements 14 in FIG. 1A, overlaying one another.
Adjacent discontinuous armor layers may be arranged relative to
each other such that at least a portion of the gaps in one
discontinuous armor layer are covered by armor plates of the second
discontinuous layer. In this manner, the multilayer armor assembly
may provide for increased protection by covering gaps in an
individual layer with armor plates from another armor layer while
also allowing for the flexibility and breathability imparted by
each of the armor layers including gaps between adjacent armor
plates.
[0087] FIG. 5 is a conceptual diagram illustrating, from a plan
view, a portion of example armor assembly 24 including example
first and second discontinuous armor layers. The first and second
discontinuous armor layers are formed of first armor plates 12a-1
(referred to collectively as plates 12) and second armor plates
22a-i (referred to collectively second armor plates 22),
respectively. For ease of illustration, the coupling elements
(e.g., ropes) used to connect armor plates within the same armor
layer and/or armor plates from different armor layers are not shown
in FIG. 5. However, the coupling elements used to connect first
armor plates 12 and second armor plate 22 of the first and second
discontinuous armor layers, respectively, may be substantially the
same or similar to that described above for coupling element 14
shown, for example, in FIGS. 1A and 1B. Coupling elements may
connect plates of assembly 24 in the horizontal and/or vertical
directions.
[0088] The first discontinuous armor layer (bottom layer as
illustrated in FIG. 5) formed via first armor plates 12 may be the
same or substantially similar to that of similarly number plates 12
of assembly 10. Adjacent plates 12 are separated by gaps 18 which
extend through the first discontinuous armor layer formed by plates
12. In a similar fashion, the second discontinuous armor layer (top
layer as illustrated in FIG. 5) is formed via second armor plates
22, and adjacent plates 22 are separated by gaps 18 which extend
through the second discontinuous layer formed by plates 22. Second
plates 22 may be substantially the same or similar to that of
plates 12 described above, e.g., in terms of plate composition
dimensions and the like. Similarly, the second discontinuous layer
may be formed via second plates 22 in a manner substantially the
same or similar to that described above with regard to the
discontinuous armor layer of armor assembly 10. In some examples,
second plates 22 may on average be smaller (e.g., in terms of
surface area) than that of first plates 12. In other examples,
first and second plates 12, 22 may be substantially the same
size.
[0089] As shown in FIG. 5, the pattern, shape, and gap density for
each of the first and second armor layers is substantially the same
as each other. However, second plates 22 are offset from that of
plates 12 such that at least a portion of gap 18 in the first
discontinuous armor layer is covered by second plates 22 and at
least a portion of gap 19 in the second discontinuous layer is
covered by first plates 12. By overlying the second plates 22 of
the second discontinuous layer over the first plates 12 of the
first discontinuous layer in such a fashion, the total area of gaps
extending all the way through both the first and second
discontinuous layer, e.g., gap 28 shown in FIG. 5, is less than
that of the total gap area of either the first discontinuous layer
or second discontinuous layer. In this manner, armor assembly 24
may provide increased protection compared to that of the first and
second armor layers individually, while also allowing for an armor
assembly 24 including two discontinuous armor layers that may be
flexible and/or breathable. Put another way, by offsetting the
first and second discontinuous armor layers, one armor layer offers
protection where the other layer is weakest (e.g., at the gaps of
each armor layer).
[0090] FIG. 6 is another conceptual diagram illustrating, from a
plan view, a portion of example armor assembly 26 including example
first and second discontinuous layers. The first and second
discontinuous armor layers are formed of first armor plates 12a-d
(referred to collectively as plates 12) and second armor plates
22a-g (referred to collectively as second armor plates 22),
respectively. Again, for ease of illustration, the coupling
elements (e.g., ropes) used to connect armor plates within the same
armor layer and/or armor plates from different armor layers are not
shown in FIG. 6. However, the coupling elements used to connect
first armor plates 12 and second armor plate 22 of the first and
second discontinuous armor layers, respectively, may be
substantially the same or similar to that described above for
coupling element 14 shown, for example, in FIGS. 1A and 1B.
Coupling elements may connect plates of assembly 26 in the
horizontal and/or vertical directions.
[0091] Armor assembly 26 may be substantially the same or similar
to that of armor assembly 24 of FIG. 5. For example, a second
discontinuous armor layer formed of second armor plates 22 overlays
a first discontinuous armor layer formed by first armor plates 12.
The second discontinuous armor layer is arranged relative to the
first discontinuous armor layer such that at least a portion of
second plates 22 cover gaps between adjacent plates 12 of the first
layer, and vice versa. Gap 28 extending through both the first and
second discontinuous armor layers is present albeit on a smaller
scale compared to that shown in FIG. 5.
[0092] Unlike that of armor assembly 24 (FIG. 5), the shape and
pattern of second plates 22 in the second discontinuous armor layer
is different from that of the shape and pattern of first plates 12
in the first discontinuous armor layer. As illustrated by armor
assembly 26, instead of using two identical discontinuous armor
layers, a first discontinuous armor layer can be used with a second
discontinuous armor layer of plates that are designed to cover a
relatively narrow area around the gaps in the first discontinuous
armor layer. This may allow for improved weight efficiency since
the second discontinuous layer does not overlap as extensively with
the first discontinuous armor layer. For example, the second
discontinuous armor layer may be described as having a gap area
density that is greater than that of the first discontinuous armor
layer. In some examples, first armor plates 12 that form the first
discontinuous armor layer may be referred to herein as Solid Armor
Plates (SAP) and the second plates 22 of the second discontinuous
armor layer may be referred to herein as Gap Plugging Plates
(GPP).
[0093] FIG. 7 is a conceptual diagram illustrating a portion of
example assembly 30 including example first and second
discontinuous layers from a side view. The first discontinuous
armor layer is formed of SAPs 12a-12d (collectively SAPs 12) and
the second discontinuous armor layer is formed of GPPs 22a-c
(collectively GPPs 22). Again, for ease of illustration, the
coupling elements used to attach SAPs 12 and GPPs 22 to each other
are not shown. However, the coupling elements used to connect SAPs
12 and GPPs 22 of the first and second discontinuous armor layers,
respectively, may be substantially the same or similar to that
described above for coupling element 14 shown, for example, in
FIGS. 1A and 1B. Coupling elements may connect plates of assembly
30 in the horizontal and/or vertical directions.
[0094] As shown in FIG. 7, GPPs 22 overlay at least a portion of
SAPs 12 to cover at least a portion of gaps 18 present between SAPs
12 in the first discontinuous layer. Similarly, gaps 19 between
GPPs 22 are covered to at least some extent by SAPs 22. Each GPPs
22 has a "T" shape that allows a portion of each GPPs 22 to extend
into gap 18 between SAPs 12 while also including a portion that
directly overlays a surface of SAPs 12. As will be described below,
such a configuration may increase the ease with which GPPs 22 are
attached to SAPs 12. The thickness of first and second
discontinuous armor layers formed by SAPs 12 and GPPs 22,
respectively, may be substantially the same or may be different
from one another.
[0095] FIGS. 9A and 9B are conceptual diagrams illustrating GPP 22a
of FIG. 7 from a perspective view and side view, respectively. As
shown, GPP 22a has a "T" shape as shown in FIG. 7. In some
examples, a "T" shape can provide improved low angle performance in
an armor assemblies designed to stop knife attacks. FIGS. 8A and 8B
are conceptual diagrams illustrating another example GPP 22d from a
perspective view and side view, respectively. Unlike that of GPP
22a, GPP 22d has an elongated flat shape rather than a "T" shape.
GPP 22a may be used in addition to or alternatively to that of GPP
22d in assembly 30 to at least partially cover gaps 18 between SAPs
12. However, the flat, elongated shape of GPP 22d does not allow
for a portion of GPP 22d to be extending into gap 18 in the first
discontinuous armor layer. Other geometries for GPPs are
contemplated.
[0096] Some examples GPPs such as GPPs having a "T" shape include a
vertical portion. The vertical portion may give the GPP
substantially greater strength against bending under an applied
force or impact because of the relatively large moment of inertia
and higher bending modulus exhibited by the GPP about a horizontal
bending axis, e.g., in the plane of FIG. 11 below. Additionally,
GPP embodiments incorporating a vertical portion may tend to lock
the vertical portion in place in the gap between adjacent SAPs. In
one embodiment, the length of a GPP may be larger than its width
and the height of the vertical portion may be approximately equal
to the width of the GPP. In other embodiments, the height of the
vertical portion may be less than the width of the GPP, and in
still other embodiments the height of the vertical portion may be
greater than the width of the GPP. In one embodiment, the length of
the GPP is at least 50% larger than its width.
[0097] FIGS. 10A and 10B are conceptual diagrams illustrating an
example assembly including SAPs 12a, 12b and GPPs 22a coupled to
each other via an example rope 14. FIG. 10A illustrates a side view
of SAPs 12a, 12b and GPPs 22a, and FIG. 10B illustrates a
cross-sectional view along a plane that intersects apertures 16 in
SAPs 12a, 12b, and apertures 32 in GPP 22a. As shown, a portion of
"T" shaped GPP 22a extends into gap 18 between SAPs 12a, 12b. Rope
14 forms a secure loop that extends through apertures 16 in SAPs
12a, 12b and apertures 32 in GPP 22a to attach GPP 22a and SAPs
12a, 12b to each other. In this manner, rope 14 may attach
individual armor plates in the same discontinuous layer (SAPs 12a,
12b) to one another in the horizontal direction as well as
individual armor plates that are in other discontinuous layers in
the vertical direction. As described above, coupling elements 14
may couple armor plates that are in the same discontinuous armor
layer, in different discontinuous armor layers, or both.
[0098] FIG. 11 is a conceptual diagram illustrating an alternate
example assembly including SAPs 12a, 12b and GPPs 22a coupled to
each other via an example rope 14. SAPs 12a, 12b and GPP 22a are
shown along a cross-section similar to that shown in FIG. 10B. As
shown in FIG. 11, the shape and relative configuration of GPP 22a
and SAPs 12a, 12b is substantially the same or similar to that
shown in FIGS. 10A and 10B. However, apertures 32 in GPP 22a extend
through GPP 22a in substantially the same direction as apertures 16
extend through SAPs 12a, 12b, rather than in substantially
orthogonal directions. In other examples, apertures 16, 32 may
extend through GPP 22a and/or SAP along an angular path that is
neither substantially orthogonal nor substantially parallel to the
surface plane of the first and/or second discontinuous layer. When
assembled as shown in FIG. 11, apertures 32 are approximately
aligned in the horizontal direction with apertures 16 of SAPs 12a,
12b, and rope 14 forms a secure loop through each aperture to
attached GPP 22a to SAP 12a, 12b.
[0099] FIGS. 40A and 40B are conceptual diagrams illustrating a
bullet 80 impacting an example armor assembly at a portion similar
to that shown in FIG. 10B. As shown, when bullet 80 impacts GPP
22a, the example armor assembly is self-tightening or
self-enhancing in the sense that when GPP 22a is pushed down by
bullet 70, first and second SAPs 12a, 12b, which support GPP 22a,
approach each other and tighten the grip on GPP 22a. As will be
described below, in a three-layer armor assembly, when a bullet
impacts on an isolated hole cover, e.g., IHC 46 shown in FIG. 26,
there is a self-enhancing effect where the bullet pushes on IHC 46
which tends to pull adjacent SAPs closer to each other.
[0100] FIGS. 12A and 12B are conceptual diagrams illustrating
example GPP 22a from perspective and side-views, respectively. As
shown, GPP 22a has a "T" shape, and includes a plurality of
apertures 32 extending through a portion of GPP 22a in a manner
consistent with the example shown in FIGS. 10A and 10B. In FIGS.
12A and 12B, GPP 22a also includes two protrusions 34 on the
surface of GPP 22a directly adjacent to the upper surface of SAPs
12a, 12b when inserted into gap 18 as shown, e.g., in FIG. 13 for
armor assembly 38. Protrusions 34 allows the contact between GPP
22a and SAPs 12a, 12b to be localized to protrusions 34 rather than
along substantially the entire length of gap 18 filled by GPP 22a
so as to not restrict air flow through the first and second
discontinuous layers through gap 18. FIG. 14 shows example air flow
36 through the armor assembly of FIG. 13. Such airflow allows for
breathability in the example in which armor assembly forms a
portion of body armor. Adequate airflow and moisture passage across
body armor may be important for human comfort. Ample air passage
through the armor of the present invention can be achieved due to
the nature of the design. Protrusions 34 of GPP 22a provides
additional space between GPP 22a and SAPs 12a, 12b for air or
moisture to pass through. Alternatively or additionally, SAPs 12a,
12b may include protrusions to provide for separation between GPP
22a and SAPs 12a, 12b.
[0101] In some examples, the configuration of multiple
discontinuous layer armor assemblies, such as one or more of those
examples armor assemblies described in this disclosure, may be such
that one or gaps are formed in the armor assembly which extend
along a substantially continuous, nonlinear path through all of the
individual discontinuous armor layers of an armor assembly. In this
manner, the air flow through one or more continuous gaps through
the armor assembly may provide for a relatively breathable armor
assembly, e.g., in case in which the armor assembly is worn as a
body armor. In some examples, the average air flow exhibited
throughout the entire armor assembly may be greater than the air
flow, if any, through an individual armor plate of the assembly. In
this manner, solid armor plates may be used in an example armor
assembly while also providing for suitable air flow through the
armor assembly as a whole, e.g., via gaps between the solid armor
plates.
[0102] FIGS. 15A and 15B are conceptual diagrams illustrating an
example process for forming example GPP having a "T" shape. As
show, multiple layers of high tensile strength yarns or fabrics 43
may be soaked with a properly selected resin and then arranged as
shown in FIG. 15A on adjacent molding members 39, 41. Bottom layers
of the yarns or fabric are pushed into a cavity between members 39,
41 to form the protruding portion of the "T" shape while top layers
of the yarns or fabric extend straight across the "T" shape. The
assembly is heated under pressure between members 49, 41, 45, as
illustrated in FIG. 15B. The part is removed once the resin is
cured resulting in GPP 22a shown in FIG. 16. In some examples,
apertures 32 may be drilled or otherwise formed into a portion of
GPP 22a to result in a configuration such as that shown in FIG. 10B
or 11. In some examples, apertures 32 may be formed through GPP 22a
so that ropes can be used to sew together the top layers of yarns
or fabric with the bottom layers of yarns or fabric as shown in
FIG. 17. The resin used in constructing GPP 22a is selected so that
GPP 22a is sufficiently rigid and the resin is also selected to be
ductile enough that GPP 22 does not easily fracture under ballistic
impact.
[0103] FIGS. 18A-E are conceptual diagrams illustrating an example
armor plate 22j from various viewpoints. In particular, FIGS. 18A
and 18B shows plate 22j from top and bottom views, respectively.
FIG. 18C show plate 22j rotated 90 degrees from the top view shown
in FIG. 18A along the major axis. FIGS. 18D and 18E show plate 22
from a side view of FIGS. 18A and 18B, respectively. Similar to
those other example "T" shaped GPP described above, armor plate 22j
may be utilized as a GPP in an armor assembly that covers one or
more gap portions between an adjacent discontinuous armor layer
formed of SAPs coupled to one another via one or more coupling
elements.
[0104] As shown in FIGS. 18A and 18B, the top portion or horizontal
portion of the "T" shaped plate include a plurality of apertures
including example aperture 43b extending all the way through the
top portion. As shown in FIG. 18C, the side portion or vertical
portion of plate 22j includes a plurality of apertures including
example aperture 43a that extends all the way through the side
portion. In each case, apertures 43a, 43b may be used to receive a
coupling element at the discrete locations along plate 22j to
attach plate 22j to other GPPs within the same discontinuous armor
layer and/or attach plate 22j to one or more armor plates in a
directly or indirectly adjacent discontinuous layer formed of a
plurality of plates, such as, e.g., a discontinuous layer including
a plurality of SAPs.
[0105] FIG. 19 is a conceptual diagram illustrating three example
armor plates 12a, 12b, 22j attached to each other via coupling
elements 14a-c from a side view. Armor plates 12a, 12b, 22j may be
configured relative to each other similar to that shown in FIG.
10A, for example. Armor plates 12a, 12b may form a first
discontinuous armor layer of SAPs. Armor plate 22j may be
substantially the same as that shown in FIGS. 18A-E, and may form a
portion of a second discontinuous armor layer of GPPs that overlies
the first armor layer of SAPs such that all or a portion of the
gaps between SAPs are covered by the second discontinuous layer of
GPPs.
[0106] The path of coupling elements 14a-c within plates 12a, 12b,
22j within one or more apertures in plates 12a, 12b, 22j are shown
as dashed lines. As shown, coupling elements 14a and 14b are used
to attach armor plates 12a, 12b, 22j in a generally vertical
direction while coupling element 14 attach armor plates 12a, 12b,
22j in a generally horizontal direction. Coupling element 14c may
extend through the same apertures in plates 12a, 12b as that of
coupling elements 14a, 14b or may extend through different
apertures on plates 12a, 12b that spaced apart from one another on
the perimeter of the respective plates.
[0107] FIGS. 20A-D are conceptual diagrams illustrating example
armor plates 12a, 12b, 22k from various viewpoints. Armor plates
12a, 12b may form a portion of a discontinuous armor layer
including a plurality of SAPs. Armor plate 22k may form a portion
of another discontinuous armor layer formed of a plurality of GPPs
directly adjacent to that the discontinuous armor layer including
armor plates 12a, 12b. Armor plate 22k may be substantially the
same or similar to that of armor plate 22j of FIGS. 18A-E except
that armor plate 22k includes a total of sixteen apertures, e.g.,
43c, in the top surface rather than fourteen as shown for armor
plate 22j of FIGS. 18A and 18B. FIGS. 20A and 20C illustrates
plates 12a, 12b, 22k along cross-section B-B in FIG. 20D, with FIG.
20C being rotated 90 degrees from that shown in FIG. 20A. FIG. 20D
is a top-view of plates 12a, 12b, 22k. FIG. 20B is a view of plates
12a, 12b, 22k along cross-section C-C in FIG. 20D.
[0108] As shown in FIGS. 20A-D, armor plates 12a, 12b, 22k are
attached to each other via coupling element 14d by extending
through the apertures (e.g., aperture 43c of plate 22k) of plates
12a, 12b, 22k in both the vertical and horizontal directions for
interlayer attachment and intralayer attachment. While the
illustrated example includes only a single coupling element 14d to
attach plates 12a, 12b, 22k, other examples may include a plurality
of coupling elements over a portion an armor assembly formed in
part by plates 12a, 12b, 22k.
[0109] FIGS. 21A-D are conceptual diagrams illustrating an example
armor assembly 42 including multiple example discontinuous armor
layers formed of SAPs 12a-d and GPPs 22a-d. In particular, FIGS.
21A and 21C illustrate top and bottom view, respectively, of
assembly 42, and FIGS. 21B and 21D illustrates side views. Although
not shown for ease of illustration, SAPs 12a-d and GPPs 22a-d may
be connected to each other via one or more coupling elements as
described above. As before, SAPs 12a-d form a first discontinuous
armor layer that is adjacent to a second discontinuous armor layer
formed by GPPs 22a-d. GPPs 22a-d have a "T" shape and covers a
least a portion of the gaps in the first discontinuous armor layer
formed between SAPs 12a-d. Similarly, at least a portion of the
gaps in the second discontinuous armor layer formed between GPPs
22a-d are covered by SAPs 12a-d.
[0110] Despite the overlaying configuration of GPPs 22a-d and SAPs
12a-d, gap 28 may exist in armor assembly 42. As shown, gap 28
extends through both the first and second discontinuous armor layer
along a substantially linear path perpendicular to the surface
plane of assembly 42. In some examples, gap 28 may present a
weakness in armor assembly 42, and may be covered in some
embodiments by one or more armor plates that form a third
discontinuous armor layer overlaying the first and second layers of
SAPs and GPPs, respectively. As will be described further below,
the third discontinuous armor layer is formed of a plurality of
individual plates, where individual armor plates are each used to
cover a single gap 28.
[0111] FIGS. 22A-C are conceptual diagrams illustrating another
portion of an example armor assembly 44 including multiple example
discontinuous armor layers. FIG. 22A is a plan view of the top
surface of armor assembly 44, FIG. 22B is a side view of armor
assembly 44, and FIG. 22C is a plan view of the bottom surface of
armor assembly 44. Only a portion of SAPs 12a-d are shown in FIG.
22C for ease of illustration. Similar to that described above, SAPs
12-d form a first discontinuous armor layer, and GPPs 22a-d form a
second discontinuous armor layer overlaying the first armor layer
to at least partially covers gaps between SAPs 12a-d.
[0112] Armor assembly 44 also includes armor plate 46 which forms
at least a part of a third discontinuous armor layer that overlays
a portion of the first and second armor layer, and covers the gap,
such as gap 28 shown in FIG. 18A, extending through both the first
and second armors layers along a substantially linear path. In this
manner, armor plate 46 effectively "plugs" the remaining gap in
armor assembly 44 from the first and second discontinuous armor
layers. Of course, only a portion of armor assembly 44 is
illustrated in FIGS. 22A-C and a number of relatively isolated gaps
in the first and second armor layers may be present over the entire
assembly requiring a plurality of armor plates 46 to cover
substantially all, or at least some, of the gaps. In some examples,
armor plate 46 may also be referred to herein as Isolated Hole
Cover (IHC) 46.
[0113] As the gaps extending through the first and second
discontinuous armor layers along a linear path may be relatively
isolated in the surface of armor assembly 42, the gap area density
of the third discontinuous layer, which includes armor plate 46,
required to cover gaps 28 may be relatively high. However, the
third discontinuous armor layer may cover more surface area of the
first and second layers to provide multiple layers of armor plate
at points in an armor assembly to increase the overall degree of
protection provided by armor assembly. In some examples, IHC 46 may
be formed of the same or similar materials as that of GPPs 22a-d
and/or SAPs 12a-d, or may be formed of different materials than
that of GPPs 22a-d and/or SAPs 12a-d. Suitable armor materials may
include those described in this disclosure for example GPPs and
SAPs. IHC 46 may have any suitable thickness and may be the same or
different than that of GPPS 22a-d and/or SAPs 12a-d.
[0114] Similar to that of SAPs 12a-d, GPPs 22a-d, IHC 46 may
include one or a plurality of apertures, e.g., aperture 48a, that
allows IHC 46 to be coupled to one or more armor plates of armor
assembly 44. As shown in FIGS. 22A and 22C, ropes 14 or other
coupling element extends vertically through aligned apertures,
including aperture 48a, for example, to connect SAPs 12a-d, GPPs
22a-d and IHC 46 to each other to form the pattern shown in FIGS.
22A-22C. As with the other examples described in this disclosure,
such a pattern may be repeated over all or a portion of armor
assembly 44. In some examples, IHC 46 may be attached or otherwise
fixed in place to cover one or more gaps extending through the
first and second discontinuous armor layers of assembly 44 without
the use of a coupling element to connect IHC to the adjacent
layers.
[0115] As illustrated by FIG. 22A-22C, for example, in some
embodiments of this disclosure, multiple layer constructions may be
used for armor assemblies which provide for substantially 100
percent areal coverage while maintaining flexibility and/or
breathability of the armor assembly. Moreover, in some examples,
such as the example three discontinuous layer assembly construction
shown in FIGS. 22A-22C, an armor assembly may provide for reduced
weight, e.g., compared to armor assemblies having one or more
continuous layers. For example, for an armor assembly configuration
similar to that shown in FIG. 27 below, the armor assembly can have
a weight equivalent of approximately 1.23 times the weight of a
single, continuous layer of using the same material and thickness
of SAPs 12a-12f (ignoring the weight of coupling elements 14). If
three substantially identical discontinuous layers of SAPs are
used, a weight of approximately 2.56 times the weight of a single
full coverage layer of SAP material would be obtained in such an
example.
[0116] FIGS. 23A-C are conceptual diagrams illustrating an example
armor plate 22a from bottom, side and end views, respectively.
Armor plate 22a may be the same or substantially similar to that
shown in FIGS. 22A-C, and may form a portion of a discontinuous
armor layer including a plurality of GPPs. FIGS. 24A and 24B are
conceptual diagrams illustrating from side and plan views,
respectively, example armor plate 46 from FIGS. 22A-C. As shown,
armor plate 22a includes a plurality of apertures, including 43d
that may be used to connect armor plate 22a to armor plate 46 using
a rope or other coupling element that extends through both
apertures 43d, 48a when arranged as shown in FIGS. 22A-C. Although
armor plate 46 is shown as having a octagonal shape, other suitable
shapes are contemplated.
[0117] FIG. 25 is a conceptual diagram illustrating an example
portion of example armor assembly 50. Armor assembly 50 includes a
first discontinuous layer including SAPs 12a-d and a second
discontinuous layer including GPPs 22a-22d which covers at least a
portion of the gaps in the first discontinuous layer. As shown,
armor assembly 50 may be the same or substantially similar to armor
assembly 42 of FIGS. 21A-21D. An example pattern for the plurality
of apertures, e.g., apertures 16a, 43a, used to couple the plates
in the respective layers to each other, e.g., via a rope or other
coupling element, are shown in FIGS. 21A-21D. Other apertures
patterns are contemplated. Similar to that of armor assembly 42,
armor assembly 50 includes gap 28 which extend through the first
and second discontinuous layers along a substantially linear
path.
[0118] FIG. 26 is a conceptual diagram illustrating an example
portion of another example armor assembly 52. Armor assembly 52 is
substantially the same or similar to that of armor assembly 50.
However, in addition to SAPs 12a-d and GPPs 22a-d, armor assembly
52 includes armor plate or IHC 46 which covers gap 28 that was
present in armor assembly 50 in FIG. 25. IHC 46 has a square shape
and is directly connected to each of SAPs 12a-d and GPPs 22a-d via
coupling element 14 that extend through at least one aperture (not
labeled) in each respective plate. For ease of illustration, not
all coupling elements are shown in FIG. 26. As shown, SAPs 12a-d,
GPPs, 22a, and IHC 46 forms a portion of armor assembly 52 in which
substantially no gaps defining a substantially linear path through
the respective armor layers exist over the surface of assembly
52.
[0119] FIG. 27 is a conceptual diagram illustrating an example
portion of example armor assembly 54. The portion of armor assembly
shown may be substantially the same or similar to that of the
portion of armor assembly 52 shown in FIG. 26. However, the portion
of armor assembly 54 illustrated includes SAPs 12a-f, GPPs, 22a-g,
and IHCs 46a, 46b. Additionally, IHCs 46a, 46b have an octagonal
shape rather than a square shape. Other shapes for IHC plates are
contemplated. In some examples, a circular or rectangular armor
plate can be used for the IHC.
[0120] FIG. 28 is a conceptual diagram illustrating an example
portion of another example armor assembly 56. The portion of armor
assembly shown may be substantially the same or similar to that of
the portion of armor assembly 54 shown in FIG. 27. However, the
portion of armor assembly 54 illustrated does not include IHCs
covering the gaps in the assembly which define a substantially
linear path through both the first and second discontinuous armor
layers formed via SAPS 22a-f and GPPs 22a-h. The perimeters of SAPs
22a-f covered by GPPs 22a-h are shown as dashed lines. As shown,
for armor assembly 56, coupling elements 14 form a grid pattern
which extend over SAPs 12b and 12d.
[0121] FIGS. 29A-C are conceptual diagrams illustrating various
example discontinuous armor layers on an example portion of example
armor assembly 58. In each case, the coupling element(s) used to
connect respective armor plates of armor assembly 58 are not shown
for ease of illustration. FIG. 29A illustrates a first
discontinuous armor layer that include sixteen, square-shaped SAPs,
including SAP 12a, arranged in a 4.times.4 pattern which a
plurality of apertures around the perimeter of each SAP. FIG. 29B
illustrates the first discontinuous layer of FIG. 29A overlaid with
a second discontinuous layer including twenty four, square-shaped
GPPs, including GPP 22a, arranged in a pattern that is offset
approximately 45 degrees from that of the first discontinuous
layer. FIG. 29C illustrates the first and second discontinuous
layers of assembly 58 overlaid with a third discontinuous layer
including nine, square-shaped IHCs, including IHC 46a arranged in a
pattern that is aligned with the first discontinuous layers and
offset approximately 45 degrees from that of the second
discontinuous armor layer. In the example shown in FIG. 29C, the
square-shaped IHCs may be approximately the same size as that of
the SAPS, and the GPPs may be approximately half the size of the
SAPs.
[0122] FIGS. 30A and 30B are conceptual diagrams illustrating
various example discontinuous armor layers on an example portion of
another example armor assembly 60. In each case, the coupling
element(s) used to connect respective armor plates of armor
assembly 60 are not shown for ease of illustration. FIG. 30A
illustrates the first and second discontinuous layers of assembly
60. Similar to that of armor assembly 58, the first discontinuous
layer includes sixteen, square-shaped SAPs, including SAP 12a,
arranged in a 4.times.4 pattern which a plurality of apertures
around the perimeter of each SAP. The second discontinuous layer
overlaying a portion of the first discontinuous layers includes
nine, square-shaped GPPs, including GPP 22a, arranged in a
3.times.3 pattern. FIG. 30B illustrates the first and second
discontinuous layers of assembly 60 overlaid with a third
discontinuous layer including eighteen, square-shaped IHCs,
including IHC 46a arranged in a pattern that is aligned with the
first discontinuous layers and offset approximately 45 degrees from
that of the first and second discontinuous armor layers. Each of
the configurations illustrated in FIGS. 30A and 30b, as well as the
other example configurations, may be repeated as necessary to
provide an armor assembly that covers a desired surface area. In
the example shown in FIG. 30B, the square-shaped IHCs may be
approximately half the size of that of the SAPS and GPPs.
[0123] As noted above, the coupling element(s) used to connect the
SAPs, GPPs, and IHCs of armor assembly 58 and armor assembly 60 are
not shown. However, in these and other examples, such coupling
element(s) can extend both horizontally and vertically within the
three layer structure, e.g., a coupling element may extend between
SAPs, horizontally between GPPs, and vertically between the GPP
layer and the SAP layer. The armor plates in FIGS. 29C and 30B
include two rows of apertures that allow for additional coupling
elements to be used to hold the armor plates together. Tying
respective armor plates together both horizontally and vertically
can offer improved ballistic performance since a bullet will not be
able to penetrate near the boundary of a GPP without bursting ropes
and damaging plates.
[0124] In some examples, the use of GPPs and IHCs plates in
conjunction with SAPs act to reduce the weight of an armor
assembly, e.g., as compared to an armor assembly including three
continuous armor layers. Moreover, the pattern, shape and other
design configurations may be provided to reduce the weight of armor
assemblies with three discontinuous layers. As an illustration, if
3.times.3 inch square plates are used for all three layers in an
armor assembly with a pattern similar to that shown in FIG. 29A,
with a 0.25 inch gap between the armor plates in each discontinuous
layer, each layer covers 85.2% of the total area. The total
coverage would then be 255.6%, or just over 2.5 layers of SAP
material. With the geometry shown in FIGS. 22A-C with a GPP width
of 1/3 of the SAP plate to plate distance (1.08 inches) and a IHC
width of half of the SAP plate to plate distance (0.65 inches), the
SAP layer has an areal coverage of approximately 85.2%, the GPP
layer has an areal cover of approximately 23.7% and the IHC layer
has an areal coverage of approximately 14.0%. This results in a
total coverage of 122.9%, less than half of coverage, and hence the
weight, of using 3 layers of identical square plates. Therefore,
using selected patterns and geometries, e.g., as shown in FIGS.
22A-C for the GPP and ICH layers results in a reduction of total
guard plate weight by more than 50%. In this manner, some example
armor assembly of this disclosure may provide complete coverage
using armor plate layers with less than three full coverage layers
of plates. For example, in some examples, the GPP layer of plates
can cover less than 60 percent, such as, e.g., less than 50
percent, of the total area of the armor assembly and the IHC layer
of plates can cover less than 40 percent, such as, e.g., less than
25 percent of the total area of the armor assembly. Thus, the
weight of the final body armor assembly is less than an embodiment
with three layers of identical plates. In addition, such a
configuration of progressively reduced sizes for plates in the
upper layers will also improve the overall ability to bend and the
flexibility of the three layered plate system of this body
armor.
[0125] FIG. 31 is a conceptual diagram illustrating an example
portion of example armor assemblies 61 from a cross-sectional view.
In particular, the cross-section of FIGS. 31-36 are illustrated
along a cross-section bisecting an gap portions extending through
first discontinuous layer including SAPs 12a, 12b, and second
discontinuous layers including GPPs 22a, 22b. As shown, armor
assembly 61 also includes IHC 63, which is positioned such that IHC
63 covers or "plugs" the gap in the first and second discontinuous
layers. IHC includes first and second hole plugging heads 62a, 62b
connected via shaft 64, which runs through the gap portion between
the first and second discontinuous layers. In this manner, IHC 63
may take a dumbbell or bobbin type shape. The size of first and
second hole plugging heads 62a, 62b connected via shaft 64 are
sized such that IHC 63 is secured within assembly 61 and cannot
fall through the gap being plugged between the first and second
discontinuous layers. As show in FIG. 31, in some examples an IHC,
such as, IHC 63 may include both a portion (e.g., head 62a) above
the outer surface of the discontinuous layer formed via the GPPs
and also a portion (e.g., head 62) below the outer surface of the
discontinuous layers formed via the SAPs. In this manner, IHC may
be described in some examples as forming two discontinuous layers,
where one discontinuous layer is adjacent to the discontinuous
layer formed via the GPPs and another discontinuous layer is
adjacent to the discontinuous layer formed via the SAPs.
[0126] First and second hole plugging heads 62a, 62b may be formed
of any suitable hard and/or tough material and may include armor
material such as, e.g., those materials described herein. In some
examples, shaft 64 connecting heads 62a, 62b may be a rigid member
formed of a suitable material, armor or otherwise. In other
examples, shaft 64 may include a rope or other coupling member that
may be knotted to function as hole plugging heads 62a, 62b. For
example, shaft 64 may include one more examples of high-strength
rope described above with regard to coupling element 14.
[0127] FIGS. 32-34 are conceptual diagrams of example IHCs 63a,
63b, 63c including first and second hole plugging heads 62a, 62b
connected to each other via rope shaft 64. Each example IHC 63a,
63b, 63c may be incorporated into an example armor assembly, for
example, as shown in FIG. 31. In each case, first and second hole
plugging heads 62a, 62b include one or more knots in the rope used
for shaft 64. The knots for one or both of heads 62a, 62b may be
tied once shaft 64 is inserted in a gap extending through first and
second armor layers are shown in FIG. 31. In FIGS. 33 and 34, first
and second heads 62a, 62b include semi-sphere shaped and
cone-shaped solid head members are engaged by the knots at either
end of shaft 64 to assist in securing IHCs 63b, 63c in place within
a multiple layer armor assembly as described in this
disclosure.
[0128] In some examples, the first and/or second hole plugging head
of an IHC may include a cap covering the one or more knots at
either end of rope shaft of the IHC. FIGS. 35 and 36 are conceptual
diagrams illustrating an example portion of example armor
assemblies from cross-sectional views. In particular, similar to
that of FIG. 31, the cross-section of FIGS. 35 and 36 are
illustrated along a cross-section bisecting gap portions extending
through first discontinuous layer including SAPs 12a, 12b, and
second discontinuous layers including GPPs 22a, 22b of the armor
assembly. In each case, IHC 63d, 63e cover or "plugs" the gap
between the first and second discontinuous layers.
[0129] As shown, for IHC 63d and IHC 63e, each of the first and
second hole plugging heads 62a, 62b, respectively, include one or
more knots at either end of shaft 64 which are covered by caps 68a,
68b. Caps 68a, 68b may be constructed of any suitably hard or tough
material. Example materials may include ceramic, composites,
hardened Kevlar.RTM. or other tough polymeric materials, including
those armor materials described herein. In an alternative
embodiment, the area under one or more of caps 68a, 68b covering
the knot is filled with a rubbery yet strong glue.
[0130] In the example of FIG. 36, first hole plugging head 62a
includes ring 66 which extends around the perimeter of the gap
filled by IHC 63e to provide additional support for securing IHC
63e in place by preventing the rope knot or other portion of first
hole plugging head from pushing through the gap in the first and
second discontinuous armor layers, e.g., in the case of impact by a
ballistic object. FIG. 38 is a conceptual diagram illustrating ring
66 from a perspective view and may take the form of a washer in
some instances. Other examples, ring 66 may have a shape other than
that of a circle. FIG. 39 is an example IHC 61f in which both first
and second hole plugging heads 62a, 62b include ring 66.
[0131] In some examples, an IHC having a bobbin configuration such
as IHC 63 of FIG. 31 that is formed of rope rather than a rigid
material, especially for that of the shaft 64, may prevent the
shaft or other portion of the IHC from becoming a solid, rigid
projectile upon direct ballistic impact. FIGS. 39A and 39B are
conceptual diagrams illustrating armor assembly 74 with IHC 63g
plugging a gap between armor plates 76a, 76b, where IHC 63g
includes a rigid shaft. Upon impact by bullet 70, the rigid shaft
of IHC 63g may become projectile. Such a scenario may be prevented
by the use of a rope-based IHC or other IHC with a flexible shaft
rather than substantially rigid shaft. However, in other examples,
rigid shaft IHC may also be suitable for use in armor
assemblies.
EXAMPLES
Example 1
[0132] A variety of example materials were evaluated for use in
forming one or more armor plates of an armor assembly according to
this disclosure. As described above, a variety of material
properties may be analyzed when selecting a material to form armor
plates for use in an armor assembly. Tables 1a-d list a variety of
example materials and corresponding values for various properties
that may be evaluated when selected an armor material. For example,
Tables 1a-d include a toughness value for each material. Toughness
values (normalized to energy per weight, J/g) were calculated using
Equation 1:
T(estimate)=0.5(.sigma..sub.yield*.epsilon..sub.ultimate)+0.5.sigma..sub-
.ultimate(.epsilon..sub.ultimate-.epsilon..sub.yield) (1)
where T(estimate) is the estimated toughness value,
.sigma..sub.yield is the stress at the yield point on the
stress-strain curve, .sigma..sub.ultimate is the stress at the
ultimate strength point on the stress-strain curve,
.epsilon..sub.yield is the strain at the yield point on the
stress-strain curve, .epsilon..sub.ultimate is the strain at the
ultimate strength point on the stress-strain curve.
TABLE-US-00001 TABLE 1a Ultimate Yield Tensile Young's Toughness/
Stress Strength Elongation Modulus Density Toughness Density
Material (MPa) (MPa) at Break (MPa) (g/cm) (MPa) (J/g) Ti Grade 5
1100 1170 0.1 114000 4.43 107.86 24.35 TI Grade 2 340 430 0.28
102000 4.51 107.08 23.74 440 Steel 345 485 0.18 140000 8 74.1 9.26
1340 Steel, oil 814 876 0.21 200000 7.87 175.67 22.32 quenched from
830.degree. C. (1525.degree. F.), 595.degree. C. (1100.degree. F.)
temper Al 7075-T6 505 570 0.11 72000 2.81 57.13 20.33 or T651 Al
6061-T91 395 405 0.12 69000 2.7 46.84 17.35 Al 7076-T61 470 510
0.14 67000 2.82 66.81 23.69 Al 7475-T61 500 550 0.12 72000 2.8
61.09 21.82 Al 7001-T6 625 675 0.09 71000 2.84 55.53 19.55 or T651
Al 7001-T75 495 580 0.12 71000 2.84 62.48 22 Allvac .RTM. M-252 345
1378 0.5 100000 8.24 428.37 51.99 Nickel (estimated) Superalloy,
Heat Treatment: 1177.degree. C. (2150.degree. F.) Anneal Nickelvac
.RTM. 414 1035 0.6 100000 9.22 432.56 46.92 L-605 Nickel
(estimated) Superalloy, Heat Treatment: 1204.degree. C.
(2200.degree. F.) Anneal Gall-Tough .RTM. 414 1110 0.63 100000 8.94
477.76 53.44 Stainless, (estimated) Room Temp.
TABLE-US-00002 TABLE 1b Ultimate Yield Tensile Young's Toughness/
Stress Strength Elongation Modulus Density Toughness Density
Material (MPa) (MPa) at Break (MPa) (g/cm) (MPa) (J/g) Haynes .RTM.
188 425 965 0.42 140000 8.94 290.44 32.49 alloy, 10% cold
reduction, 3.2 mm thick sheet, 1175.degree. C. for 5 minutes Haynes
.RTM. 25 alloy, 470 1030 0.62 225000 9.13 461.67 50.57 room
temperature after 25% cold reduction, 1175.degree. C. anneal for 5
minutes AISI Type S21900 640 841 0.6 200000 7.83 442.95 56.57
Stainless Steel, 15% final cold reduction, stress relieving heat
treatment 705.degree. C. (1300.degree. F.) for 2 hours, air
cooled
TABLE-US-00003 TABLE 1c Ultimate Yield Tensile Young's Toughness/
Stress Strength Elongation Modulus Density Toughness Density
Material (MPa) (MPa) at Break (MPa) (g/cm) (MPa) (J/g) AISI Type
640 841 0.6 200000 7.83 442.95 56.57 S21904 (Alloy 21-6-9)
Stainless Steel, 15% final cold reduction, stress relieving heat
treatment 705.degree. C. (1300.degree. F.) for 2 hours, air cooled
Manganese Brass, 683 689 0.6 100000 8.42 409.25 48.62 UNS C66700
(estimated) Beryllium Copper, 1344 1462 0.48 127500 8.25 665.73
80.7 UNS C17200 Copper, 1379 2141 0.4 100000 8.89 689.24 77.53 UNS
C71700 (estimated) MRC Polymers 53.8 53.8 2 1690 1.1 106.74 97.04
EMAREX 308 High Impact Modified Nylon 6
TABLE-US-00004 TABLE 1d Ultimate Yield Tensile Young's Toughness/
Stress Strength Elongation Modulus Density Toughness Density
Material (MPa) (MPa) at Break (MPa) (g/cm) (MPa) (J/g) Ensilon 6/6
85.49 85.49 0.9 2827 1.14 75.65 66.36 Xenoy 1103 52 50 1.5 1900 1.2
75.82 63.18 Xenoy 1101 53 59 1.2 2040 1.21 66.43 54.9 Xenoy 5720 50
50 1.65 1720 1.17 81.77 69.89 Lexan 141 62 69 1.3 2340 1.2 84.24
70.2 304 steel 215 505 0.7 196000 8 251.72 31.47 Kevlar 3620 3620
0.04 70300 1.44 37.12 25.78 302 Steel 255 585 0.57 193000 7.86
239.01 30.41
Example 2
[0133] A sample sheet of body armor was constructed according to
the armor assembly embodiment shown in FIG. 22A-C using
approximately 3.times.3 inch square, 20 ply HB50 Dyneema SAP
plates. For the GPPs armor plates, approximately 2 inch wide HB50
Dyneema armor plates with "T" shapes, such as, e.g., those as shown
in FIGS. 16 and 17 were used. These GPP plates with 20 plies had a
thickness of approximately 5 mm. For the IHC armor plates, HB50 20
ply Dyneema, octagonally shaped IHCs (similar to that shown in
FIGS. 24A and 24B were attached over the holes. The Dyneema plates
were manufactured by Tencate. The rope coupling element used to
connect the plates in the armor assembly was Spectra 1.6 mm
diameter cord from RW Rope Warehouse. The sample armor assembly
successfully protected against a 44 Magnum Semi Jacketed hollow
point at NIJ Level IIIA. This is a Level IIIA Protection Level
according to the National Institute of Justice Ballistic Resistance
of Body Amor NIJ Standard-0101.06.
[0134] Various embodiments of the invention have been described.
These and other embodiments are within the scope of the following
claims.
* * * * *