U.S. patent application number 14/489117 was filed with the patent office on 2015-09-24 for non-flammable blast mitigating mat.
The applicant listed for this patent is BAE Protection Systems. Invention is credited to Adrienne M. Bourque, Peter Chu, Steven P. Diaz, Thomas J. Dorsch, Mei Lam, Michael McCullough.
Application Number | 20150268008 14/489117 |
Document ID | / |
Family ID | 54141784 |
Filed Date | 2015-09-24 |
United States Patent
Application |
20150268008 |
Kind Code |
A1 |
Dorsch; Thomas J. ; et
al. |
September 24, 2015 |
NON-FLAMMABLE BLAST MITIGATING MAT
Abstract
A blast mitigation mat which protects soldiers from an explosion
and from the fire and toxic fumes that result. The mat may include
a surface layer that includes traction component, an energy
absorptive, metallic, non-flammable layer which can include a
hollow metallic structure, and a finishing layer. The non-flammable
layer is comprised of materials that melt rather than burn. The
finishing layer can be mounted to the vehicle or other surfaces
subject to blast impulses.
Inventors: |
Dorsch; Thomas J.; (Los
Gatos, CA) ; Chu; Peter; (San Mateo, CA) ;
Diaz; Steven P.; (San Jose, CA) ; McCullough;
Michael; (San Jose, CA) ; Lam; Mei; (San Jose,
CA) ; Bourque; Adrienne M.; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BAE Protection Systems |
Phoenix |
AZ |
US |
|
|
Family ID: |
54141784 |
Appl. No.: |
14/489117 |
Filed: |
September 17, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61878931 |
Sep 17, 2013 |
|
|
|
Current U.S.
Class: |
89/36.08 |
Current CPC
Class: |
F42D 5/05 20130101; F41H
7/042 20130101 |
International
Class: |
F41H 7/04 20060101
F41H007/04 |
Claims
1. A mat for minimizing the effect of a blast impulse, the mat
comprising an upper plate, a hollow metallic core plate, and a
mounting plate, wherein the upper plate is bonded to a first face
of the hollow metallic core plate, the hollow metallic core plate
thicker than the upper plate so as to deform upon a blast impulse,
and the mounting plate bonded to a second face of the hollow
metallic core.
2. The mat of claim 1 wherein the upper plate provides an anti-slip
surface.
3. The mat of claim 2 wherein the anti-slip surface is a diamond
plate.
4. The mat of claim 1 wherein the upper plate is bonded to the
hollow metallic core plate by adhesives, welding or brazing.
5. The mat of claim 1 wherein the hollow metallic core plate is
formed of a metallic foam.
6. The mat of claim 5 wherein the metallic foam is an open cell or
closed cell foam
7. The mat of claim 1 wherein the hollow metallic core plate is
formed of dimpled aluminum sheets.
8. The mat of claim 1 wherein the hollow metallic core plate is
formed of an aluminum honeycomb.
9. The mat of claim 1 wherein the hollow metallic core plate is
formed of a discontinuous foam so as to create pillars between the
upper plate and the mounting plate.
10. The mat of claim 1 wherein the mounting plate is connected to
the hollow core metallic plate by adhesives, welding or
brazing.
11. The mat of claim 1 wherein the mounting plate is attached to a
vehicle.
12. A non-flammable blast mitigating vehicle mat for minimizing the
effect of a blast impulse, the mat comprising an upper plate, a
core plate, and a mounting plate, wherein the core plate includes
internal spaces formed by a honeycomb structure, the honeycomb
structure absorbing force upon impact such that the mounting plate
never experiences a force greater than the core plate crush
strength.
13. The mat of claim 12 wherein the core plate is a Nomex
honeycomb.
14. The mat of claim 12 wherein the core plate is an aluminum
honeycomb.
15. The mat of claim 12 wherein the honeycomb structure is
comprised of a non-flammable material.
16. The mat of claim 12 wherein the mounting plate is attached to a
floor of a vehicle.
17. The mat of claim 12 further including an adhesive layer between
the upper plate and the core plate.
18. The mat of claim 12 wherein the core plate deforms upon impact.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to blast mitigating
devices. Specifically, the present invention is directed to a
non-flammable blast mitigating mat to protect those in a
vehicle.
BACKGROUND OF THE INVENTION
[0002] Wars in Iraq and Afghanistan have subjected troops within
combat vehicles to roadside improvised explosive devices (IED)
which are cheap to make but are also highly potent. IEDs are very
effective, in part, because they can be buried near the road and
explode when a combat vehicle drives past, such that the energy of
the blast is directed from the ground up through the under-carriage
of the vehicle. In recent years combat vehicles have been shaped to
help deflect the explosive percussions away from the undercarriage,
thus reducing the amount of energy absorbed by the vehicle and its
passengers. Since a vehicle cannot deflect all of the energy from
an IED bomb blast, combat vehicles have also been designed with
materials that absorb the force of the blast so that less of the
blast is absorbed by the occupants.
[0003] Currently, some combat vehicles are outfitted with blast
mitigating mats. Traditionally, mats are placed on the vehicle
floor where soldiers stand or sit and protect the lower extremities
from damaging impulse loads. Existing mats, which are typically
made from polymeric materials such as molded elastomer or foam,
significantly reduce the risk of injury from a bomb blast itself.
However, a secondary effect of the blast is fire. Unfortunately,
the existing mats are inherently flammable, even when formulated
with flame retardants. Many times the blast force ignites
combustibles in the vehicle. Not only is there a risk from fire,
but burning polymers typically emit toxic gases which are also
hazardous to soldiers in the vehicle. As the occupants are
frequently belted in place, the fire and smoke from a burning mat
creates unacceptable life threatening conditions. Therefore, there
is a need for a non-flammable blast mitigating mat.
SUMMARY OF THE INVENTION
[0004] The current invention is a blast mitigation mat which
protects soldiers from an explosion by absorbing the energy of a
blast. Unlike existing mats which can burn and emit toxic gases,
the current invention may melt but cannot burn; thus, it protects
soldiers from fire and toxic fumes. The current invention, in one
embodiment, consists of three layers: a surface layer, an absorbent
layer which is primarily a hollow metallic structure, and a
finishing layer.
[0005] In one embodiment, the surface layer consists of a diamond
tread nonskid plate for walking or standing. The absorbent layer
consists of a non-flammable energy absorbing material such as
aluminum foam or Nomex.TM. Honeycomb. The thickness, density, and
material may be tuned for specific purposes. The absorbing material
layer deforms to minimize the amount of energy transmitted to the
occupant standing or sitting on the mat. The finishing layer
consists of a metal plate which provides a means of attachment to
the vehicle structure or floor. It is clear that such material may
also be placed on other walls and structures which maybe exposed to
blast pressure from explosives.
[0006] The present invention is a mat for minimizing the effect of
a blast impulse. The mat comprising; an upper plate, a hollow
metallic core plate, and a mounting plate, wherein the upper plate
is bonded to a first face of the hollow metallic core plate, the
hollow metallic core plate at least five times thicker than the
upper plate, and the mounting plate bonded to a second face of the
hollow metallic core.
[0007] The upper plate provides an anti-slip surface such as a
diamond plate. The upper plate is bonded to the hollow metallic
core plate by adhesives, welding or brazing.
[0008] The hollow metallic core plate may be formed of a metallic
foam. The metallic foam may be an open cell or closed cell foam.
Alternatively, the hollow metallic core plate is formed of dimpled
aluminum sheets, or an aluminum honeycomb.
[0009] The core may comprise a uniform or non-uniform construction.
It may be formed of a discontinuous foam so as to create pillars
between the upper plate and the mounting plate.
[0010] The present invention is a mat for minimizing the effect of
a blast impulse, the mat comprising: an upper plate, a core plate,
and a mounting plate. The core plate includes internal spaces
formed by a honeycomb structure, the honeycomb structure absorbing
force upon impact such that the mounting plate never experiences a
force greater than the core plate crush strength. The core plate
can be a Nomex.TM. honeycomb, an aluminum honeycomb or similar
material have the required strength, energy absorption and flame
retardation qualities.
[0011] The above summary of the various representative embodiments
of the invention is not intended to describe each illustrated
embodiment or every implementation of the invention. Rather, the
embodiments are chosen and described so that others skilled in the
art can appreciate and understand the principles and practices of
the invention. The figures in the detailed description that follow
more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention can be completely understood in consideration
of the following detailed description of various embodiments of the
invention in connection with the accompanying drawings, in
which:
[0013] FIG. 1 is a perspective view of the present invention
mat.
[0014] FIG. 2 is a cross sectional view of the mat.
[0015] FIG. 3 is a perspective view of the mat in FIG. 1 after an
energetic event.
[0016] FIG. 4 is a cut-away view of the mat.
[0017] FIG. 5 is a perspective view of the mat atop an ammunition
container.
[0018] FIG. 6 is a perspective view of the mat as an attachment to
body armor.
[0019] FIG. 7 is a perspective view of the mat installed on the
floor of a vehicle
[0020] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DETAILED DESCRIPTION
[0021] Embodiments of the present invention are discussed in detail
below. In describing embodiments, specific terminology is employed
for the sake of clarity. However, the present invention is not
intended to be limited to the specific terminology so selected. A
person skilled in the relevant art will recognize that other
equivalent parts can be employed and other methods developed
without parting from the spirit and scope of the present
invention.
[0022] By manufacturing the mat entirely out of non-flammable
materials, this mat improves upon existing mats because it reduces
the force which is transmitted from the blast to nearby soldiers
and eliminates the risk of a subsequent fire. In addition to being
non-flammable, the structure can absorb large blasts while
remaining lightweight.
[0023] Referring to FIG. 1, in one embodiment, mat 100 is a blast
mitigation surface that can absorb the impulse from an explosion.
Mat 100 comprises a surface layer 102, absorptive layer 104, and a
finishing layer 106. In this embodiment, mat 100 is designed to be
placed on the floor of a vehicle [See FIG. 7]. Surface layer 102 of
mat 100 can be approximately 3 mm thick and provides an anti-slip
surface 108 for walking or standing. Anti-slip surface 108 is one
embodiment is a diamond plate. Surface layer 102 is bonded, in this
case adhesively, but could be welded or brazed, to absorptive layer
104. In other embodiments, surface layer 102 can comprise different
thicknesses or materials, depending on the application of mat
100.
[0024] Referring to FIG. 1, in the same embodiment, absorptive
layer 104 is primarily a hollow metallic structure approximately 1
to 1.5 inches thick. Absorptive layer 104 is structured to absorb
blast accelerations. The structure is composed of metallic
ligaments or thin skins formed by foaming, casting, stamping, or
drawing. Open-cell foams have a complex microstructure consisting
of an interconnected network of ligaments that form along the edges
of randomly packed cells that evolve during the foaming process.
The core material may be discontinuous in the form of space
pillars, but this is not necessary. FIG. 1 shows absorptive layer
104 configured using an open cell aluminum foam, however one
skilled in the art will recognize that other materials, metal or
non-metal, may be used for absorptive layer 104.
[0025] Material selection for absorptive layer 104 is preferably a
non-flammable material, such as for example, aluminum foam,
Nomex.TM. or a metal honeycomb. Aluminum foam can be open cell or
closed cell. Nomex.TM. honeycomb is made from Nomex.TM. paper--a
form of paper based on Kevlar.RTM., rather than cellulose fibers.
It is widely used in fire retardant applications. Aluminum
honeycomb produces one of the highest strength/weight ratios of any
structural material. Various configurations of the aluminium foil
which can lead to a variety of geometric cell shapes (usually
hexagonal). Properties can also be controlled by varying the foil
thickness and cell size.
[0026] Finishing layer 106 is of similar thickness to surface layer
102. In one embodiment it is designed to provide a means of
attachment to the vehicle structure or floor. It may be attached to
absorptive layer 104 in a manner similar to the way surface layer
102 is attached to the absorptive layer 104. Finishing layer 106
may have apertures or other connecting elements to mount the blast
mitigation surface to a structure.
[0027] In operation of the embodiment above, absorptive layer 104
is comprised of aluminum foam which will not burn. Existing mats
typically use a polymer such as polyurethane foam. Polymer based
foams are susceptible to fire, even if coated with a fire resistive
material. Referring to FIG. 2, when a combat vehicle drives over an
IED the energy of the blast 107 is directed upward from through the
undercarriage of the vehicle. The energy travels through the floor
of the vehicle to finishing layer 106 of mat 100. The energy
further travels into absorptive layer 104, which absorbs most of
the energy and causes the aluminum foam to deform. The aluminum
foam can heat up as it deforms. Because the absorptive layer is
made of aluminum foam rather than polyurethane, the foam will not
burn when it heats up; instead it will melt. By using a hollow
metallic structure such as aluminum foam, the mat is able to absorb
large blasts while remaining lightweight, durable, and importantly,
non-flammable.
[0028] In operation, referring to FIG. 3, mat 100 is shown after a
simulated explosion. A soldier 110 is standing atop surface layer
102. A mechanical device 112 exerts a sudden force upward through
finishing layer 106. Absorptive layer 104 absorbs most of the
energy from 112 which causes it to deform. The deformation is
greatest where soldier 110 has the most weight on surface layer
102. Since absorbing layer 104 and surface layer 102 absorb most of
the energy, less energy is transmitted to soldier 110 which
drastically reduces injuries to the lower extremities.
[0029] This concept is not limited to floor mats; additional
embodiments of non-flammable blast mitigation mats may include mats
for seats, walls, bulkheads, ceilings, ammunition compartments for
ships and aircraft, and even protective gear such as helmets and
body armor.
[0030] Referring to another embodiment, FIG. 4, shows non-flammable
blast mitigation mat 200 which is designed to cover walls. Surface
layer 202 may be a thin layer of non-reflective coating. Absorptive
layer 204 may be several inches thick. It may consist of aluminum
foam, or the foam may be made with even stronger or heavier metals.
Finishing layer 206 may be similar to the finishing layer 106 of
the floor mat embodiment, allowing mat 200 to be attached to the
wall via screws or other fasteners, or bonded to the wall with
adhesives, welding, or brazing.
[0031] Operably, energy from an explosive event impacts surface
layer 202. Absorptive layer 204 absorbs the majority of the blast
energy causing the aluminum foam to deform and melt. Finishing
layer 206 is attached to the exterior of a structure. Because
absorptive layer 204 absorbs most of the blast energy, the
structure remains standing long enough for its occupants to make a
safe exit. After the explosion, mat 200 may be replaced by removing
detaching finishing layer 206 from the structure.
[0032] Referring to another embodiment, FIG. 5, shows non-flammable
blast mitigation mat 300 which is designed for ammunition
compartments. Surface layer 302 may consist of a thin layer of
metal with handholds or hinges depending upon which area of the
ammunition compartment the mat covers. Absorptive layer 304 may be
aluminum or titanium foam several inches thick. Finishing layer 306
may be omitted if there is no need to attach the mat to another
object.
[0033] An explosive event may occur within ammunition compartment
312 or outside ammunition compartment 312. Operably, when the
explosion occurs outside ammunition compartment 312, energy from an
explosive event impacts surface layer 302. Absorptive layer 304
absorbs the majority of the blast energy causing the aluminum foam
to deform and melt. Finishing layer 306 prevents the melted foam
from contacting the contents of ammunition compartment 312. If
ordinance within ammunition compartment 312 explodes, absorptive
layer 304 absorbs the blast energy, preventing injury to nearby
soldiers.
[0034] Referring to another embodiment, FIG. 6, shows non-flammable
blast mitigation mat 400 which is designed for body armor. Surface
layer 402 may be a layer of Kevlar.RTM.. Absorptive layer 404 may
be only a few millimeters thick. Absorptive layer 404 may be a
carbon nanotube structure. Finishing layer 406 may be another layer
of Kevlar.RTM.. An explosive event may be due to a bomb blast or
bullet. Operably, energy from the blast strikes mat 400 and is
transmitted through surface layer 402 and is absorbed by absorptive
layer 404. Absorptive layer 404 absorbs the energy of the blast
and, in the case of a bullet, absorbs enough energy to slow down a
bullet. Finishing layer 406, made of Kevlar.RTM., provides
additional protection to stop any bullets that pierce absorptive
layer 404.
[0035] FIG. 7 depicts the present invention mat 100 installed on
the crew area of a military vehicle 160. The mat 100 is laid in
tile sheets and then held in place by mat strips 150. The strips
150 overlap portions of the mat 100. Fasteners 152 are used to
attach the mat strip 150 to the base floor 154 of the military
vehicle 160.
* * * * *