US20120097017A1 - Armor system and method of manufacture - Google Patents
Armor system and method of manufacture Download PDFInfo
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- US20120097017A1 US20120097017A1 US12/362,256 US36225609A US2012097017A1 US 20120097017 A1 US20120097017 A1 US 20120097017A1 US 36225609 A US36225609 A US 36225609A US 2012097017 A1 US2012097017 A1 US 2012097017A1
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Images
Classifications
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10064—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising at least two glass sheets, only one of which being an outer layer
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- B32B15/18—Layered products comprising a layer of metal comprising iron or steel
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/061—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
- B32B17/10027—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet the glass sheet not being an outer layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
- B32B17/10045—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets with at least one intermediate layer consisting of a glass sheet
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10082—Properties of the bulk of a glass sheet
- B32B17/10119—Properties of the bulk of a glass sheet having a composition deviating from the basic composition of soda-lime glass, e.g. borosilicate
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
- F41H5/04—Plate construction composed of more than one layer
- F41H5/0414—Layered armour containing ceramic material
- F41H5/0421—Ceramic layers in combination with metal layers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
- F41H5/04—Plate construction composed of more than one layer
- F41H5/0414—Layered armour containing ceramic material
- F41H5/0428—Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/911—Penetration resistant layer
Definitions
- This invention relates to ballistic armor. More specifically, this invention relates to an armor system utilizing a multi-layer structure incorporating glass-ceramics and laminates.
- projectiles In order to provide protection of personnel and equipment from ballistic projectiles, explosive ordnance, and forces and objects from detonation of improvised explosive devices (collectively hereinafter “projectiles”), it is necessary to provide a means of disbursing the kinetic energy of such projectiles to prevent them from reaching their target. Although this may be accomplished by interposing a large mass of any of a number of different materials between the target and the incoming projectile, experience has shown that a much more efficient means of energy disbursement is provided by suitably engineered ballistic armor structures wherein layers of different materials act to disrupt and disperse the energy of an incoming projectile.
- Such structures strive to maximize the amount of material which may be acted upon to absorb and disburse the energy of the projectile, while at the same time breaking or deforming the projectile and distributing these resulting fragments into a wider area. Such structures further strive to minimize the total amount of materials required for the protection of a specific area.
- Ballistic armor structures generally contain one or more layers of material engineered to spread the force of the impact by deforming, deflecting, or fragmenting the ballistic projectile while the ballistic armor itself undergoes deformation or localized fragmentation.
- the deformation and localized fragmentation processes of the ballistic armor structure absorb a large portion of energy from the projectile while simultaneously spreading the impacted area to involve more material in successive layers. Both hardness and toughness of the ballistic armor structure are required for these functions.
- the initial layer of material used to disrupt the incoming ballistic projectile is often referred to as the “strike face,” or alternatively, the “hard face.”
- the hard face is typically a layer of relatively hard and tough material designed to deform, and in some cases fragment, to absorb at least some of the energy of the incoming projectile, thereby distributing the projectile's energy.
- Following the hard face are other layers specifically designed to absorb the remaining energy of the impacting material and pieces of the previous hard face. These layers are often referred to as the “backing” or “catcher.”
- the process of energy absorption and disbursement of the incoming projectile by the ballistic armor structure is generally intended to result in deformation, displacement and/or localized fracture of the hard face, and deformation and/or displacement of the backing, but without penetration through the ballistic armor structure by any fragments of the ballistic projectile. Selection of materials for these distinct functions and careful attention to construction and coupling of the various layers is essential to optimizing performance of the ballistic armor structure.
- the armor system for limiting the transfer of impact force from a projectile and method of manufacture is disclosed herein.
- the armor system includes a hard face and at least one reinforcing layer covering a rear surface of the hard face. At least one resilient layer forms a rearward outer layer of the armor system.
- the hard face is defined by a layer fabricated from a ballistic ceramic material.
- the reinforcing layer is fabricated from a glass-ceramic substance having a hardness and compressive strength, both in dynamic conditions and standard temperature and pressure conditions, sufficient to substantially absorb at least a portion of the impact from an incoming projectile.
- the resilient layer is selected to have a sufficient thickness and strength to withstand stresses imparted to the resilient layer under ballistic impact of the hard face.
- the resilient layer is fabricated from a metal, such as steel.
- the resilient layer is fabricated from an aramid.
- the resilient layer is fabricated from a polymer.
- a plurality of hard faces are provided, each hard face being held in parallel and spaced apart arrangement with respect to one another.
- a first hard face is selected to have a sufficient thickness and strength to partially disrupt an incoming projectile, while the second hard face is selected to have a thickness and strength sufficient to substantially absorb the remaining portion of the impact from the incoming projectile.
- Each hard face includes at least one reinforcing layer covering a rear surface of the hard face and at least one resilient layer covering the at least one reinforcing layer opposite the hard face.
- a method of manufacture of the armor system generally includes providing a hard face, arranging at least one reinforcing layer rearward of the hard face, and arranging at least one resilient layer rearward of the reinforcing layer.
- bonding layers are arranged in a substantially parallel planar fashion between the various layers. The various layers are then held against one another in the substantially parallel planar configuration and heated to allow the layers to join to one another.
- FIG. 1 is a cross-sectional view of one embodiment of the armor system constructed in accordance with several features of the present invention
- FIG. 2 is a cross-sectional view of the armor system of FIG. 1 , showing a projectile impacting the hard face;
- FIG. 3 is a cross-sectional view of another embodiment of the armor system
- FIG. 4 is a cross-sectional view of the armor system of FIG. 3 , showing a projectile impacting the hard face;
- FIG. 5 is a cross-sectional view of another embodiment of the armor system, in which two spaced apart hard faces with cooperating reinforcing and resilient layers are included;
- FIG. 6 is a cross-sectional view of the armor system of FIG. 5 , showing a projectile impacting the armor system;
- FIG. 7 is an exploded perspective view of various layers used to manufacture one embodiment of the armor system, together with a substantially airtight container;
- FIG. 8 is a perspective view of the materials of FIG. 7 , showing the substantially airtight container containing the laminate structure, with the airtight container sealed and evacuated;
- FIG. 9 is a perspective view showing one corner of the substantially airtight container of FIG. 8 ;
- FIG. 10 is a cross-sectional view of a vessel containing the sealed and evacuated container of FIG. 9 .
- an armor system for limiting the transfer of impact force from a projectile and corresponding method of manufacture is disclosed herein.
- the armor system is illustrated generally at 10 in the figures.
- one embodiment of the armor system 10 a includes a hard face 12 having a front surface 13 configured to face an anticipated incoming projectile 16 and a rear surface 18 configured opposite the anticipated incoming projectile 16 .
- At least one reinforcing layer 22 covers the rear surface 18 of the hard face 12
- at least one resilient layer 14 is disposed against the at least one reinforcing layer 22 opposite the hard face 12 .
- the hard face 12 is defined by a layer fabricated from a substance having a hardness and compressive strength sufficient to substantially absorb at least a portion of the impact from an incoming projectile 16 .
- the hard face 12 can vary in thickness, configuration, density, and weight in order to enhance the projectile stopping power. It is generally understood that the stiffness of a body is a function of the thickness of the body, and that generally the thicker the hard face 12 , the more effective the hard face 12 is in disrupting an incoming projectile 16 . Thus, it will be understood that in selecting the overall thickness of the hard face 12 , there is a weight versus effectiveness trade off in certain applications. For example, it is important that armor for personal use be lightweight, while armor for vehicle use or for building use can be of a heavier weight.
- the specific type of material suitable for use in the hard face 12 depends upon the mass, velocity, and impact characteristics of the projectile to be armored against.
- the hard face 12 is fabricated from a ballistic ceramic material, such as boron carbide, silicon carbide, aluminum oxide, titanium diboride, or the like.
- the hard face 12 is fabricated from a metal, such as iron, steel, aluminum, tungsten, titanium, or the like.
- At least one reinforcing layer 22 is secured along the rear surface 18 of the hard face 12 .
- the reinforcing layer 22 is fabricated from a glass-ceramic substance having a hardness and compressive strength sufficient to substantially absorb at least a portion of the impact from the incoming projectile 16 .
- one reinforcing layer 22 is laminated against the rear surface 18 of the hard face 12 .
- multiple reinforcing layers 22 in varying configurations may be provided as further discussed below.
- the glass-ceramic material forming the reinforcing layer 22 is generally a material produced by traditional glass making processes but having been subsequently annealed under specific conditions leading to the nucleation and growth of crystalline bodies throughout the mass of the glass-ceramic material.
- the crystalline bodies are composed of a lithium-alumino silicate phase which is crystallized during production of the glass-ceramic material.
- those skilled in the art will recognize other materials containing suitable crystalline bodies. Increasing the crystallization of the mass of the glass-ceramic material will as a general rule, enhance its shielding power.
- the reinforcing layer 22 is fabricated from a glass-ceramic formed of crystals having an average dimension per crystal of less than or equal to approximately two-hundred (200) nanometers. However, crystalline structures exhibiting an average dimension per crystal greater than two-hundred (200) nanometers are contemplated.
- One factor to consider in deciding the specific properties of the glass-ceramic material for use in the reinforcing layer 22 is the hardness relative to the sonic velocity of the incoming projectile 16 .
- the armor system was able to completely disrupt four rounds of 7.62 millimeter rifle ammunition travelling at 3,180 feet per second.
- Another armor system incorporating a glass-ceramic layer having dimensions of 19 inches by 19 inches by 3.49 inches and a density of 37.8 pounds per square foot was able to disrupt four rounds of 0.30-06 calibur, 165 grain APM2 rifle ammunition travelling at approximately 2,900 feet per second.
- the resilient layer 14 is a material forming a rearward outer layer of the armor system 10 a opposite the hard face 12 .
- the resilient layer 14 maintains at least simple intimate contact with the at least one reinforcing layer 22 .
- the resilient layer 14 is selected to have a sufficient thickness and strength to withstand stresses imparted to the resilient layer 14 under ballistic impact of the hard face and reinforcing layers 12 , 22 .
- the maximum stress that the hard face and reinforcing layers 12 , 22 impart to the resilient layer 14 is related to the specific yield stress of the hard face 12 and the specific yield stress of each of the at least one reinforcing layers 22 .
- the resilient layer 14 is an aramid material.
- the resilient layer 14 is fabricated from a polymer material such as silica-covered polycarbonate or other polymer material.
- the resilient layer 14 is fabricated from a metal such as steel, titanium, or the like. Those skilled in the art will recognize other materials having suitable strength for use in fabrication of the resilient layer 14 .
- At least one bonding layer is provided between one or more of the various layers 12 , 14 , 22 to bond the layers together.
- the bonding layer is fabricated from a material exhibiting adhesion sufficient to maintain shear compliance between the various layers 12 , 14 , 22 .
- the bonding layer is fabricated from a material exhibiting a coefficient of thermal expansion sufficiently low as to exhibit thermal expansion properties comparable to the glass-ceramic material.
- the bonding layer is fabricated from a material exhibiting adhesion sufficient to maintain shear compliance between the various layers 12 , 14 , 22 while the layers undergo thermal expansion due to changes in temperature of the armor system 10 a ranging from below freezing to over 85 degrees Centigrade.
- the materials for fabrication of the various layers 12 , 14 , 22 are selected such that the various layers 12 , 14 , 22 adhere directly to one another absent the inclusion of a bonding layer.
- suitable devices for joining the various layers 12 , 14 , 22 and such devices may be used without departing from the spirit and scope of the present invention.
- mechanical fasteners are provided to secure the various layers 12 , 14 , 22 in an overlapping, parallel planar configuration.
- FIG. 2 illustrates the armor system 10 a during the initial impact of an incoming projectile 16 .
- deformation and fracture of the hard face 12 occurs in response to forces resulting from impact by the incoming projectile 16 .
- the degree to which the hard face 12 deforms and fractures is relative to the magnitude of the impact forces of the incoming projectile 16 .
- the incoming projectile 16 transmits impact energy to the hard face 12 of sufficient magnitude that the hard face 12 fails to absorb substantially all of the impact energy of the incoming projectile 16
- at least a portion of the remaining impact energy of the incoming projectile 16 is transferred to the reinforcing layer 22 .
- the reinforcing layer 22 serves to provide structural stability to the armor system 10 a and to further absorb energy transferred to the reinforcing layer 22 from the hard face 12 during structural failure of the hard face 12 resulting from ballistic impact. Similarly to the hard face 12 , it is contemplated that deformation and fracture of the reinforcing layer 22 occurs in response to the portion of the impact force transferred to the reinforcing layer 22 . Also, the degree to which the reinforcing layer 22 deforms and fractures is relative to the magnitude of the impact forces transferred to the reinforcing layer 22 .
- the reinforcing layer 22 is fabricated from a glass-ceramic material with an approximately 65% by volume non-continuous phase of crystals, each crystal having a dimension of approximately less than 100 nanometers.
- the glass-ceramic material offers material properties during the time period of ballistic impact that are neither anticipated nor predicted by properties of the glass-ceramic material measured under standard temperature and pressure.
- the continuous glassy phase of the glassceramic material which is a super-cooled liquid, plastically compresses and conforms for a brief time under the pressure of a ballistic impact.
- This plastic compression brings the crystals into closer proximal location, thus presenting a heightened ballistic resistance exhibited by the temporarily plastically compressed glass-ceramic material.
- the inclusion of the at least one glass-ceramic reinforcing layer 22 provides an increased ability of the armor system 10 to disrupt an incoming projectile 16 , as compared to a conventional hard face of comparable thickness.
- such fabrication of the reinforcing layer 22 from a glass-ceramic material allows a thinner and therefore more lightweight armor to provide similar disruption of an incoming projectile 16 , as compared to a conventional ballistic armor material.
- the reinforcing layer 22 is selected such that, upon impact of the armor system 10 a by a projectile 16 having significant impact energy, extensive fracturing and granulation of at least a portion of the reinforcing layer 22 proximate the point of impact of the projectile 16 occurs. At least a portion of the impact forces imparted to the reinforcing layer 22 are expended during fracturing of the reinforcing layer 22 , and the remaining impact forces are thereafter transferred to the resilient layer 14 .
- the extensively fractured granules of the reinforcing layer 22 cooperate to disburse and spread such impact forces to form a pressure 10 ad along at least a portion of the resilient layer 14 .
- the resilient layer 14 is selected to have a sufficient tensile strength to resist tensile failure as a result of the 10 ad imparted by the granules of the reinforcing layer 22 .
- the granules of the reinforcing layer 22 further cooperate to limit fractured pieces of the hard face 12 or the projectile 16 from impacting the resilient layer 14 , thereby discouraging shear failure of the resilient layer 14 resulting from such impact.
- the at least intimate contact between the resilient layer 14 and the reinforcing layer 22 provides a means for containing debris resulting from fracture of the hard face and reinforcing layers 12 , 22 , such as, for example, fracture resulting from projectile impact.
- debris containment serves to limit the various fractured pieces of the hard face 12 and the reinforcing layer 22 from propulsion through the resilient layer 14 and toward a target protected by the armor system 10 a .
- debris containment further serves to retain such fractured pieces substantially within the original configurations of the hard face and reinforcing layers 12 , 22 , thereby improving the multi-hit performance and field durability of the armor system 10 a.
- FIG. 3 illustrates another embodiment of the armor system 10 b of the present invention.
- a plurality of reinforcing layers 22 are provided in a substantially overlapping, parallel planar configuration rearward of the hard face 12 .
- the various reinforcing layers 22 serve to provide structural stability to the armor system 10 b and to further absorb energy transferred to the reinforcing layers 22 from the hard face 12 during structural failure of the hard face 12 resulting from ballistic impact.
- Each subsequent reinforcing layer 22 opposite the hard face 12 from the projectile 16 further absorbs energy transferred from the previous layer.
- the amount of fracture, deformation, and other damage done to each successive layer 12 , 22 decreases as the impact forces of the projectile 16 are partially absorbed by the fracture and deformation of each preceding layer 12 , 22 .
- the layers adjacent to the reinforcing layer 22 cooperate to provide a means for containing debris resulting from the fracture of the reinforcing layer 22 , such as, for example, fracture resulting from projectile impact. In this manner, the layers adjacent to each reinforcing layer 22 cooperate to maintain such debris substantially within the original configuration of the reinforcing layer 22 , thereby further improving the multi-hit performance and field durability of the armor system 10 b .
- three reinforcing layers 22 are provided. However, it will be understood that any number of reinforcing layers 22 with cooperating hard face 12 and resilient layers 14 may be provided without departing from the spirit and scope of the present invention.
- a plurality of resilient layers 14 a , 14 b are provided in an adjacent, overlapping configuration rearward of the reinforcing layers 22 .
- the plurality of resilient layers 14 a , 14 b cooperate to resist stresses imparted to the resilient layers 14 a , 14 b under ballistic impact of the hard face and reinforcing layers 12 , 22 .
- a first resilient layer 14 a is fabricated from an aramid material, while a second resilient layer 14 b is fabricated from a metal such as titanium.
- the second resilient layer 14 b serves to limit fractured pieces of the hard face 12 , the projectile 16 , and the preceding reinforcing layers 22 from impacting the first resilient layer 14 a , thereby discouraging shear failure of the first resilient layer 14 a resulting from such impact.
- titanium foil has been shown to elongate under certain surface pressure loading by as much as over 50% prior to exhibiting tensile failure.
- the first resilient layer 14 a is fabricated from an aramid material and the second resilient layer 14 b is fabricated from titanium foil.
- those skilled in the art will recognize other materials having suitable strength for use in fabrication of the various resilient layers 14 a , 14 b , and such materials may be used without departing from the spirit and scope of the present invention.
- a plurality of hard faces are provided and secured in a parallel planar configuration and spaced apart therebetween.
- a first hard face 12 a and a second hard face 12 b are provided.
- the first hard face 12 a is provided with at least a first reinforcing layer 22 a laminated to the rear surface 18 a of the first hard face 12 a
- the second hard face 12 b is provided with at least a second reinforcing layer 22 b laminated to the rear surface 18 b of the second hard face 12 b .
- At least a first resilient layer 14 c is disposed to maintain at least intimate contact with a rear surface of the at least one first reinforcing layer 22 a
- a second resilient layer 14 d is disposed to maintain at least intimate contact with a rear surface of the at least one second reinforcing layer 22 b
- the first hard face 12 a and cooperating at least one reinforcing layer 22 a and resilient layer 14 c are held in a spaced apart relationship relative to the second hard face 12 b and cooperating at least one reinforcing layer 22 b and resilient layer 14 d by conventional means, such as by spaced apart fasteners, within the confines of a frame, or other conventional means.
- a plurality of reinforcing layers 22 a , 22 b are provided rearward of each cooperating hard face 12 a , 12 b .
- Each reinforcing layer 22 a , 22 b cooperates with adjacent resilient layers 14 c , 14 d and corresponding hard face layers 12 a , 12 b to increase the overall rigidity of the armor system 10 c .
- reinforcing layers 22 a , 22 b provided for each hard face 12 a , 12 b
- any number of reinforcing layers 22 a , 22 b may be provided to any hard face 12 a , 12 b , in numerous configurations, without departing from the spirit and scope of the present invention.
- FIG. 6 shows an incoming projectile 16 impacting the armor system 10 c of FIG. 5 .
- the first hard face 12 a and cooperating reinforcing layers 22 a are each selected to have a sufficient thickness and strength to absorb a portion of the impact from an incoming projectile 16 .
- deformation and fracture of the portions of the first hard face 12 a and cooperating reinforcing layers 22 a local to the area of impact of the projectile 16 is contemplated.
- complete disruption of the incoming projectile 16 by the first hard face 12 a is contemplated.
- the spacing of the first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 a proximate the second hard face 12 b allows for multiple impacts to armor system 10 c before damage to the second hard face 12 b occurs.
- penetration of the first hard face 12 a and cooperating reinforcing layers 22 a by the projectile 16 is also contemplated, such that, upon penetration of the first hard face 12 a and cooperating reinforcing layers 22 a by the projectile 16 , at least partial disruption of the projectile 16 by the first hard face 12 a and cooperating reinforcing layers 22 a occurs.
- such partial disruption results in a change in the trajectory of the projectile 16 following penetration of the first hard face 12 a .
- the partial disruption of the projectile 16 by the first hard face 12 a promotes a tendency for the projectile 16 to begin to tumble along its new trajectory.
- the spacing of the first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 c proximate the second hard face 12 b is selected so as to allow the various fractured pieces of the projectile 16 to spread apart as the projectile 16 assumes its changed trajectory following penetration of the first hard face 12 a and cooperating reinforcing layer 22 a and resilient layer 14 c , prior to impact with the second hard face 12 b .
- first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 c proximate the second hard face 12 b depends upon the shape, size, mass, velocity, and impact characteristics of the projectile to be armored against, as well as the thickness of the respective hard face layers and the resultant ability of the hard face layers to effect change of the trajectory of the impacted projectile 16 .
- a relatively heavy and fast-moving projectile such as certain high powered rifle bullets or explosive fragments
- a relatively heavy and fast-moving projectile may require an increased spacing of the first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 c proximate the second hard face 12 b , of a given thickness and composition of hard face and cooperating reinforcing and resilient layers, in order to allow the projectile pieces to spread apart
- a relatively short, light, slower-moving projectile such as certain handgun bullets, may require less spacing of the first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 c proximate the second hard face 12 b before such spreading of the projectile pieces occurs.
- the partially disrupted projectile 16 impacts the second hard face 12 b .
- the partial disruption of the projectile 16 by the first hard face 12 a results in impact characteristics of the projectile 16 which are generally less focused along the original trajectory of the projectile 16 than those of the projectile 16 prior to impact with the first hard face 12 a .
- the forces of impact of the partially disrupted projectile 16 are applied to an increased surface area of the second hard face 12 b .
- FIGS. 5-6 allow for the provision of a armor panel having a reduced amount of material per unit area, and thus, a lighter armor panel.
- the embodiment of FIGS. 5-6 allows for an increased effectiveness of the armor panel as compared to an armor panel of equal weight per unit area.
- the spaced apart relationship of the first hard face 12 a and cooperating reinforcing and resilient layers 22 a , 14 c proximate the second hard face 12 b of the present embodiment allows for the placement therebetween of a thermally insulative material, such as air, argon gas, nitrogen gas, insulative liquid, or other thermally insulative material.
- a thermally insulative material such as air, argon gas, nitrogen gas, insulative liquid, or other thermally insulative material.
- FIGS. 5-6 provides an armor panel having improved thermally insulative qualities as compared to conventional armor panels.
- Other benefits of the various features of the present embodiment of the armor system 10 c will be recognized by one skilled in the art.
- FIGS. 7-10 pertain to a method of manufacture of the armor system 10 , also disclosed herein.
- the method of manufacture generally includes providing a hard face 12 , arranging at least one reinforcing layer 22 rearward of the hard face 12 , and arranging at least one resilient layer 14 rearward of the reinforcing layer 22 .
- the bonding layers 20 are arranged in a substantially parallel planar fashion between at least two of the various layers 12 , 14 , 22 .
- the various layers 12 , 14 , 20 , 22 are then held together in the substantially parallel planar configuration and allowed to join to form a laminate structure 36 .
- a substantially compliant and substantially airtight container 34 is provided to hold the various layers in the substantially parallel planar configuration.
- the container 34 is of approximate dimensions and volume to contain a panel fabricated from the armor system 10 .
- the laminate structure 36 is placed within the container 34 .
- the container 34 is then sealed and evacuated to a low pressure, thereby forcing the various components of the laminate structure 36 into close proximity.
- the container 34 containing the laminate structure 36 is placed into a vessel 38 .
- the vessel 38 is then heated, such that the laminate structure 36 is heated to a temperature in which at least every other layer is thermally expanded, softened, and becomes adhesive.
- Gaseous pressure is thereafter applied inside the vessel 38 , exterior to the container 34 .
- the combination of temperature of the laminate structure 36 and pressure within the vessel 38 is maintained for a sufficient time as to allow a desirable amount of lamination within the laminate structure 36 .
- lamination within the laminate structure 36 is continued until such point that temperature reduction of the laminate structure 36 absent excessive deleterious residual stresses within the laminate structure 36 is possible.
- the temperature of the laminate structure 36 is reduced, such as to firmly set the various layers 12 , 14 , 20 , 22 in lamination to one another, thereby forming a finished armor system 10 .
- the pressure in the vessel 38 and the vacuum in the container are then released, and the finished armor system 10 is removed.
- the armor system provides a ballistic armor structure which is capable of providing ballistic protection comparable to conventional armor structures, but with reduced aerial weight as compared to the conventional armor structures.
- the armor system provides a laminate structure exhibiting cohesive interlaminar strength, multi-hit capability, thermal environment stability, and light weight.
- the armor system provides a ballistic armor structure which is capable of providing increased ballistic protection compared to a conventional armor structure of similar aerial weight.
Abstract
Description
- This application is a Continuation-In-Part of U.S. application Ser. No. 12/349,832, filed Jan. 7, 2009; which is a Continuation-In-Part of U.S. application Ser. No. 11/689,299, filed Mar. 21, 2007.
- Not Applicable
- 1. Field of Invention
- This invention relates to ballistic armor. More specifically, this invention relates to an armor system utilizing a multi-layer structure incorporating glass-ceramics and laminates.
- 2. Description of the Related Art
- In order to provide protection of personnel and equipment from ballistic projectiles, explosive ordnance, and forces and objects from detonation of improvised explosive devices (collectively hereinafter “projectiles”), it is necessary to provide a means of disbursing the kinetic energy of such projectiles to prevent them from reaching their target. Although this may be accomplished by interposing a large mass of any of a number of different materials between the target and the incoming projectile, experience has shown that a much more efficient means of energy disbursement is provided by suitably engineered ballistic armor structures wherein layers of different materials act to disrupt and disperse the energy of an incoming projectile. Such structures strive to maximize the amount of material which may be acted upon to absorb and disburse the energy of the projectile, while at the same time breaking or deforming the projectile and distributing these resulting fragments into a wider area. Such structures further strive to minimize the total amount of materials required for the protection of a specific area.
- Ballistic armor structures generally contain one or more layers of material engineered to spread the force of the impact by deforming, deflecting, or fragmenting the ballistic projectile while the ballistic armor itself undergoes deformation or localized fragmentation. The deformation and localized fragmentation processes of the ballistic armor structure absorb a large portion of energy from the projectile while simultaneously spreading the impacted area to involve more material in successive layers. Both hardness and toughness of the ballistic armor structure are required for these functions.
- In the field of ballistic armor structures, the initial layer of material used to disrupt the incoming ballistic projectile is often referred to as the “strike face,” or alternatively, the “hard face.” The hard face is typically a layer of relatively hard and tough material designed to deform, and in some cases fragment, to absorb at least some of the energy of the incoming projectile, thereby distributing the projectile's energy. Following the hard face are other layers specifically designed to absorb the remaining energy of the impacting material and pieces of the previous hard face. These layers are often referred to as the “backing” or “catcher.”
- The process of energy absorption and disbursement of the incoming projectile by the ballistic armor structure is generally intended to result in deformation, displacement and/or localized fracture of the hard face, and deformation and/or displacement of the backing, but without penetration through the ballistic armor structure by any fragments of the ballistic projectile. Selection of materials for these distinct functions and careful attention to construction and coupling of the various layers is essential to optimizing performance of the ballistic armor structure.
- In many armor applications, traditional materials such as steel offer some level of protection from ballistic projectiles and shell fragments. However, great advances have been made in selection of materials for optimizing the performance of ballistic armor structures. Use of high-strength, hard, and in some cases “tough” ceramics like aluminum oxide, boron carbide, titanium diboride and silicon carbide for the hard face; and rigid or soft laminates of fibrous materials such as fiberglass, aramid, or polyethylene fiber for the backing have greatly reduced the mass and bulk of protective structures. These advances, unfortunately, are limited in the amount of ballistic energy that can reasonably be dissipated, and therefore these advances have not been readily applicable to those situations in which protection against a significant ballistic threat is required.
- Accordingly, there is a need for improvement in lighter weight, thinner ballistic armor to meet the increasing threats posed by newer, more energetic, and more powerful projectiles. Specifically, there is a need for improvement in lighter weight, thinner ballistic armor which can disrupt and disburse projectiles emanating from significant ballistic threats, which can easily be utilized by personnel, vehicles, equipment, buildings, and the like.
- An armor system for limiting the transfer of impact force from a projectile and method of manufacture is disclosed herein. The armor system includes a hard face and at least one reinforcing layer covering a rear surface of the hard face. At least one resilient layer forms a rearward outer layer of the armor system.
- The hard face is defined by a layer fabricated from a ballistic ceramic material. The reinforcing layer is fabricated from a glass-ceramic substance having a hardness and compressive strength, both in dynamic conditions and standard temperature and pressure conditions, sufficient to substantially absorb at least a portion of the impact from an incoming projectile. The resilient layer is selected to have a sufficient thickness and strength to withstand stresses imparted to the resilient layer under ballistic impact of the hard face. In certain embodiments, the resilient layer is fabricated from a metal, such as steel. In other embodiments, the resilient layer is fabricated from an aramid. In still other embodiments, the resilient layer is fabricated from a polymer.
- In another embodiment, a plurality of hard faces are provided, each hard face being held in parallel and spaced apart arrangement with respect to one another. In this embodiment, a first hard face is selected to have a sufficient thickness and strength to partially disrupt an incoming projectile, while the second hard face is selected to have a thickness and strength sufficient to substantially absorb the remaining portion of the impact from the incoming projectile. Each hard face includes at least one reinforcing layer covering a rear surface of the hard face and at least one resilient layer covering the at least one reinforcing layer opposite the hard face.
- A method of manufacture of the armor system generally includes providing a hard face, arranging at least one reinforcing layer rearward of the hard face, and arranging at least one resilient layer rearward of the reinforcing layer. In certain embodiments, bonding layers are arranged in a substantially parallel planar fashion between the various layers. The various layers are then held against one another in the substantially parallel planar configuration and heated to allow the layers to join to one another.
- The above-mentioned features of the invention will become more clearly understood from the following detailed description of the invention read together with the drawings in which:
-
FIG. 1 is a cross-sectional view of one embodiment of the armor system constructed in accordance with several features of the present invention; -
FIG. 2 is a cross-sectional view of the armor system ofFIG. 1 , showing a projectile impacting the hard face; -
FIG. 3 is a cross-sectional view of another embodiment of the armor system; -
FIG. 4 is a cross-sectional view of the armor system ofFIG. 3 , showing a projectile impacting the hard face; -
FIG. 5 is a cross-sectional view of another embodiment of the armor system, in which two spaced apart hard faces with cooperating reinforcing and resilient layers are included; -
FIG. 6 is a cross-sectional view of the armor system ofFIG. 5 , showing a projectile impacting the armor system; -
FIG. 7 is an exploded perspective view of various layers used to manufacture one embodiment of the armor system, together with a substantially airtight container; -
FIG. 8 is a perspective view of the materials ofFIG. 7 , showing the substantially airtight container containing the laminate structure, with the airtight container sealed and evacuated; -
FIG. 9 is a perspective view showing one corner of the substantially airtight container ofFIG. 8 ; and -
FIG. 10 is a cross-sectional view of a vessel containing the sealed and evacuated container ofFIG. 9 . - An armor system for limiting the transfer of impact force from a projectile and corresponding method of manufacture is disclosed herein. The armor system is illustrated generally at 10 in the figures. With reference to
FIG. 1 , one embodiment of thearmor system 10 a includes ahard face 12 having afront surface 13 configured to face an anticipatedincoming projectile 16 and arear surface 18 configured opposite the anticipatedincoming projectile 16. At least one reinforcinglayer 22 covers therear surface 18 of thehard face 12, and at least oneresilient layer 14 is disposed against the at least one reinforcinglayer 22 opposite thehard face 12. - The
hard face 12 is defined by a layer fabricated from a substance having a hardness and compressive strength sufficient to substantially absorb at least a portion of the impact from anincoming projectile 16. Thehard face 12 can vary in thickness, configuration, density, and weight in order to enhance the projectile stopping power. It is generally understood that the stiffness of a body is a function of the thickness of the body, and that generally the thicker thehard face 12, the more effective thehard face 12 is in disrupting anincoming projectile 16. Thus, it will be understood that in selecting the overall thickness of thehard face 12, there is a weight versus effectiveness trade off in certain applications. For example, it is important that armor for personal use be lightweight, while armor for vehicle use or for building use can be of a heavier weight. It is further understood that the specific type of material suitable for use in thehard face 12 depends upon the mass, velocity, and impact characteristics of the projectile to be armored against. In the illustrated embodiment, thehard face 12 is fabricated from a ballistic ceramic material, such as boron carbide, silicon carbide, aluminum oxide, titanium diboride, or the like. In another embodiment, thehard face 12 is fabricated from a metal, such as iron, steel, aluminum, tungsten, titanium, or the like. Those skilled in the art will recognize numerous other materials suitable for use in fabrication of thehard face 12, and such materials may be used without departing from the spirit and scope of the present invention. - At least one reinforcing
layer 22 is secured along therear surface 18 of thehard face 12. The reinforcinglayer 22 is fabricated from a glass-ceramic substance having a hardness and compressive strength sufficient to substantially absorb at least a portion of the impact from theincoming projectile 16. In the illustrated embodiment, one reinforcinglayer 22 is laminated against therear surface 18 of thehard face 12. However, multiple reinforcinglayers 22 in varying configurations may be provided as further discussed below. - The glass-ceramic material forming the reinforcing
layer 22 is generally a material produced by traditional glass making processes but having been subsequently annealed under specific conditions leading to the nucleation and growth of crystalline bodies throughout the mass of the glass-ceramic material. In one embodiment, the crystalline bodies are composed of a lithium-alumino silicate phase which is crystallized during production of the glass-ceramic material. However, those skilled in the art will recognize other materials containing suitable crystalline bodies. Increasing the crystallization of the mass of the glass-ceramic material will as a general rule, enhance its shielding power. In one embodiment, the reinforcinglayer 22 is fabricated from a glass-ceramic formed of crystals having an average dimension per crystal of less than or equal to approximately two-hundred (200) nanometers. However, crystalline structures exhibiting an average dimension per crystal greater than two-hundred (200) nanometers are contemplated. - One factor to consider in deciding the specific properties of the glass-ceramic material for use in the reinforcing
layer 22 is the hardness relative to the sonic velocity of theincoming projectile 16. For example, in a ballistic test of an armor system incorporating a layer of glass-ceramic material having dimensions of 18.8 inches by 18.8 inches by 4.54 inches and a density of 51.8 pounds per square foot, the armor system was able to completely disrupt four rounds of 7.62 millimeter rifle ammunition travelling at 3,180 feet per second. Another armor system incorporating a layer of glass-ceramic material of similar dimensions, but with a density of 46.3 pounds per square foot, was shown to stop three shots of 20 millimeter fragment-simulating projectiles fired at approximately 5,000 feet per second in a 160 millimeter triangular-shaped pattern against the glass-ceramic layer. Another armor system incorporating a glass-ceramic layer having dimensions of 19 inches by 19 inches by 3.49 inches and a density of 37.8 pounds per square foot was able to disrupt four rounds of 0.30-06 calibur, 165 grain APM2 rifle ammunition travelling at approximately 2,900 feet per second. - The
resilient layer 14 is a material forming a rearward outer layer of thearmor system 10 a opposite thehard face 12. In several embodiments, theresilient layer 14 maintains at least simple intimate contact with the at least one reinforcinglayer 22. Theresilient layer 14 is selected to have a sufficient thickness and strength to withstand stresses imparted to theresilient layer 14 under ballistic impact of the hard face and reinforcinglayers layers resilient layer 14 is related to the specific yield stress of thehard face 12 and the specific yield stress of each of the at least one reinforcing layers 22. Specifically, the higher the yield stress of a previously encounteredlayer resilient layer 14. In one embodiment, theresilient layer 14 is an aramid material. In another embodiment, theresilient layer 14 is fabricated from a polymer material such as silica-covered polycarbonate or other polymer material. In yet another embodiment, theresilient layer 14 is fabricated from a metal such as steel, titanium, or the like. Those skilled in the art will recognize other materials having suitable strength for use in fabrication of theresilient layer 14. - In several embodiments, at least one bonding layer is provided between one or more of the
various layers various layers various layers armor system 10 a ranging from below freezing to over 85 degrees Centigrade. In other embodiments, the materials for fabrication of thevarious layers various layers various layers various layers -
FIG. 2 illustrates thearmor system 10 a during the initial impact of anincoming projectile 16. As shown inFIG. 2 , it is contemplated that deformation and fracture of thehard face 12 occurs in response to forces resulting from impact by theincoming projectile 16. Of course, the degree to which thehard face 12 deforms and fractures is relative to the magnitude of the impact forces of theincoming projectile 16. In applications in which the incoming projectile 16 transmits impact energy to thehard face 12 of sufficient magnitude that thehard face 12 fails to absorb substantially all of the impact energy of theincoming projectile 16, it is contemplated that at least a portion of the remaining impact energy of theincoming projectile 16 is transferred to the reinforcinglayer 22. Thus, the reinforcinglayer 22 serves to provide structural stability to thearmor system 10 a and to further absorb energy transferred to the reinforcinglayer 22 from thehard face 12 during structural failure of thehard face 12 resulting from ballistic impact. Similarly to thehard face 12, it is contemplated that deformation and fracture of the reinforcinglayer 22 occurs in response to the portion of the impact force transferred to the reinforcinglayer 22. Also, the degree to which the reinforcinglayer 22 deforms and fractures is relative to the magnitude of the impact forces transferred to the reinforcinglayer 22. - It has been found that mechanical properties of glass-ceramic materials at standard temperature and pressure (STP) are dissimilar from the properties of glass-ceramic materials during the very short time intervals of a ballistic event. Specifically, plastic compression resulting from ballistic impact often alters the material properties of glass-ceramic materials during the brief period while ballistic impact occurs. As an example, in one embodiment, the reinforcing
layer 22 is fabricated from a glass-ceramic material with an approximately 65% by volume non-continuous phase of crystals, each crystal having a dimension of approximately less than 100 nanometers. In this embodiment, the glass-ceramic material offers material properties during the time period of ballistic impact that are neither anticipated nor predicted by properties of the glass-ceramic material measured under standard temperature and pressure. In this embodiment, the continuous glassy phase of the glassceramic material, which is a super-cooled liquid, plastically compresses and conforms for a brief time under the pressure of a ballistic impact. This plastic compression brings the crystals into closer proximal location, thus presenting a heightened ballistic resistance exhibited by the temporarily plastically compressed glass-ceramic material. As such, it is appreciated that the inclusion of the at least one glass-ceramic reinforcinglayer 22 provides an increased ability of the armor system 10 to disrupt anincoming projectile 16, as compared to a conventional hard face of comparable thickness. Alternatively, such fabrication of the reinforcinglayer 22 from a glass-ceramic material allows a thinner and therefore more lightweight armor to provide similar disruption of anincoming projectile 16, as compared to a conventional ballistic armor material. - As shown in
FIG. 2 , the reinforcinglayer 22 is selected such that, upon impact of thearmor system 10 a by a projectile 16 having significant impact energy, extensive fracturing and granulation of at least a portion of the reinforcinglayer 22 proximate the point of impact of the projectile 16 occurs. At least a portion of the impact forces imparted to the reinforcinglayer 22 are expended during fracturing of the reinforcinglayer 22, and the remaining impact forces are thereafter transferred to theresilient layer 14. As the remaining forces resulting from impact by the incoming projectile 16 travel through the reinforcinglayer 22 to theresilient layer 14, the extensively fractured granules of the reinforcinglayer 22 cooperate to disburse and spread such impact forces to form a pressure 10 ad along at least a portion of theresilient layer 14. Theresilient layer 14 is selected to have a sufficient tensile strength to resist tensile failure as a result of the 10 ad imparted by the granules of the reinforcinglayer 22. The granules of the reinforcinglayer 22 further cooperate to limit fractured pieces of thehard face 12 or the projectile 16 from impacting theresilient layer 14, thereby discouraging shear failure of theresilient layer 14 resulting from such impact. - The at least intimate contact between the
resilient layer 14 and the reinforcinglayer 22 provides a means for containing debris resulting from fracture of the hard face and reinforcinglayers FIG. 2 , such debris containment serves to limit the various fractured pieces of thehard face 12 and the reinforcinglayer 22 from propulsion through theresilient layer 14 and toward a target protected by thearmor system 10 a. Such debris containment further serves to retain such fractured pieces substantially within the original configurations of the hard face and reinforcinglayers armor system 10 a. -
FIG. 3 illustrates another embodiment of thearmor system 10 b of the present invention. In the embodiment ofFIG. 3 , a plurality of reinforcinglayers 22 are provided in a substantially overlapping, parallel planar configuration rearward of thehard face 12. As shown inFIG. 4 , the various reinforcinglayers 22 serve to provide structural stability to thearmor system 10 b and to further absorb energy transferred to the reinforcinglayers 22 from thehard face 12 during structural failure of thehard face 12 resulting from ballistic impact. Each subsequent reinforcinglayer 22 opposite thehard face 12 from the projectile 16 further absorbs energy transferred from the previous layer. In this configuration, it is anticipated that the amount of fracture, deformation, and other damage done to eachsuccessive layer layer - For each reinforcing
layer 22, the layers adjacent to the reinforcinglayer 22 cooperate to provide a means for containing debris resulting from the fracture of the reinforcinglayer 22, such as, for example, fracture resulting from projectile impact. In this manner, the layers adjacent to each reinforcinglayer 22 cooperate to maintain such debris substantially within the original configuration of the reinforcinglayer 22, thereby further improving the multi-hit performance and field durability of thearmor system 10 b. In the illustrated embodiment ofFIGS. 3 and 4 , three reinforcinglayers 22 are provided. However, it will be understood that any number of reinforcinglayers 22 with cooperatinghard face 12 andresilient layers 14 may be provided without departing from the spirit and scope of the present invention. - As shown in
FIGS. 3 and 4 , in one embodiment a plurality ofresilient layers resilient layers resilient layers layers resilient layer 14 a is fabricated from an aramid material, while a secondresilient layer 14 b is fabricated from a metal such as titanium. In this configuration, the secondresilient layer 14 b serves to limit fractured pieces of thehard face 12, the projectile 16, and the preceding reinforcinglayers 22 from impacting the firstresilient layer 14 a, thereby discouraging shear failure of the firstresilient layer 14 a resulting from such impact. It is understood that titanium foil has been shown to elongate under certain surface pressure loading by as much as over 50% prior to exhibiting tensile failure. Thus, in a preferred embodiment, the firstresilient layer 14 a is fabricated from an aramid material and the secondresilient layer 14 b is fabricated from titanium foil. However, those skilled in the art will recognize other materials having suitable strength for use in fabrication of the variousresilient layers - In one embodiment of the
armor system 10 c, as illustrated inFIG. 5 , a plurality of hard faces are provided and secured in a parallel planar configuration and spaced apart therebetween. In the illustrated embodiment, a firsthard face 12 a and a secondhard face 12 b are provided. The firsthard face 12 a is provided with at least a first reinforcinglayer 22 a laminated to therear surface 18 a of the firsthard face 12 a, and the secondhard face 12 b is provided with at least a second reinforcinglayer 22 b laminated to therear surface 18 b of the secondhard face 12 b. At least a firstresilient layer 14 c is disposed to maintain at least intimate contact with a rear surface of the at least one first reinforcinglayer 22 a, and a secondresilient layer 14 d is disposed to maintain at least intimate contact with a rear surface of the at least one second reinforcinglayer 22 b. The firsthard face 12 a and cooperating at least one reinforcinglayer 22 a andresilient layer 14 c are held in a spaced apart relationship relative to the secondhard face 12 b and cooperating at least one reinforcinglayer 22 b andresilient layer 14 d by conventional means, such as by spaced apart fasteners, within the confines of a frame, or other conventional means. - In the illustrated embodiment, a plurality of reinforcing
layers layer resilient layers armor system 10 c. While the illustrated embodiment depicts two reinforcinglayers hard face layers hard face -
FIG. 6 shows an incoming projectile 16 impacting thearmor system 10 c ofFIG. 5 . Referring toFIG. 6 , in the present embodiment, the firsthard face 12 a and cooperating reinforcinglayers 22 a are each selected to have a sufficient thickness and strength to absorb a portion of the impact from anincoming projectile 16. As the incoming projectile 16 impacts the firsthard face 12 a, deformation and fracture of the portions of the firsthard face 12 a and cooperating reinforcinglayers 22 a local to the area of impact of the projectile 16 is contemplated. In several embodiments, complete disruption of theincoming projectile 16 by the firsthard face 12 a is contemplated. In these embodiments, the spacing of the firsthard face 12 a and cooperating reinforcing andresilient layers hard face 12 b allows for multiple impacts toarmor system 10 c before damage to the secondhard face 12 b occurs. In certain impact scenarios involving impact of thearmor system 10 c by high-energy projectiles 16, penetration of the firsthard face 12 a and cooperating reinforcinglayers 22 a by the projectile 16 is also contemplated, such that, upon penetration of the firsthard face 12 a and cooperating reinforcinglayers 22 a by the projectile 16, at least partial disruption of the projectile 16 by the firsthard face 12 a and cooperating reinforcinglayers 22 a occurs. In several embodiments, it is contemplated that such partial disruption results in a change in the trajectory of the projectile 16 following penetration of the firsthard face 12 a. In other embodiments, it is contemplated that the partial disruption of the projectile 16 by the firsthard face 12 a promotes a tendency for the projectile 16 to begin to tumble along its new trajectory. - In several embodiments, it is contemplated that partial disruption of the projectile 16 results in fracture of the projectile 16 into a plurality of pieces. Accordingly, the spacing of the first
hard face 12 a and cooperating reinforcing andresilient layers hard face 12 b is selected so as to allow the various fractured pieces of the projectile 16 to spread apart as the projectile 16 assumes its changed trajectory following penetration of the firsthard face 12 a and cooperating reinforcinglayer 22 a andresilient layer 14 c, prior to impact with the secondhard face 12 b. It is understood that the specific spacing of the firsthard face 12 a and cooperating reinforcing andresilient layers hard face 12 b depends upon the shape, size, mass, velocity, and impact characteristics of the projectile to be armored against, as well as the thickness of the respective hard face layers and the resultant ability of the hard face layers to effect change of the trajectory of the impactedprojectile 16. For example, a relatively heavy and fast-moving projectile, such as certain high powered rifle bullets or explosive fragments, may require an increased spacing of the firsthard face 12 a and cooperating reinforcing andresilient layers hard face 12 b, of a given thickness and composition of hard face and cooperating reinforcing and resilient layers, in order to allow the projectile pieces to spread apart, while a relatively short, light, slower-moving projectile, such as certain handgun bullets, may require less spacing of the firsthard face 12 a and cooperating reinforcing andresilient layers hard face 12 b before such spreading of the projectile pieces occurs. - As shown in
FIG. 6 , it is anticipated that, upon partial disruption of the projectile 16 by the firsthard face 12 a and cooperating reinforcinglayers 22 a, and upon the resultant promotion of tumbling of the projectile 16, the partially disrupted projectile 16 impacts the secondhard face 12 b. To this extent, it is understood that the partial disruption of the projectile 16 by the firsthard face 12 a results in impact characteristics of the projectile 16 which are generally less focused along the original trajectory of the projectile 16 than those of the projectile 16 prior to impact with the firsthard face 12 a. Thus, the forces of impact of the partially disrupted projectile 16 are applied to an increased surface area of the secondhard face 12 b. Furthermore, such forces of impact of the partially disrupted projectile 16 are applied to the secondhard face 12 b along a trajectory which is directed at an oblique angle to the secondhard face 12 b. In this manner, the partial disruption of the projectile 16 by the firsthard face 12 a serves to decrease the ballistic effectiveness of the projectile 16 while promoting the effectiveness of the secondhard face 12 b at completely disrupting the projectile 16. - It will be understood by one skilled in the art that additional benefits of the various features of the embodiment of the
armor system 10 c shown inFIGS. 5-6 will be readily apparent to one of ordinary skill in the art. To this extent, the embodiment ofFIGS. 5-6 allows for the provision of a armor panel having a reduced amount of material per unit area, and thus, a lighter armor panel. Alternatively, the embodiment ofFIGS. 5-6 allows for an increased effectiveness of the armor panel as compared to an armor panel of equal weight per unit area. The spaced apart relationship of the firsthard face 12 a and cooperating reinforcing andresilient layers hard face 12 b of the present embodiment allows for the placement therebetween of a thermally insulative material, such as air, argon gas, nitrogen gas, insulative liquid, or other thermally insulative material. In this respect, the embodiment ofFIGS. 5-6 provides an armor panel having improved thermally insulative qualities as compared to conventional armor panels. Other benefits of the various features of the present embodiment of thearmor system 10 c will be recognized by one skilled in the art. -
FIGS. 7-10 pertain to a method of manufacture of the armor system 10, also disclosed herein. As is further discussed below, the method of manufacture generally includes providing ahard face 12, arranging at least one reinforcinglayer 22 rearward of thehard face 12, and arranging at least oneresilient layer 14 rearward of the reinforcinglayer 22. In an embodiment in which bonding layers are provided, the bonding layers 20 are arranged in a substantially parallel planar fashion between at least two of thevarious layers various layers laminate structure 36. - In the embodiment of the method illustrated in
FIGS. 7-10 , a substantially compliant and substantiallyairtight container 34 is provided to hold the various layers in the substantially parallel planar configuration. Thecontainer 34 is of approximate dimensions and volume to contain a panel fabricated from the armor system 10. As shown inFIG. 8 , thelaminate structure 36 is placed within thecontainer 34. Thecontainer 34 is then sealed and evacuated to a low pressure, thereby forcing the various components of thelaminate structure 36 into close proximity. As shown inFIG. 10 , while still evacuated, thecontainer 34 containing thelaminate structure 36 is placed into avessel 38. Thevessel 38 is then heated, such that thelaminate structure 36 is heated to a temperature in which at least every other layer is thermally expanded, softened, and becomes adhesive. - Gaseous pressure is thereafter applied inside the
vessel 38, exterior to thecontainer 34. The combination of temperature of thelaminate structure 36 and pressure within thevessel 38 is maintained for a sufficient time as to allow a desirable amount of lamination within thelaminate structure 36. In one embodiment, lamination within thelaminate structure 36 is continued until such point that temperature reduction of thelaminate structure 36 absent excessive deleterious residual stresses within thelaminate structure 36 is possible. When a desirable amount of lamination within thelaminate structure 36 has been reached, the temperature of thelaminate structure 36 is reduced, such as to firmly set thevarious layers vessel 38 and the vacuum in the container are then released, and the finished armor system 10 is removed. - From the foregoing description, it will be understood that an armor system 10 and method of manufacture have been provided. The armor system provides a ballistic armor structure which is capable of providing ballistic protection comparable to conventional armor structures, but with reduced aerial weight as compared to the conventional armor structures. The armor system provides a laminate structure exhibiting cohesive interlaminar strength, multi-hit capability, thermal environment stability, and light weight. Furthermore, the armor system provides a ballistic armor structure which is capable of providing increased ballistic protection compared to a conventional armor structure of similar aerial weight.
- While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Claims (20)
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US12/362,256 US8176829B1 (en) | 2007-03-21 | 2009-01-29 | Armor system and method of manufacture |
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US11/689,299 US9091510B2 (en) | 2007-03-21 | 2007-03-21 | Transparent armor system and method of manufacture |
US12/349,832 US8176828B2 (en) | 2007-03-21 | 2009-01-07 | Glass-ceramic with laminates |
US12/362,256 US8176829B1 (en) | 2007-03-21 | 2009-01-29 | Armor system and method of manufacture |
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US12/349,832 Continuation-In-Part US8176828B2 (en) | 2007-03-21 | 2009-01-07 | Glass-ceramic with laminates |
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