Composite armor panel and method of manufacturing same

• US 20070017359A1
• Filed: 06/21/2005
• Published: 01/25/2007
• Est. Priority Date: 06/21/2005
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV), the united states of america as represented by the secretary of the navy
• Original Assignee: the united states of america as represented by the secretary of the navy
• Inventors: Cork, Michael, Gamache, Raymond, Helton, Irvin
• Granted Patent: US 8,220,378 B2
• Time in Patent Office: Days
• US Class Current: 89/36.40
• CPC Class Codes: F41H 5/0492 Layered armour containing hard elements, e.g. plates, spheres, rods, separated from each other, the elements being connected to a further flexible layer or being embedded in a plastics or an elastomer matrix

Abstract

A composite armor panel and method of manufacturing the same are disclosed. In one embodiment, a plurality of ceramic spheres are positioned in contact with an armor substrate. A polyurea layer is interposed between the plurality of ceramic spheres such that the polyurea layer partially encapsulates the plurality of ceramic spheres and bonds the plurality of ceramic spheres to the armor substrate. The plurality of ceramic spheres are partially exposed and oriented in a direction of anticipated impact.

Claims

1. A composite armor panel, comprising:

an armor substrate;

a plurality of ceramic spheres positioned in contact with the armor substrate; and

a polymer layer interposed between the plurality of ceramic spheres, the polymer layer partially encapsulating the plurality of ceramic spheres and bonding the plurality of ceramic spheres to the armor substrate such that the plurality of ceramic spheres include respective exposed ceramic surfaces that are oriented in a direction of anticipated impact.

2. The composite armor panel as recited in claim 1, wherein the armor substrate has a thickness from about 0.125″

to about 0.4″

.

3. The composite armor panel as recited in claim 1, wherein the plurality of ceramic spheres are positioned in a single layer of A and B rows, the A rows being shifted with respect to the B rows by approximately ½

the diameter of a ceramic sphere.

4. The composite armor panel as recited in claim 1, wherein the plurality of ceramic spheres comprise a material selected from the group consisting of aluminum oxide (alumina or Al₂O₃), boron carbide (B₄C), boron nitride (BN), silicon carbide (SiC), silicon nitride (Si₃N₄), and zirconium oxide (zirconia or ZrO₂).

5. The composite armor panel as recited in claim 1, wherein the polymer layer comprises a polymer selected from the group consisting of polyureas, polyurethanes, and hybrids thereof.

6. The composite armor panel as recited in claim 1, wherein the armor substrate comprises a material selected from the group consisting of steel, hardened metal, aluminum, and high hard steel.

7. A composite armor panel, comprising:

an armor substrate;

a plurality of ceramic spheres positioned in contact with the armor substrate; and

a polymer layer completely encapsulating the plurality of ceramic spheres and bonding the plurality of ceramic spheres to the armor substrate such that a portion of the polymer layer is positioned and exposed at a point of anticipated impact.

9. The composite armor panel as recited in claim 7, wherein the armor plate comprises a material selected from the group consisting of steel, hardened metal, aluminum, and high hard steel.

12. The composite armor panel as recited in claim 7, wherein the plurality of ceramic spheres are positioned in a first layer of A and B rows, the A rows being shifted with respect to the B rows by approximately ½

the diameter of a ceramic sphere.

8. (canceled)

10. (canceled)

11. (canceled)

13. (canceled)

14. A method of manufacturing a composite armor panel, the method comprising:

spraying a polymer onto an armor substrate;

potting a plurality of ceramic spheres in the polymer such that the plurality of ceramic spheres are at least partially encapsulated in the polymer and in contact with the armor substrate;

maintaining during the potting, respective exposed ceramic surfaces on the ceramic spheres;

permitting the polymer to set; and

positioning the armor substrate such that the exposed ceramic surfaces of the ceramic spheres are oriented in a direction of anticipated impact.

15. The method as recited in claim 14, further comprising:

impacting a projectile onto the composite armor panel;

responsive to projectile and ceramic sphere contact, asymmetrically deforming the projectile; and

dispensing the kinetic energy of the deformed projectile through the polymer layer, thereby providing blast and fragment protection.

16. The method as recited in claim 14, further comprising:

impacting a fragment onto the composite armor panel;

responsive to fragment and ceramic sphere contact, asymmetrically deforming the projectile; and

dispensing the kinetic energy of the deformed fragment through the polymer layer, thereby providing blast and fragment protection.

17. A composite armor panel, comprising:

a layer of ceramic spheres, responsive to projectile impact, for asymmetrically deforming the projectile;

a polymer layer positioned coplanar with the layer of ceramic spheres, the polymer layer encapsulating the layer of ceramic spheres and dissipating the kinetic energy of the deformed projectile through the polymer layer; and

an armor substrate coupled to the polymer layer.

18. The composite armor panel as recited in claim 17, wherein the polymer layer comprises a polymer selected from the group consisting of polyureas, polyurethanes, and hybrids thereof.

19. The composite armor panel as recited in claim 17, wherein the polymer layer is interposed between the armor substrate and the layer of ceramic spheres.

20. The composite armor panel as recited in claim 17, wherein the layer of spherical ceramic elements comprises a material selected from the group consisting of aluminum oxide (alumina or Al₂O₃), boron carbide (B₄C), boron nitride (BN), silicon carbide (SiC), silicon nitride (Si₃N₄), and zirconium oxide (zirconia or ZrO₂).

21. The composite armor panel as recited in claim 17, wherein the layer of ceramic spheres comprises a single layer of ceramic spheres positioned in A and B rows, the A rows being shifted with respect to the B rows by approximately ½

the diameter of a ceramic sphere.

22. A composite armor panel, comprising:

a layer of ceramic spheres, responsive to fragment impact, for asymmetrically deforming the fragment;

a polymer layer positioned coplanar with the layer of ceramic spheres, the polymer layer encapsulating the layer of ceramic spheres and dissipating the kinetic energy of the deformed fragment through the polymer layer; and

an armor substrate coupled to the polymer layer.

23. The composite armor panel as recited in claim 22, wherein the polymer layer comprises a polymer selected from the group consisting of polyureas, polyurethanes, and hybrids thereof.

24. The composite armor panel as recited in claim 22, wherein the polymer layer is interposed between the armor substrate and the layer of ceramic spheres.

25. The composite armor panel as recited in claim 22, wherein the layer of spherical ceramic elements comprises a material selected from the group consisting of aluminum oxide (alumina or Al₂O₃), boron carbide (B₄C), boron nitride (BN), silicon carbide (SiC), silicon nitride (Si₃N₄), and zirconium oxide (zirconia or ZrO₂).

26. The composite armor panel as recited in claim 22, wherein the layer of ceramic spheres comprises a single layer of ceramic spheres positioned in A and B rows, the A rows being shifted with respect to the B rows by approximately ½

the diameter of a ceramic sphere.

27. (canceled)

28. (canceled)

29. (canceled)