Method and apparatus for armor having integrated battery power

• US 9,140,523 B2
• Filed: 10/03/2011
• Issued: 09/22/2015
• Est. Priority Date: 10/03/2011
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Wahlquist, Gary F., Horvath, Charles L., Imholt, Timothy J., VanRees, H. Barteld
• Primary Examiner(s): Slifka, Sarah A
• Application Number:
  US13/251,691
• Publication Number:
  US 20130084473A1
• Time in Patent Office: 1,450 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: F41H 5/0421 Ceramic layers in combination with metal layers
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Methods and apparatus for battery armor including a first ballistic protection layer comprising a non-conductive material to provide ballistic protection, and a second ballistic protection layer abutting the first ballistic protection layer, the second ballistic protection layer including a battery layer. Exemplary embodiments for battery armor include layers of non-conductive and conductive materials to provide ballistic protection and electrical power.

Claims

1. A body armor system, comprising:

an armor stack, comprising;

a first ballistic protection layer having opposing first and second surfaces, the first ballistic protection layer comprising a non-conductive material to provide ballistic protection; and

a second ballistic protection layer having opposing first and second surfaces wherein the second surface of the first ballistic protection layer is disposed over the first surface of the second ballistic protection layer, the second ballistic protection layer comprising;

a first battery layer having opposing first and second surfaces, the first battery layer including;

an anode layer having opposing first and second surfaces;

a cathode layer having opposing first and second surfaces;

an electrolyte layer chemically coupled to the second surface of the anode layer and the first surface of the cathode layer;

a first conductive layer abutting the first surface of the anode layer; and

a second conductive layer abutting the second surface of the cathode layer,

wherein the first conductive layer and the second conductive layer comprise steel having a thickness of at least 0.04 inches to form electrical contact with the respective anode layer and the cathode layer, transfer heat away from the respective anode layer and the cathode layer, and contribute to ballistic protection of the second ballistic protection layer, wherein the first ballistic protection layer, the second ballistic protection layer, and the first battery layer in the armor stack provide a continuous armor layer without the first battery layer being disposed in a cavity of the first ballistic protection layer.

2. The system according to claim 1, wherein the first ballistic protection layer comprises a substantially rigid material.

3. The system according to claim 1, wherein the first ballistic protection layer comprises a ceramic material.

4. The system according to claim 1, wherein the first ballistic protection layer comprises a material that includes Alumina, Boron Carbide, Silicon Carbide, and/or Titanium Diboride.

5. The system according to claim 1, wherein the system comprises a second battery layer electrically coupled to the first battery layer, wherein the first ballistic protection layer is disposed between the first and second batteries.

6. The system according to claim 1, wherein the system comprises battery body armor.

7. The system according to claim 1, wherein the system comprises battery vehicle armor.

8. The system according to claim 1, wherein the system comprises battery exoskeleton armor.

9. The system according to claim 1, wherein the system comprises a battery armor tile configured to engage a further battery armor tile.

10. The system according to claim 1, further including a seal layer abutting an outer surface of the first ballistic protection layer.

13. The system according to claim 1, wherein the system further includes front and back protectors configured to hold removable armor plates.

14. The system according to claim 1, wherein the battery layer has a thickness ranging from about 0.08 inch to about 0.5 inch.

15. The system according to claim 1, wherein the cathode layer comprises Lithium manganese dioxide (LiMnO₂).

16. The system according to claim 1, wherein the anode layer comprises graphite.

11. A vehicle, comprising:

an electrical system including a power distribution module; and

battery vehicle armor including a battery coupled to the power distribution module, the battery vehicle armor comprising;

an armor stack, comprising;

a first ballistic protection layer having opposing first and second surfaces, the first ballistic protection layer comprising a non-conductive material to provide ballistic protection; and

a second ballistic protection layer having opposing first and second surfaces wherein the second surface of the first ballistic protection layer is disposed over the first surface of the second ballistic protection layer, the second ballistic protection layer comprising;

a first battery layer having opposing first and second surfaces, the first battery layer including;

an anode layer having opposing first and second surfaces;

a cathode layer having opposing first and second surfaces;

an electrolyte layer chemically coupled to the second surface of the anode layer and the first surface of the cathode layer;

a first conductive layer abutting the first surface of the anode layer; and

a second conductive layer abutting the second surface of the cathode layer,

wherein the first conductive layer and the second conductive layer comprise steel having a thickness of at least 0.04 inches to form electrical contact with the respective anode layer and the cathode layer, transfer heat away from the respective anode layer and the cathode layer, and contribute to ballistic protection of the second ballistic protection layer, wherein the first ballistic protection layer, the second ballistic protection layer, and the first battery layer in the armor stack provide a continuous armor layer without the first battery layer being disposed in a cavity of the first ballistic protection layer.

12. The vehicle according to claim 11, wherein the battery vehicle armor comprises tiles.

17. A body armor system, comprising:

an armor stack having opposing first and second surfaces, the armor stack comprising;

a first steel layer having opposing first and second surfaces, wherein the first surface of the first steel layer corresponds to the first surface of the armor stack;

a first ballistic protection layer having opposing first and second surfaces, wherein the first surface of the first ballistic protection layer is disposed over the second surface of the first steel layer, the first ballistic protection layer comprising a non-conductive material to provide ballistic protection;

a second ballistic protection layer having opposing first and second surfaces, wherein the first surface of the second ballistic protection layer is disposed over the second surface of the first ballistic protection layer, the second ballistic protection layer comprising;

a stack of at least two battery layers, with each of the at least two battery layers having opposing first and second surfaces, wherein the first surface of a first one of the at least two battery layers corresponds to the first surface of the second ballistic protection layer and the stack of the at least two battery layers are stacked on top of each other relative to the second surface of the first ballistic protection layer such that the second surface of the first one of the at least two battery layers is disposed over the first surface of a second one of the at least two battery layers, each of the at least two battery layers including;

a battery having opposing first and second surfaces, the battery including;

 

an anode layer having opposing first and second surfaces;

 

a cathode layer having opposing first and second surfaces; and

 

an electrolyte layer chemically coupled to the second surface of the anode layer and the first surface of the cathode layer;

a first conductive layer having opposing first and second surfaces, the second surface of the first conductive layer disposed over the first surface of the battery, wherein the first surface of the first conductive layer corresponds to the first surface of each of the battery layers; and

a second conductive layer having opposing first and second surfaces, the first surface of the second conductive layer disposed over the second surface of the battery, wherein the second surface of the second conductive layer corresponds to the second surface of each of the battery layers;

a ballistic protection material disposed between each of the battery layers in the stack of at least two battery layers, the ballistic protection layer having opposing first and second surfaces, Wherein the first and second surfaces of the ballistic protection material are disposed over abutting surfaces of corresponding battery layers;

a third ballistic protection layer having opposing first and second surfaces, wherein the first surface of the third ballistic protection layer is disposed over the second surface of a last one of the at least two battery layers, the third ballistic protection layer comprising a non-conductive material to provide ballistic protection; and

a second steel layer having opposing first and second surfaces, wherein the first surface of the second steel layer is disposed over the second surface of the third ballistic protection layer and the second surface of the second steel layer corresponds to the second surface of the armor stack,

wherein the first conductive layer and the second conductive layer of each of the battery layers comprise steel having a thickness of at least 0.04 inches to form electrical contact with the respective anode layer and the cathode layer, transfer heat away from the respective anode layer and the cathode layer, and contribute to ballistic protection of the second ballistic protection layer, wherein the first steel layer, the first ballistic protection layer, the second ballistic protection layer, the at least two battery layers, the third ballistic protection layer and the second steel layer in the armor stack provide a continuous armor layer without the at least two battery layers being disposed in a cavity of the first ballistic protection layer.