Armor system
An armor system is provided having an outer case of woven or unidirectional fibers filled with one or more protective materials. The outer case includes a pressure sensitive adhesive bonded to one side for quick and easy application to a body to be protected. The protective materials may include ceramic material which may be in the form of ceramic tile sheets, loose ceramic balls, or perforated tiles, multiple layers of woven or unidirectional cloth, and steel mesh. These materials may be used alone or in any combination. A tensioned energy layer and/or a self-healing layer may be provided to fill a void created by a projectile.
This invention claims the benefit of co-pending U.S. Provisional Application No. 60/373,755, entitled “Armor System”, filed Apr. 17, 2002, the entire disclosure of which is hereby incorporated by reference as if set forth in its entirety for all purposes.
TECHNICAL FIELDThe present invention is directed to armor systems and more particularly to an armor system that can be quickly and easily applied to an animate or inanimate body to be protected.
BACKGROUND OF THE INVENTIONMany and various types of armor systems are known for shielding personnel, vehicles, and equipment from injury and/or damage from projectiles. Such armor systems are typically used in military environments to protect military personnel as well as military equipment such as, for example, aircraft, tanks, ships, and other vehicles. Armor systems are also used in law enforcement and other environments in which protection from armor piercing projectiles or other type of ballistic missiles is desired.
Armor can be made of various materials depending on what is to be protected and the level of threat or danger. For example, some armor is used in or with clothing to protect the body of military or law enforcement personnel. Such armor is typically a soft body armor of multiple plies of aramid and/or polyethylene cloth and is used with or incorporated into clothing such as, for example, body vests. Another type of armor is a rigid laminated fiberglass used to protect solid structures such as armored cars, bank teller windows, and police structures. Yet another type of armor is special alloy steel, aluminum, or ceramic plate, which may be used in combination with other materials for military applications. Ceramic materials in various forms are also used as armor.
In some applications the armor is incorporated into the structure that is to be protected. Such applications may include military vehicles, armored vehicles, and structures for cashiers or security personnel. Since the armor must be incorporated into these structures it is not possible to quickly and easily provide armor for protection for structures or bodies that do not have “built-in” armor.
Some armor systems do employ some means of attaching the armor system to the body or structure to be protected. For example, some armor systems may be attached to a body or structure with fasteners such as bolts or screws. Other armor systems may utilize glue to adhere the armor to the body. However, this usually requires the application of a liquid glue to the armor and/or the body to which the armor is being attached. This increases the time and cost of applying the armor. Furthermore, such glues are costly, inconvenient to apply, and may be hazardous due to fumes or other hazardous chemicals involved. Also, such liquid glues require storage, which further increases costs especially if a special storage facility is required.
Some armor systems use a magnet to attach the armor to a body. However, magnetic armor systems are limited in use to metallic bodies and structures and are not suitable for some applications.
Another problem encountered with prior art armor systems is weight. Some armor systems employ thick steel plates. However, the weight of the steel plates makes such armor systems undesirable. Furthermore, with the development of armor piercing projectiles the thickness of the steel plates used in armor systems has increased which further increases the cost and weight of the armor system and decreases its ability to conform to some surfaces.
In order to provide a more lightweight armor, some systems have employed forms of ceramic material that have had some effect against projectiles. For example, ceramic tiles have been used to dissipate the kinetic energy of projectiles. In some armor systems, the ceramic tiles are arranged in a specific pattern and attached to a backing material such as nylon to form a ceramic tile sheet. The ceramic tiles may have a variety of shapes such as, for example, a square or octagonal shape. However, upon impact the ceramic tiles shatter creating voids and dangerous fragments. In order to be effective, the ceramic tiles must be arranged with a minimum spacing between them. The spacing provides room for the ceramic tiles to expand as they crack and/or shatter to absorb the energy of the projectile. This precise spacing of the ceramic tiles is time consuming and adds to the cost of manufacture of the armor system. Furthermore, if the spacing is not right the armor system may not be effective. In other armor systems, single or multiple ceramic tiles may be employed at one or more locations within the armor system. However, as with the ceramic sheets, the ceramic tiles may shatter creating dangerous fragments.
One solution to the problem of the creation of ceramic fragments is to combine the ceramic sheet or sheets with thick sheets or layers of glass or plastic cloth to absorb the shattered ceramic pieces. Such cloth is typically a woven ballistic cloth, such as Kevlar® and Spectra® film.
Even though such armor systems have proven effective the weight is still more than is desirable. Additionally, the cost of the ceramic tiles is expensive.
Another problem encountered with prior armor systems is their inability to conform to some surfaces. It is desirable that the armor system be flexible so that it can conform to a variety of bodies to be protected. For example, such armor systems are desirable for use as body suits for military or law enforcement personnel as well as for vehicles and other objects. It is preferable that the armor system be adaptable to any of such uses.
Another problem with prior armor systems is that any projectiles that penetrate the armor system create voids in the armor system leaving the body to be protected vulnerable to damage from additional projectiles. Additionally, such voids subject the body to be protected from other types of damage. For example, in marine environments a void created by a projectile may allow water to penetrate and damage the body to be protected. Such voids may also allow nuclear, chemical, or biological agents to penetrate the through the armor system.
Examples of prior art ceramic armor systems include U.S. Pat. Nos. 3,924,038, 4,911,061, and 5,705,764, the subject matter of which is incorporated herein by reference.
However, none of the prior art discloses an armor system that can be quickly and easily applied to a body or structure.
SUMMARY OF THE INVENTIONThe foregoing problems are overcome and other advantages are provided by an armor system that can be quickly and easily applied to a body to be protected and that provides a high degree of protection from a projectile.
In certain embodiments, the present invention provides an armor system that is flexible and can conform to a variety of shapes and surfaces.
The present invention provides an armor system that can be quickly and easily applied to a body or object to be protected. The armor system preferably includes one or more armor units that include a pressure sensitive adhesive such as, for example, a “peel and stick” adhesive to adhere the armor system to the body to be protected. The pressure sensitive adhesive adheres to most surfaces and adheres extremely well to high-energy surfaces such metal, wood, concrete, glass, or other smooth surfaces. The pressure sensitive adhesive can be formed on either the backside of the armor system for application to an outer surface of the body or structure or can be formed on the front side of the armor system for application to an inner surface of the body or structure. Alternatively, the pressure sensitive adhesive can be formed on both the front and back side of the armor system for an even wider range of applications.
The present invention may also provide an armor system that includes layers of different protective materials that can be arranged in various combinations depending on factors such as, for example, the level of threat, cost, weight, and environment of use.
The armor units may include an outer case that can be filled with layers of different protective materials either alone or in various combinations depending on factors such as threat level, weight, cost, and conformability. One of the preferred layers may be a ceramic layer that may in various forms of ceramic including ceramic plates, sheets of ceramic tiles, or loose ceramic spheres or balls. Other layers of protective materials may include multiple layers of woven or unidirectional cloth and a steel mesh layer.
In one possible embodiment, the ceramic layer includes loose ceramic filler material that randomly fills the outer case. The ceramic filler material is preferably in the form of ceramic balls or spheres but may be in any desired shape. The ceramic balls may have substantially uniform diameters or may have various diameters. Additionally, the ceramic filler material may be encapsulated within a resin matrix instead being a loose fill. The ceramic balls are combined with at least one layer of steel mesh and plural layers of woven ballistic cloth.
In another possible embodiment, the armor unit includes a self-healing layer in which the void left by the projectile is filled and the armor unit is sealed to prevent the protective materials from spilling out of the outer case. In one arrangement of the self-healing embodiment, the armor unit includes plural bags of loose ceramic fill combined with a tensioned steel spring and a layer of foam packets each of which include foam that expands and hardens when exposed to air. When the armor unit is pierced by a projectile the foam expands into the void left by the projectile and hardens preventing the loose ceramic fill from spilling out of the outer case. In another embodiment, the armor unit includes a layer of tubes filled with ceramic material located adjacent a layer of foam packets. Each tube includes springs located at each end to place the ceramic material under compression and explosive end caps at each end. When the tube is shattered by a projectile the ceramic material is forced by the springs into the void created by the projectile. Since the foam packets is the first layer to encounter the projectile at least one of the foam packets is ruptured by the projectile so that the foam is exposed to air and expands hardens to prevent the ceramic material from spilling out of the outer case.
The self-healing armor unit may include various layers of strengthening material for added protection. A high strength woven adhesive tape material is provided that can be adhered to one or both sides of one of the protective layers such as, for example, one or more of the layers of ceramic or tensioned steel spring. Another strengthening material that may be bonded to one of the layers may be a high strength metal layer.
The present invention further provides a lighter weight ceramic layer that includes perforated ceramic tiles. Each ceramic tile includes plural holes that reduce the weight of the ceramic tile but allows the ceramic tile to retain its strength properties. In one embodiment, the holes are filled with a polymer material capable of bonding a high strength protective material, such as, for example, a metal plate to the ceramic tile.
The present invention provides an armor system that is lightweight and that can be quickly and easily applied to many bodies and vehicles. The armor system is preferably flexible so that it can be easily applied to either flat or non-flat areas on military or law enforcement personnel, vehicles, critical systems such as, for example, oil and gas pipelines, and other objects where protection from weapons or explosives are required. One example of such use is the application of the flexible armor system to surfaces of helicopter fuselages to protect pilots and critical flight systems.
The present invention provides a light flexible armor that easily conforms to different surfaces and shapes, that adheres aggressively to a variety of curved or flat surfaces, and that is capable of stopping numerous types of threats.
The foregoing embodiments and features are for illustrative purposes and are not intended to be limiting, persons skilled in the art being capable of appreciating other embodiments from the scope and spirit of the foregoing teachings.
BRIEF DESCRIPTION OF THE DRAWINGS
In certain embodiments, the armor system of the present invention provides an armor that can be quickly and easily applied to a body to be protected and adapted to a variety of situations depending on the level of threat and the level of protection needed. The armor system may include plural armor units that include an outer case that can be filled with a variety of protective materials either alone or in combination with other protective materials. The type and combination of materials that are enclosed within the outer case depend on several factors such as, for example, the level of threat and protection that is needed against the threat, the weight of the armor system, the need for the armor system to conform to the body to which it is to protects, and the cost of the armor system.
In order to quickly and easily apply armor unit 10 to a body or structure outer case 10 includes a pre-applied securing layer on any portion thereof such as, for example, on one or both sides of outer case 10. The securing layer may be either a heat sensitive or a pressure sensitive securing layer. One example of a pre-applied pressure sensitive securing layer is Velcro® or any other securing layer that can mate with a complementary surface on the body to be protected. Preferably, the securing layer is a pre-applied adhesive on a side allowing that side to be applied to the body or structure. The pressure sensitive adhesive is preferably a “peel and stick” type of adhesive in which a release liner is peeled away to expose the adhesive, which is then applied to a surface of the body or structure to be protected. As shown in
Referring to
An optional protective second layer is located adjacent the initial impact layer to further absorb the energy of the projectile. The optional protective second layer is shown to include a steel mesh layer 36 which may be used to further break up and absorb the kinetic energy of a projectile. The most effective location for steel mesh layer 36 is directly behind cloth layers 34. However, steel mesh layer 36 could be placed in other locations. In one example, steel mesh layer 36 comprises 25×110 woven wire mesh of 0.015 in. (mesh thickness)×0.0105 in. (wire diameter) formed in a Plain Dutch weave. A third energy-absorbing layer of firm or hard material is provided to further absorb the energy of the projectile and to break it up. The energy-absorbing layer preferably includes a ceramic 38. The ceramic material used in ceramic layer 38 may be any type of ceramic such as, for example, an aluminum oxide, a silicon carbide, or a boron carbide. For example, the ceramic material may have an alumina content of between about 85 to about 99 percent to provide an aggregate of extreme hardness having a great resistance to fracture because of its very high compressive strength. For example, suitable ceramic materials are available from CoorsTek of Golden, Colo. or other manufacturers such as, for example, Fujimi America, Inc. of Portland, Oreg. In addition, the energy-absorbing layer may be other hard materials such as, for example, polymer compositions including a woven high-density polyethylene, glass or vitreous-like materials, metals including tungsten wire or mesh-based elements, and other substances with similar impact-resistant and/or energy-absorbing properties.
The energy-absorbing layer may be in any number of forms and may include, for example, at least one and preferably a plurality of single ceramic plates 40 enclosed within the outer case 12 and having a thickness sufficient to provide protection depending on need.
An alternative energy-absorbing layer may include, for example, one or more multi-tile sheets 42 (
The ceramic tiles shown in
The ceramic tiles or other energy-absorbing tiles or elements may have different dimensions depending on the application. For example, ceramic tiles for use with body armor preferably have a thickness of about 3.1750 mm in order to provide flexibility. Ceramic tiles with greater dimensions may be employed when the threat level is higher and/or flexibility is less of an issue. An example of ceramic tile dimensions for use in a higher threat level include ceramic tiles having a width of about 50 mm, a length of about 50 mm, and a thickness of between about 3 and 20 mm. Alternatively, ceramic tiles may have a width of about 100 mm, a length of about 150 mm, and a thickness of between 4 and 50 mm may be used for even higher threat level. For greater protection, ceramic tiles may have a width of about 11.4 mm, a length of about 228 mm, and a thickness of between about 6 and 50 mm. These represent examples of ceramic tile dimensions and the invention is not limited to these specific examples. The brittle nature of the ceramic tiles may cause them to shatter upon contact with projectiles or flying fragments. This shattering of the ceramic tiles at least partially absorbs the kinetic energy of the projectile and also fragments the incoming projectile. Additionally, cloth layers 34 help absorb the impact of the projectile and also catch or contain ceramic pieces as they shatter due to the impact.
Flexibility for a layer can be varied by sizing energy absorbing materials into small tiles which can be of various shapes and sizes as seen most clearly in
In another embodiment seen in
A self-healing armor unit 11 is shown in
Expansion packets 58 may be provided in a single layer (
In order to counter the force of an incoming projectile, self-healing armor unit 11 shown in
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances which fall within the scope of the appended claims.
Claims
1. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material, and
- a securing layer bonded to at least one of the front side or the backside of the outer case for attaching the armor unit to the body to be protected.
2. The armor system of claim 1, wherein the securing layer comprises an adhesive layer includes a pressure sensitive adhesive and a removable release liner that exposes the pressure sensitive adhesive when the release liner is removed.
3. The armor system of claim 1, further including a securing layer bonded to the front side of the outer case and the backside of the outer case.
4. The armor system of claim 3, wherein the securing layer comprises an adhesive layer includes a pressure sensitive adhesive and a removable release liner that exposes the pressure sensitive adhesive when the release liner is removed.
5. The armor system of claim 1, wherein the outer case includes layers of protective material that includes at least one initial impact layer, at least one layer of steel mesh, and at least one energy-absorbing material layer.
6. The armor system of claim 5, wherein the initial impact layer includes at least one layer of woven glass or plastic fibers.
7. The armor system of claim 6, wherein the woven glass or plastic fibers is one of Spectra™, Kevlar™, or Dyneema™.
8. The armor system of claim 5, wherein the at least one energy absorbing material layer includes ceramic material.
9. The armor system of claim 8, wherein the ceramic material includes ceramic files.
10. The armor system of claim 9, wherein the ceramic tiles are perforated with a plurality of holes.
11. The armor system of claim 5, wherein the at least one energy absorbing material layer includes loose discrete elements randomly located in the outer case.
12. The armor system of claim 11, wherein the loose discrete elements include ceramic balls.
13. The armor system of claim 1., wherein the armor unit includes a self-healing layer to fill a void formed by a projectile.
14. The armor system of claim 13, further including at least one layer of ceramic material and at least one layer of tensioned spring material.
15. The armor system of claim 13, wherein the self-healing layer includes an agent that expands and hardens when exposed to air.
16. The armor system of claim 15, wherein the self-healing layer includes packets filled with foam that expands and hardens when exposed to air.
17. The armor system of claim 10, wherein the at least one energy absorbing material layer includes plural bags of loose discrete elements.
18. The armor system of claim 17, wherein the loose discrete elements include ceramic balls.
19. The armor system of claim 13, further including a layer of ceramic material and at least one layer of glass or plastic composite material.
20. The armor system of claim 19, wherein the at least one layer of woven glass or plastic fibers is one of Spectra™, Kevlar™, or Dyneema™.
21. The armor system of claim 19, wherein the layer of ceramic material includes at least one layer of ceramic tile and further including a tensioned energy layer.
22. The armor system of claim 21, wherein the at least one layer of ceramic tile includes at least one of hexagonal tiles, square tiles, rectangular tiles, and perforated tiles with plural holes formed therein.
23. The armor system of claim 21, wherein the tensioned energy layer includes tubes of glass or plastic including plural ceramic balls under compression by at least one spring.
24. The armor system of claim 23, wherein each tube includes a spring located at each end of the tube to apply a compression force to the ceramic balls.
25. The armor system of claim 21, wherein the tensioned energy layer includes at least one glass or plastic tube including plural ceramic balls and an end cap located at each end of the tube to release energy upon impact.
26. The armor system of claim 21, wherein the tensioned energy layer includes at least one glass or plastic tube including plural ceramic balls, springs located at each end thereof, and an end cap located at each end of the tube to release energy upon impact.
27. The armor system of claim 1, further including a high strength woven adhesive tape applied to at least one side of the at least one layer of protective material.
28. The armor system of claim 1, further including a high strength woven adhesive tape applied to both sides of the at least one layer of protective material.
29. The armor system of claim 1, wherein one layer of protective material includes a layer of ceramic material with a high strength metal bonded thereto.
30. The armor system of claim 1, wherein one layer of protective material includes a layer of perforated ceramic tiles with holes formed therein.
31. The armor system of claim 31, further including a polymer material filling the holes in the ceramic tile.
32. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of self-healing material to fill a void formed by a projectile, and
- an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
33. The armor system of claim 32, wherein the self-healing material includes packets filled with an agent that expands and hardens when exposed to air.
34. The armor system of claim 33, wherein the agent is foam.
35. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of perforated ceramic tiles having holes formed therein, and
- an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
36. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material with a high strength woven tape applied to at least one side thereof, and
- an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
37. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of self-healing material to fill a void formed by a projectile.
38. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of perforated ceramic tiles having holes formed therein.
39. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material with a high strength woven tape applied to at least one side thereof.
40. The armor system of claim 1, wherein the outer case is made of one of Kevlar® and Dyneema®.
41. An armor system for protecting a vehicle, comprising:
- a vehicle having a body to be protected,
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material, and
- an adhesive securing layer bonded to at least one of the front side or the backside of the outer case for attaching the armor unit to the vehicle.
42. An armor system for protecting a body, comprising:
- at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one tensioned energy layer including plural discrete elements under tension that are released upon impact to repopulate a void created by the projectile.
43. A method of protecting a body, comprising:
- providing at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material, and
- providing a securing layer bonded to at least one of the front side or the backside of the outer case for attaching the armor unit to the body to be protected.
44. A method of protecting a body, comprising:
- providing at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of self-healing material to fill a void formed by a projectile, and
- providing an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
45. A method of protecting a body, comprising:
- providing at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of perforated ceramic tiles having holes formed therein, and
- providing an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
46. A method of protecting a body, comprising:
- protecting at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of protective material with a high strength woven tape applied to at least one side thereof, and
- protecting an adhesive layer bonded to at least one of the front side or the backside of the outer case for adhering the armor unit to the body to be protected.
47. A method of protecting a body, comprising:
- providing at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of self-healing material to fill a void formed by a projectile.
48. A method of protecting a body, comprising:
- providing at least one armor unit having an outer case with a front side and a backside forming an interior, the interior of the outer case including at least one layer of perforated ceramic tiles having holes formed therein.
Type: Application
Filed: Apr 17, 2003
Publication Date: Mar 30, 2006
Inventor: James Henry (Wilsonville, OR)
Application Number: 10/511,781
International Classification: F41H 5/02 (20060101);