ARMOR ASSEMBLY INCLUDING MULTIPLE ARMOR PLATES

Abstract

In some example, the disclosure provides armor assembly designs utilizing multiple solid armor plates and one or more coupling elements, such as, e.g., high-strength ropes, to couple the solid armor plates to each other. For example, the solid armor plates may be attached to one another and held in position via high-strength ropes for form a discontinuous armor layer. The armor assemblies may include multiple layer arrangements of the solid armor plates that provide substantially complete coverage of a surface when the multiple discontinuous layers are combined. Ropes or other coupling elements may be used to horizontally connect plates together within the same discontinuous layer of armor plates and ropes may also be used to vertically connect plates in different armor layers. In some example, the armor assembly may be highly flexible and breathable to provide body armor that may be comfortably worn. In some examples, armor assemblies may be adapted for use as vehicle armor or other armor applications.

Description

This application also claims the benefit of U.S. Provisional Application No. 61/212,657, filed Apr. 14, 2009. This application also claims the benefit of U.S. Provisional Application No. 61/214,103, filed Apr. 20, 2009. This application also claims the benefit of U.S. Provisional Application No. 61/216,100, filed May 13, 2009. The entire content of each of these provisional applications is incorporated herein by reference.

TECHNICAL FIELD

The disclosure relates to protective materials that can be used as body armor against ballistic threats or knife threats.

BACKGROUND

In some examples, flexible body armor designs utilize many layers of fabric formed of high-tensile strength yarns. While such materials can be effective at stopping hand gun rounds, the flexible body armor may be uncomfortable to the wearer. Factors contributing to discomfort to the wearer may include lack of breathability, weight, and/or stiffness of the body armor.

SUMMARY

In general, the disclosure relates to armor assemblies including a plurality of protective armor plates coupled to one another by via ropes or other coupling elements. The protective armor plates may be arranged adjacent to one another to form a discontinuous armor layer. Armor plates adjacent to one another may be directly coupled to one another via ropes or other coupling elements throughout the assembly such that substantially all armor plates in the assembly are coupled to all other plates either directly or indirectly. A gap portion in the discontinuous layer may be defined by adjacent neighboring plates. The discontinuous layer formed plurality of coupled armor plates may provide an armor assembly that provide protection against, for example, firearm-fired projectiles, shrapnel from explosions, and/or weapons-grade knives over the areas covered by armor plates and while also provide a degree of flexibility and breathability via the gaps between the armor plates.

In some examples, multiple discontinuous layers each formed via a plurality of armor plates connected to each other via ropes or other coupling elements are formed. Adjacent layers may overly one another such that the armor plates of one layer cover at least a portion of the gap portions of an adjacent layer. In this manner, the multiple discontinuous layers may provide for increased coverage area of armor plates relative to the gap areas in the assembly while also providing flexibility and breathability for the armor assembly. In one embodiment, a series of three or more discontinuous layers each formed of a plurality of armor plates coupled to each other via rope or other coupling element form an armor assembly in which substantially no gaps extend through all layers of the armor assembly along a substantially linear path, thereby providing armor protection over substantially the entire surface of the armor assembly while maintaining flexibility and/or breathability of the armor assembly.

In one embodiment, the disclosure is directed to an armor assembly comprising a plurality of armor plates; and at least one coupling element that couples the plurality of armor plates to each other, wherein the plurality of armor plates are coupled to each other via the at least one coupling element at discrete locations on each armor plate to form a discontinuous armor layer.

In another embodiment, the disclosure is directed to an armor assembly comprising a first discontinuous armor layer including of a first plurality of armor plates; a second discontinuous armor layer including of a second plurality of armor plates; a third discontinuous layer armor including of a third plurality of armor plates; and at least one coupling element that couples the first, second, and third plurality of armor plates to each other to form at least a portion of the armor assembly.

In another embodiment, the disclosure is directed to a method comprising coupling a plurality of armor plates to each other via at least one coupling element, wherein the plurality of armor plates are coupled to each other via the at least one coupling element at discrete locations on each armor plate to form a discontinuous armor layer.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A and 1B are conceptual diagrams illustrating, from a plan view, a portion of an example armor assembly including a plurality of example armor plates connected to each other via example coupling elements.

FIG. 2 is a conceptual diagram illustrating an example armor plate from the assembly of FIGS. 1A and 1B.

FIG. 3 is a conceptual diagram illustrating two example armor plates coupled to one another from a plan view.

FIG. 4 is a conceptual diagram illustrating a cross-sectional view the assembly of FIG. 1A along line A-A.

FIG. 5 is a conceptual diagram illustrating, from a plan view, an example assembly including example first and second discontinuous layers each formed of example armor plates.

FIG. 6 is another conceptual diagram illustrating, from a plan view, an example assembly including example first and second discontinuous layers each formed of example armor plates.

FIG. 7 is a conceptual diagram illustrating an example assembly including example first and second discontinuous layers from a side view.

FIGS. 8A and 8B are conceptual diagrams illustrating an example armor plate.

FIGS. 9A and 9B are conceptual diagrams illustrating another example armor plate.

FIGS. 10A and 10B are conceptual diagrams illustrating an example assembly including three example armor plates coupled to each other.

FIG. 11 is a conceptual diagram illustrating another example assembly including three example armor plates coupled to each other.

FIGS. 12A and 12B are conceptual diagrams illustrating an example armor plate.

FIG. 13 is a conceptual diagram illustrating an example assembly including the example armor plate of FIGS. 12A and 12B.

FIG. 14 is a conceptual diagram illustrating air flow through the example assembly of FIG. 13.

FIGS. 15A and 15B are conceptual diagrams illustrating an example process for forming an example armor plate.

FIGS. 16 and 17 are conceptual diagrams illustrating example armor plates.

FIGS. 18A-E are conceptual diagrams illustrating an example armor plate from various viewpoints.

FIG. 19 is a conceptual diagram illustrating three example armor plates coupled to each other.

FIGS. 20A-D are conceptual diagrams illustrating an example armor plate from various viewpoints.

FIGS. 21A-D are conceptual diagrams illustrating an example assembly including multiple example discontinuous layers formed of example armor plates.

FIGS. 22A-C are conceptual diagrams illustrating another example assembly including multiple example discontinuous layers formed of example armor plates.

FIGS. 23A-C are conceptual diagrams illustrating another example armor plate from various viewpoints.

FIGS. 24A and 24B are conceptual diagrams illustrating another example armor plate.

FIG. 25 is a conceptual diagram illustrating an example portion of an example armor assembly.

FIG. 26 is a conceptual diagram illustrating an example portion of another example armor assembly.

FIG. 27 is a conceptual diagram illustrating an example portion of another example armor assembly.

FIG. 28 is a conceptual diagram illustrating an example portion of another example armor assembly.

FIGS. 29A-C are conceptual diagrams illustrating various example discontinuous armor layers on an example portion of another example armor assembly.

FIGS. 30A and 30B are conceptual diagrams illustrating various example discontinuous armor layers on an example portion of another example armor assembly.

FIG. 31 is a conceptual diagram illustrating an example portion of example armor assemblies from a cross-sectional view.

FIGS. 32-34 are conceptual diagrams of example isolated hole covers.

FIGS. 35 and 36 are conceptual diagrams illustrating an example portion of example armor assemblies from cross-sectional views.

FIG. 37 is a conceptual diagram of an example isolated hole cover.

FIG. 38 is a conceptual diagram of an example ring from the example isolated hole cover of FIG. 37.

FIGS. 39A and 39B are conceptual diagrams illustrating the example impact of a bullet at a portion of an example armor assembly.

FIGS. 40A and 40B are conceptual diagrams illustrating the example impact of a bullet at a portion of another example armor assembly.

DETAILED DESCRIPTION

In general, the disclosure relates to armor assemblies including a plurality of protective armor plates coupled to one another by ropes or other coupling elements. The protective armor plates may be arranged adjacent to one another and along substantially the same plane to form a discontinuous armor layer. Armor plates adjacent to one another may be directly coupled to one another via ropes or other coupling elements throughout the assembly such that substantially all armor plates in the assembly are coupled to all other plates either directly or indirectly. A gap extending through the discontinuous layer may be defined by adjacent neighboring plates. As will be described further below, the discontinuous layer formed of a plurality of coupled armor plates may provide an armor assembly that provide protection against, for example, projectiles from firearms, shrapnel from explosions, and/or weapons-grade knives over the areas covered by armor plates and while also providing a degree of flexibility and breathability via the gaps between the armor plates.

In some examples, multiple discontinuous layers each formed via a plurality of armor plates connected to each other via ropes or other coupling elements are formed. The ropes or other coupling elements may attach adjacent plates in the same layer and/or adjacent plates in adjacent layers. Adjacent layers may overly one another such that the armor plates of one layer cover at least a portion of the gap portions of the neighboring layer. In this manner, the multiple discontinuous layers may provide for increased coverage area of armor plates relative to the gap areas in the assembly while also providing flexibility and breathability for the armor assembly.

In one embodiment, a series of three or more discontinuous layers each formed of a plurality of armor plates coupled to each other via rope or other coupling element form an armor assembly in which substantially no gaps extend through all layers of the armor assembly along a substantially linear path, thereby providing armor protection over substantially the entire surface of the armor assembly. Such an armor assembly may maintain a desired degree of flexibility and/or breathability, e.g., as compared to a single, relatively inflexible large armor plate having approximately the same size of the armor assembly and/or a body armor article formed of multiple layers of woven fabric.

Some multiple layer woven fabric-based body armor assemblies stop bullet penetration by arresting or capturing the bullet with yarns directly in front of the bullet at the site of impact. The energy required to straighten these strands of fabric and to displace them from the plane of the fabric acts to dissipate the energy of the bullet. Woven fabric based-assemblies also spread the incoming energy to strands of fabric in the layers below the impacted surface. Upon impact, the bullet is also plastically deformed by the fabric resistance, helping to distribute the force over a larger area and engaging more strands of fabric in the lower layers. However, due to the relatively high density of the woven fabric, such body armor may provide only a minimal amount of breathability through the fabric.

Conversely, example armor assemblies such as those described in this disclosure may include solid armor plates having an area larger than the bullet cross section at impact for the dissipation of the bullet's energy. At the same time, the ropes or other coupling elements connecting the armor plates provide a mechanism for beneficially spreading the incoming energy over a larger area, which may ultimately reduce the pressure applied on the inner surface of the protective armor structure to a sub-lethal level.

For sharp objects, such as knifes and ice picks, multiple layer woven fabric-based body armor tends to perform poorly because the point of the sharp object “slips” between the strands of the fabric such that the woven fabric based-body armor does not supply adequate resistance to stop the penetration of the sharp object. Unlike that of woven fabric material, the solid armor plates of an armor assembly may prevent the penetration of the point and may also engage the resistance of the neighboring plates via the connecting ropes. The armor plate material can be selected such that the armor assembly provides protection against bullets, shrapnel, and/or knife threats.

In some example armor assemblies of this disclosure, because there are gaps between the solid armor plates which are coupled together via ropes or other coupling elements, there is a relatively large volume of empty space in the assembly structure corresponding to the gaps between adjacent guard plates. This gap space may provide increased breathability and allow for bulk air-flow through the armor assembly as well as also allow moisture to travel through armor assembly. In addition to providing suitable breathability, the armor assembly may be flexible and supple because the solid, discrete plates may be coupled together via a flexible coupling element, such as, a flexible rope. In contrast with multi-layer woven fabric-based body armor, some embodiments of the armor assemblies described in this disclosure effectively separate the functions of penetration resistance via protective plates and the spreading of the impact energy to the neighboring structure via the coupling elements used to couple the armor plates together. Therefore, the embodiments of the body armor assembly can be made lighter than some multilayer woven fabric-based armor body armors. In some embodiments, armor assemblies of the disclosure are more comfortable to wear compared to that of multiple layer woven fabric-based body armor assemblies since embodiment of armor assemblies described herein may be more flexible, lighter in weight and configured to provide for a suitable level of air flow through the assembly.

FIGS. 1A and 1B are conceptual diagrams illustrating, from a plan view, a portion of example armor assembly 10 including a plurality of example armor plates 12a-12i (collectively referred to as armor plates 12) coupled to each other via coupling element 14. FIG. 1B illustrates a magnified view of plates 12a, 12b, 12d, and 12e. For ease of illustration, only coupling elements 14 used to directly connect adjacent edges of plates 12a, 12b, 12d, and 12e are shown in FIG. 1B.

Armor assembly 10 may provide protection against, e.g., projectiles from firearms, shrapnel from explosions, and/or weapons-grade knives. In some examples, such an assembly may be worn adjacent to portions of the body of a person to function as body armor. In other examples, assembly 10 can also be designed for use as vehicle armor that protects against, for example, improvised explosive devices. However, other uses for assembly 10 are contemplated, especially uses in which assembly 10 is utilized to provide protection from ballistic threats.

As shown in FIGS. 1A and 1B, armor plates 12 are arranged and coupled to one another via coupling element 14 in assembly 10 to form a discontinuous layer of armor material. Adjacent edges of neighboring plates 12 define gap region 18 which forms a void space that extends through the discontinuous layer formed by plates 12 and coupling element 14. In this manner, armor plates 12 and coupling element 14 may be characterized as forming a discontinuous armor layer having discrete armor plates rather than a continuous armor layer without any gaps or other breaks in the armor layer. The configuration of plates 12 as a discontinuous armor layer allows for assembly 10 to exhibit greater flexibility than an armor assembly including only a single armor plate formed of a continuous armor layer even in cases in which the composition of the armor plates for each assembly is substantially the same.

Coupling element 14 mechanically couples adjacent plates 12 to one another at discrete locations on the perimeter of plates 12. All plates 12 in assembly are connected or attached to one another via coupling element 14, whether it be directly (e.g., in the case of two individual plates that are directly adjacent to one another) or indirectly (e.g., in the case of two individual plates that are separated by one or more intervening plates). Coupling element 14 in assembly 10 may be a single continuous coupling element or a plurality of individual coupling elements. In one example, coupling element 14 may include one or more ropes that attached adjacent plates 12 in assembly 10 to one another. As will be described further below, coupling elements 14 may additionally or alternatively connect one or more of plates 12 to armor plate(s) from one or more adjacent discontinuous armor layers overlying the discontinuous layer formed by plates 12. In this manner, coupling element 14 may connect two or more armor plates 12 within the same discontinuous armor layer (referred to at some points herein as horizontal attachment) and/or to connect one or more armor plates 12 to one or more armor plates in one or more adjacent discontinuous armor layers (referred to herein at some points as vertical attachment).

Coupling element 14 may allow for some degree of movement of plates 12 relative to another while still providing for attachment to one another. In such a configuration, in the case of a ballistic impact, one or more individual plates 12 may act to arrest an immediate penetration of the impacting object (e.g., a firearm fired bullet), and the impact force may be quickly spread to a much larger area via the composite assembly of coupling elements 14 and plates 12 allowing the non-destructive dissipation of the initial energy. Because the coupling elements 14 allow plates 12 to move relative to each other, assembly 10 may be flexible compared to a single continuous armor layer formed of substantially the same material as plates 12. Further, the spacing between plates 12, armor assembly 10 allows for the bulk flow of air through assembly 10 (e.g., from the bottom surface to the top surface). As such, in some embodiments, assembly 10 may be a relatively flexible, breathable armor that is comfortable to wear.

Unlike that of an arrangement in which multiple armor plates are attached to the surface of the same woven fabric substrate to be fixed relative to each other, coupling element 14 attaches to each of plates 12a-i at discrete locations dispersed about the perimeter of each plate rather than forming a continuous fabric layer that spans across gaps 18 separating plates at substantially all locations along the perimeter of adjacent plates. In this manner, air flow through gaps 18 is not impeded by the coupling elements, or at least not impeded to the degree that would present with a continuous woven fabric substrate.

In the examples of FIGS. 1A, 1B, 2, and 3, each individual plates 12 includes a plurality of apertures 16 (only a single aperture is labeled in FIGS. 1A, 1B, 2, and 3) extending through the thickness of plate from the top surface to the bottom surface. To directly connect two or more plates to one another, coupling element 14 may be extended through at least one aperture 16 of each individual armor plates 12 and may then secured (e.g., tied or otherwise anchored) within the respective apertures 16. To increase the strength of the attachment between plates 12 in assembly 10, the number of apertures may be increased to increase number of distinct points on the perimeter of each plates engaged with coupling element 14. In FIG. 1B coupling element 14 diagonally couples all four corners of plates 12a-d.

As shown in FIGS. 1A, 1B, 2, and 3, each armor plate 12 may include a plurality of apertures 16 dispersed around the perimeter of each plate on substantially all sides. Coupling element 14 may be extended through one or more of apertures from each plate to attach plates 12 together. Coupling element 14 may extend only through a single aperture for two plates to form a loop that secure the two plates at the discrete locations of the respective apertures. In some examples, coupling element 14 may spiral or otherwise extend through a plurality of apertures in each of multiple individual plates to connect plates 12 to each other. Apertures 16 may be aligned in a row maintaining a substantially uniform distance from the edge of plates 12. In FIG. 3, plates 12a and 12b include a plurality of apertures at varying distances from the edge of plates 12a, 12b to form multiple rows of apertures.

In one embodiment, two-dimensionally arrayed armor plates are tied together using stranded fibers by looping the fibers through holes in the plates. As described below, coupling element 14 may be wire, string, yarn, rope or other elongated, substantially one-dimensional structure. In one embodiment, braided-strand ropes are used. The ropes can extend across the width of the plate in a spiral from one hole to the next and one or many ropes can be used in each hole. By spiraling from hole to hole, a single rope can be used to connect multiple pairs of plates together. Alternatively, a single rope can tie a single pair of plates together with multiple passes through each hole. The number of ropes and the thickness of the ropes can be adjusted to give the optimal performance on a per weight basis.

Other techniques for connecting plates 12 to one another via coupling elements 14 are contemplated. For example, coupling elements 14, such as ropes, may be embedded into two more of plates 12 at discrete locations about the perimeter of two or more adjacent plates to attach the plates together. In other examples, ropes (or other coupling elements) may be threaded through one or more apertures extending through the length of the plate (e.g., a direction substantially orthogonal to the major surface of plates 12) with knots or other obstructions in the ropes to restrict to the movement of the individual armor plates along the length of rope. In some examples, plates 12 may be adhered to a rope net that acts to attach plates 12a-i to each other.

FIG. 2 is a conceptual diagram illustrating example armor plate 12e from the assembly of FIGS. 1A and 1B. As shown FIG. 2, armor plate 12e includes eighteen individual apertures 16 evenly dispersed about the perimeter of plate 12e. Each aperture 16 extends through armor plate 12e from the top surface to the bottom surface, and coupling element 14 extends through aperture 16 as well as another aperture in a neighboring plate (not shown in FIG. 2) of assembly 10 to connect armor plate 12e to at least one other armor plate of assembly 10.

Solid armor plate 12e can be made from any high strength hard or reasonably hard material. Hard ceramics such as boron carbide or other lightweight ceramics may be used. Less hard, but still rigid, composite materials can also be used. Advanced composites comprising carbon nanotubes, other nano-particles or micro-particles could also be used for the plate material. Layers of polyethylene (e.g. Dyneema® or Spectra®) or aramid (e.g. Kevlar®) can be hardened through the choice of binder used to hold the layers together and these hardened layers can form the plate material. In one embodiment Dyneema® HB50, which comprises multiple layers of unidirectional polyethylene yarns held together with a binder, is used as the plate material. In other examples, multiple layers of unidirectional aramid fibers may be held together with a binder to form plates 12.

Suitable binder materials may include polymer resin materials that provide for a suitable resin matrix. In some examples, the binder resin matrix should transfer the stress load maximally to stronger ultra high molecular weight polyethylene (UHMWPE) fibers. The overall bond at the fiber-matrix interface is an aggregate of any chemical bonds formed, dipole-attraction bonds such as van der Waals and hydrogen bonding, and mechanical bonds such as interlocking. As the composite material bends after the time of impact, the primary stress the material experiences are tensional (i.e. stretching), except for the localized area in the immediate vicinity of the impact point, which primarily experience compression forces. In order to transfer the maximum amount of stress load from the weaker matrix to the stronger fiber, the integrity of the overall fiber-binder matrix bond has to be maintained as long as possible while both materials are being stretched and deformed under tension.

If both materials experience the same level of strain displacement while they are stretched and deformed under tension, the much higher Young's modulus of the fibers means that it will bear the higher percentage of stress load, thus achieving the intended goal of transferring as much load as possible from the weaker matrix to the stronger fibers. Therefore it is desirable for the matrix material's elongation at break to be higher than the fiber, to ensure that the matrix is able to survive the same degree of strain as the fiber before it fractures. In addition, the Young's modulus of the matrix should also be considerably lower than the fiber. The very high loading rate of a high-velocity bullet also may cause materials to behave more glass-like than they would under normal static load or low-velocity impact conditions. Thus, a polymer for the matrix may be sufficiently ductile and soft rather than stiff and brittle in order to avoid fracturing.

Example binder materials may include thermoplastics, such as, e.g., polyester, polyamides (i.e. nylon), polyvinyls, polyolefins, and polyurethane, elastomeric block copolymers such as polyisoprene-polyethylene-butylene-polystyrene block copolymers or polytyrene-polyisoprene-polystyrene block copolymers, and/or thermosets, such as, e.g., toughened or ductile epoxies or phenolics, unsaturated polyesters, and vinyl esters.

Metallic alloys are another category of material that can be used in constructing the solid plates. In some examples, the metal alloy may exhibit at least greater than 40% elongation at break. If the elongation at break is appreciably lower than this, the metal does not have enough ductility to plastically deform to a large degree, the main method of energy dissipation, without fracturing. Example metal alloys may include 302 stainless steel, 304 stainless steel, Gall-Tough® toughened stainless steel, Haynes® 25 and 188 metal alloys, Allvac® nickel superalloys, and/or Beryllium copper alloys.

In choosing materials for the plate material of body armor, materials having a relatively high degree high degree of toughness per weight may be preferred. The toughness of a material is associated with the amount of energy that a material can absorb before fracturing. Toughness can be measured as the area under a material's stress-strain curve. Toughness can also depend on the rate of change of the applied stress. Thus, the rate of change of the energy applied by the threat may also an important consideration when designing an armor system and selecting material for forming armor plates and/or coupling elements.

The choice of materials for the various armor plates described in this disclosure, such as, e.g., plates 12 and armor plates forming other discontinuous layers of one or more armor assemblies described herein, may be determined by the threat that the armor assembly is desired to protect against. For example, for knife stab body armors, the material chosen can exceed a certain minimum hardness threshold—if the material is too soft, the hardened steel knife blade penetrates too deeply, e.g., to pass the NIJ Stab Body Armor requirements. On a per weight basis, nylon 6/6, ballistic grade polycarbonate (Lexan®), nylon 6/6 reinforced with S-fiberglass and Garolite can be effective for such protection. For ballistic body armors designed to protect up to NIJ Level IIIA, plates made from laminations of UHMWPE and/or aramid fibers can be effective. Because the tips of bullets specified for NIJ Level IIIA and below are composed of softer metals such as lead or copper alloys that deform relatively easily, the low hardness of UHMWPE and aramid materials does not hinder their performance in stopping these projectiles. However for NIJ Level III bullets that employ a significantly harder steel tip, or NIJ Level IV armor-piercing bullets that can employ very hard, high-density metal tips such as tungsten carbide or depleted uranium, the hardness of the plate material plays a much larger role and softer UHMWPE and aramid materials may be less effective as such materials may be selected for NIJ Level IIIA and below applications.

In some examples, for cases such as NIJ Ballistics Level III, IV as described above, or NIJ Stab Body Armor, where the hardness of the plate material plays an important role, ceramic materials can be effective. The function of these ceramic plates is to maximally deform and blunt the harder metal bullet tips of NIJ Level III or IV, or the sharp, hardened steel tip of the NIJ Stab Body Armor P & S-Class test knife blades, in order to minimize the penetration depth into the supporting material layer (i.e. polymers and/or metals) underneath the outer ceramic layer. For high speed shrapnel or rifles at NIJ Level IV, plates composed of very hard ceramics such as boron carbide or silicon carbide, or ceramic plates combined with UHMWPE or aramid laminations can be effective. For the coupling element material, which will be described further below, UHMWPE and aramid fibers provide very high tensile strengths, e.g., between about 3000 and about 3500 MPa (10⁶ Pascals). The aramids offer superior high temperature performance but may be susceptible to degradation from UV exposure and water damage. The UHMWPE have good UV and water resistance but may lose tensile strength at temperatures above 70° C.

In an embodiment that may be capable of stopping handgun rounds up to NIJ Level IIIA, Dyneema® HB50 plates may be used. In an embodiment for stopping knife stab threats, relatively thin ceramic plates may be used. In an embodiment for stopping NIJ Level III and Level IV rifle rounds relatively thick ceramic plates may be used. Combinations of these materials can also be used. Other materials for armor plates 12 are contemplated.

In one embodiment, the size of each individual plate 12 is between about 1 inch and about 4 inches measured across the top surface at the maximum dimension of the plate. The actual size of the solid pate can be selected based on the curvature of the area the armor is intended to protect, e.g., greater curvature may require small armor plates to provide for increased flexible of the assembly. In some embodiments, individual plate size can be less than about 1 inch and in other embodiments it can be greater than about 4 inches. In an embodiment where the armor may be used for the protection of a vehicle, the size of the individual solid armor plates may be between about 3 inches and about 12 inches. In other embodiments, the plate size may be greater than about 12 inches.

Within an assembly of armor plates, each plate may have substantially the same size as each other. Alternatively, the size of individual plates as well as plate thickness may vary at different portions of armor assembly 10. Similarly, the pattern arrangement and shape of plates 12 may also vary within an armor assembly. In general, the shape of an armor plate refers to the 2-dimensional shape of the armor plate from a plan view substantially orthogonal to the top or bottom surface of the armor plate. For example, in the portion of assembly 10 shown in FIGS. 1A and 1B, armor plates 12 have a square shape and are arranged in a 3×3 grid. In other examples, armor plates 12 may exhibit two or more shapes and may be arranged in one or more patterns within assembly 10.

In some examples, depending on the material of armor plates, a relatively small gap may be present between adjacent plates. For example, when using Dyneema HB50 for armor plates, very little gap space may be needed for the overall armor assembly to have sufficient flexibility to conform to the curvature of a person's chest/torso region. Therefore, in such an example, the pattern of the armor plates within such an armor assembly may not as significant compared to assemblies including armor plates made of different materials. Because the Dyneema HB50 material is soft and easily deformable, there is a good degree of freedom in the overall assembly's flexural, torsional and shear movements even when adjacent plates are touching in their resting positions.

In some examples, for stiff, rigid armor materials such as metal, any pattern may be selected so long as long the radius of curvature of the overall armor assembly is small enough to conform to a desired surface, e.g., to a person's chest/torso region. The radius of curvature may refer to the curvature of the armor assembly in a “lock up” position of the overall assembly, i.e. when the armor plates no longer are free to move because the plates have been bent and extended as far as the coupling elements and interference between neighboring plates allow.

Design factors such as plate size, shape, thickness, and pattern may be selected for various portions to provide varying properties for different portions of armor assembly 10. For examples, such factors may be selected to provide for first portion of assembly 10 that is more flexible than a second portion of assembly 10. Similarly, such factors may be selected to provide for varying degrees of breathability as well as protection from ballistic threats throughout armor assembly 10. In the case of assembly 10 configured for use as body armor, portions of assembly 10 may be designed to be more flexible at portions corresponding to curved body features and less flexible for portions corresponding to portions of a body having a relatively flat surface. The level of protection provided by assembly 10 may be increased for portions designed to protect more vital portion of a body compared to that of less vital portions of a body.

Coupling element 14 may be formed of any suitable material having the strength to couple plates 12 of assembly 10 to one another as well as transfer force from a localized impact throughout armor assembly 14. Coupling element 14 may be relatively flexible to allow plates 12 to move relative to one another. For ease of description, in some cases, coupling element 14 may be referred to as rope 14. However, other suitable materials and/or structures are contemplated for coupling element 14. Suitable material may include fibers strands, yarns and ropes. In some example, coupling element 14 may include one or more ropes, such as, e.g., braided-strand ropes. It has been found that some ropes are effective in transmitting the initial stress from an impact to the surrounding structure. The ropes can be constructed from any types of fibers, such as those used for fisherman's nets or ropes used for parachutes or for mountain climbing. In some embodiments, aramid, or high molecular weight polyethylene, such as Dyneema® or Spectra®, may be utilized for the rope material. Other embodiments use nylon or blends of nylon, polyethylene and/or aramid. Combinations of any conventional or new rope materials can be used. The ropes can comprise braided yarns or other fiber structures. In one preferred embodiment, ropes having a braided helical structure are used. Ropes with braided helical structures may have the ability to deform and absorb energy more so than simple yarns or wires due at least in part to the braided structure.

Alternatively or additionally, coupling element 14 may be formed of one or more wire strands. Similar to that described for the material used to form armor plates, example metals may exhibit sufficient elongation at break and ductility in order to avoid fracturing/rupturing. The same example metals listed above for metal alloy armor plates may also be used as example metal alloy materials for coupling elements. As above, metallic alloy wire may exhibit a braided helical structures. In some examples, Dyneema/Spectra/Kevlar may be preferred over metal ropes/wires because of strength-to-weight advantage of the non-metallic materials, as examples metal alloys may significantly add to the overall weight relative to some non-metallic options. In some example, armor plates and coupling elements may be composed of identical or substantially similar materials rather than dissimilar materials to avoid potential problems caused by mismatches in mechanical impedance and modulus.

FIG. 3 is a conceptual diagram illustrating two example armor plates 12a and 12b of an armor assembly that are coupled to one another via example coupling elements 14 from a plan view. For ease of illustration, coupling elements 14 are shown only for the two adjacent edges of plates 12a, 12b. Armor plates 12a, 12b may be substantially the same or similar to that of plates 12a-i shown in FIG. 1A. A plurality of apertures 14 extending through armor plates are dispersed at discrete locations about the perimeter of plates 12a, 12b. However, unlike that of plates 12a-i shown in FIGS. 1A and B, apertures 16 are located adjacent the edge of plates 12a and 12b at varying distances to form two separate rows of apertures 16. Such a configuration may be provide for additional connections between armor plates 12a, 12b via coupling element 14 to increase the overall connection strength between plate 12a and plate 12b. In other examples, apertures may be aligned in a single row around the perimeter, e.g., as shown in FIG. 1A, or may include more than two rows, e.g., three rows, of apertures dispersed around the perimeter of individual armor plates in assembly 10.

FIG. 4 is a conceptual diagram illustrating a cross-sectional view the assembly of FIG. 1A along line A-A. As shown, armor plates 12g-i are coupled to each other via ropes 14 which extend through apertures formed in each plate. The top and bottom surface of each of plates 12g-i are arranged along substantially the same plane and plates 12g-i form a discontinuous layer of armor material when assembly 10 is laid flat. However, the plane of the discontinuous layer may vary, e.g., when assembly 10 bent around curved surface, as a result of flexibility of assembly 10 on a global level (e.g. multi-plate perspective). In some examples, even if individual plates 12 of assembly 10 are relatively rigid plates, the arrangement of plates 12 and ropes 14 in assembly 10 over a portion that includes multiple plates may allow armor assembly 10 to bend such that assembly 10 roughly follows the contour of a curved surface. For examples, in some embodiments, assembly 10, as well as other example armor assemblies described herein, may be configured such that at least a portion of armor assembly 10 may substantially conform to a flat surface as well as bend to substantially conform to a curved surface. As described above, the flexibility of an armor assembly may be described in terms of radius of curvature for the armor assembly at “lock-up.” Such radius of curvature generally refer the radius of curvature when the armor plates of an armor assembly are no longer are free to move because the plates have been bent and extended as far as the coupling elements and interference between neighboring plates allow. At such a point, the armor assembly cannot be bent further due to the configuration of the armor plates, gaps, and coupling elements, for example, without plastically deforming or otherwise permanently deforming the armor assembly. For example, for ceramic-based armor plates, after such a point, one or more ceramic plates may fracture. As another example, for metal-based armor plates, after such a point, one or more metal plates may be permanently deformed. Additionally or alternatively, the coupling elements of an armor assembly may permanently yield, e.g., ropes may become permanently stretched. In some examples, assembly 10, as well as other example armor assemblies of this disclosure, may exhibit a radius of curvature less than approximately 300 mm, such as, for example, a radius of curvature between approximately 100 mm and approximately 200 mm. In some examples, the radius of curvature may be less than approximately 30 mm. Moreover, in some examples, assembly 10, as well as other example armor assemblies of this disclosure, may have some maximum curvature, e.g., due to minimum effective plate size, maximum gap distance between plates, and/or other factors, which can be expressed in terms of a minimum radius of curvature. For example, in some cases, for assembly 10, as well as other example armor assemblies of this disclosure, the radius of curvature may be greater than approximately 30 mm, such as, e.g., greater than approximately 100 mm. In some examples, an armor assembly may also be able to conform to a substantially flat surface as well conform to a curved surface consistent with the example radius of curvature values described above. Alternatively, an example armor assembly may be configured to have a maximum radius of curvature in which case the armor assembly may not be laid flat but may still be bent to a smaller radius of curvature values.

In FIG. 4, armor plates 12g-i are shown as having substantially the same thickness as one another. In some examples, plates 12g-i may have a thickness between about 2 mm to about 30 mm, such as, e.g., about 2 mm to about 15 mm or about 4 mm to about 10 mm. In some examples, plates 12g-i have a thickness of at least 6 mm. Such example thicknesses may be applicable for a variety of armor plate compositions, including, e.g., HB50 Dyneema. Different thickness may be selected based on the composition of the armor plates and may be varied based on the level of protection desired to be provided by armor assembly 10. Plate thicknesses other than those described are contemplated. Such example thicknesses may be applicable for one or more of the plates described in this disclosure.

As shown in FIG. 4, each of armor plates 12g-i is formed of a single layer, which may be formed of one or more of the materials described above. In other example, each of armor plates 12g-i may be multiple layer structures. The thickness and composition of the layers of each armor plate may be selected to provide desired properties. Each of armor plates 12g-i may be formed of multiple layers having substantially the same composition. In other examples, plates 12g-i may be formed of multiple layers, where at least two layers have different compositions. In one embodiment, armor plates with a multiple layer structures may include an armor material base layer coated with a different material optimized for sound dampening characteristics to minimize sound when the plates hit and rub against each other. In another example, a multiple layer armor plate may include a Dyneema plate with a ceramic layer on top since the hard ceramic may effectively blunt a bullet or other projective before it engages the Dyneema layer. Another example multiple layer armor plate may include a metal plate with a ceramic layer on top. In some example, an intermediate layer can also be used in cases where there is a mechanical impedance mismatch between two dissimilar layers. Bridging the difference in mechanical impedance values will improve the energy transmission from the layer that is first impacted by the bullet to layers underneath

The edges of adjacent plates 12g-i define gaps 18. Gaps 18 between neighboring armor plates 12 (e.g., plates 12h and 12i in FIG. 4) may extend from the top surface to the bottom surface of the discontinuous layer formed via armor plates 12 in armor assembly 10. In some examples, gaps 18 may extend through the discontinuous layer formed via plates 12 along a substantially linear path. Increasing the distance between neighboring armor plates 12 may increase the size of gap 18. In some examples, gaps 18 may have a width (i.e., the distance between the edges of adjacent plates defining the gap) between approximately 2 mm to approximately 10 mm, such as, e.g., approximately 5 mm to approximately 7 mm. Gaps width may be substantially uniform throughout armor assembly 10 or may vary from plate to plates or region to region, e.g., due to different pattern and/or plate shape in armor assembly 10). In some examples, the average width of gaps 18 over one or more regions of armor assembly 10 may be expressed as gap density calculated as the overall gap surface area for a particular portion of assembly 10 divided by the overall area of the assembly 10 in that portion (i.e., plate surface area plus gap surface area). In some examples, the gap density of assembly 10 may range from approximately 5% to approximately 30% such as, e.g., approximately 10% to approximately 20%.

The gap density of assembly 10 may be selected based on the overall level of protection, breathability, and/or flexibility desired for an armor assembly. For example, as the gap density of assembly 10 is increased, the overall flexibility and/or breathability of armor assembly 10 may also be increased. However, while increasing the overall density of gaps 18 (i.e., gap space within the overall area of assembly 10) may increase the flexibility and/or breathability of armor assembly, the increase in the gap area in assembly 10 may also decrease the relative level of protection provided by assembly 10. In general, gaps 18 between neighboring plates 12 in assembly 10 represent weak portions within the assembly that may be susceptible to ballistic threats or knife threats. Accordingly, in some examples, it may be desirable to minimize the gap space of a plate while maintaining at a minimum threshold level of breathability and/or flexibility. However, for a single discontinuous armor layer, such as that shown in FIG. 1A, gaps may be present to at least some extent between individual armor plates 12 in the discontinuous armor layer of armor assembly 10 to provide flexibility and/or breathability.

In accordance with some example of the disclosure, an armor assembly may include multiple discontinuous layers of armor layers, such as, e.g., the discontinuous armor layer formed of plates 12 and coupling elements 14 in FIG. 1A, overlaying one another. Adjacent discontinuous armor layers may be arranged relative to each other such that at least a portion of the gaps in one discontinuous armor layer are covered by armor plates of the second discontinuous layer. In this manner, the multilayer armor assembly may provide for increased protection by covering gaps in an individual layer with armor plates from another armor layer while also allowing for the flexibility and breathability imparted by each of the armor layers including gaps between adjacent armor plates.

FIG. 5 is a conceptual diagram illustrating, from a plan view, a portion of example armor assembly 24 including example first and second discontinuous armor layers. The first and second discontinuous armor layers are formed of first armor plates 12a-1 (referred to collectively as plates 12) and second armor plates 22a-i (referred to collectively second armor plates 22), respectively. For ease of illustration, the coupling elements (e.g., ropes) used to connect armor plates within the same armor layer and/or armor plates from different armor layers are not shown in FIG. 5. However, the coupling elements used to connect first armor plates 12 and second armor plate 22 of the first and second discontinuous armor layers, respectively, may be substantially the same or similar to that described above for coupling element 14 shown, for example, in FIGS. 1A and 1B. Coupling elements may connect plates of assembly 24 in the horizontal and/or vertical directions.

The first discontinuous armor layer (bottom layer as illustrated in FIG. 5) formed via first armor plates 12 may be the same or substantially similar to that of similarly number plates 12 of assembly 10. Adjacent plates 12 are separated by gaps 18 which extend through the first discontinuous armor layer formed by plates 12. In a similar fashion, the second discontinuous armor layer (top layer as illustrated in FIG. 5) is formed via second armor plates 22, and adjacent plates 22 are separated by gaps 18 which extend through the second discontinuous layer formed by plates 22. Second plates 22 may be substantially the same or similar to that of plates 12 described above, e.g., in terms of plate composition dimensions and the like. Similarly, the second discontinuous layer may be formed via second plates 22 in a manner substantially the same or similar to that described above with regard to the discontinuous armor layer of armor assembly 10. In some examples, second plates 22 may on average be smaller (e.g., in terms of surface area) than that of first plates 12. In other examples, first and second plates 12, 22 may be substantially the same size.

As shown in FIG. 5, the pattern, shape, and gap density for each of the first and second armor layers is substantially the same as each other. However, second plates 22 are offset from that of plates 12 such that at least a portion of gap 18 in the first discontinuous armor layer is covered by second plates 22 and at least a portion of gap 19 in the second discontinuous layer is covered by first plates 12. By overlying the second plates 22 of the second discontinuous layer over the first plates 12 of the first discontinuous layer in such a fashion, the total area of gaps extending all the way through both the first and second discontinuous layer, e.g., gap 28 shown in FIG. 5, is less than that of the total gap area of either the first discontinuous layer or second discontinuous layer. In this manner, armor assembly 24 may provide increased protection compared to that of the first and second armor layers individually, while also allowing for an armor assembly 24 including two discontinuous armor layers that may be flexible and/or breathable. Put another way, by offsetting the first and second discontinuous armor layers, one armor layer offers protection where the other layer is weakest (e.g., at the gaps of each armor layer).

FIG. 6 is another conceptual diagram illustrating, from a plan view, a portion of example armor assembly 26 including example first and second discontinuous layers. The first and second discontinuous armor layers are formed of first armor plates 12a-d (referred to collectively as plates 12) and second armor plates 22a-g (referred to collectively as second armor plates 22), respectively. Again, for ease of illustration, the coupling elements (e.g., ropes) used to connect armor plates within the same armor layer and/or armor plates from different armor layers are not shown in FIG. 6. However, the coupling elements used to connect first armor plates 12 and second armor plate 22 of the first and second discontinuous armor layers, respectively, may be substantially the same or similar to that described above for coupling element 14 shown, for example, in FIGS. 1A and 1B. Coupling elements may connect plates of assembly 26 in the horizontal and/or vertical directions.

Armor assembly 26 may be substantially the same or similar to that of armor assembly 24 of FIG. 5. For example, a second discontinuous armor layer formed of second armor plates 22 overlays a first discontinuous armor layer formed by first armor plates 12. The second discontinuous armor layer is arranged relative to the first discontinuous armor layer such that at least a portion of second plates 22 cover gaps between adjacent plates 12 of the first layer, and vice versa. Gap 28 extending through both the first and second discontinuous armor layers is present albeit on a smaller scale compared to that shown in FIG. 5.

Unlike that of armor assembly 24 (FIG. 5), the shape and pattern of second plates 22 in the second discontinuous armor layer is different from that of the shape and pattern of first plates 12 in the first discontinuous armor layer. As illustrated by armor assembly 26, instead of using two identical discontinuous armor layers, a first discontinuous armor layer can be used with a second discontinuous armor layer of plates that are designed to cover a relatively narrow area around the gaps in the first discontinuous armor layer. This may allow for improved weight efficiency since the second discontinuous layer does not overlap as extensively with the first discontinuous armor layer. For example, the second discontinuous armor layer may be described as having a gap area density that is greater than that of the first discontinuous armor layer. In some examples, first armor plates 12 that form the first discontinuous armor layer may be referred to herein as Solid Armor Plates (SAP) and the second plates 22 of the second discontinuous armor layer may be referred to herein as Gap Plugging Plates (GPP).

FIG. 7 is a conceptual diagram illustrating a portion of example assembly 30 including example first and second discontinuous layers from a side view. The first discontinuous armor layer is formed of SAPs 12a-12d (collectively SAPs 12) and the second discontinuous armor layer is formed of GPPs 22a-c (collectively GPPs 22). Again, for ease of illustration, the coupling elements used to attach SAPs 12 and GPPs 22 to each other are not shown. However, the coupling elements used to connect SAPs 12 and GPPs 22 of the first and second discontinuous armor layers, respectively, may be substantially the same or similar to that described above for coupling element 14 shown, for example, in FIGS. 1A and 1B. Coupling elements may connect plates of assembly 30 in the horizontal and/or vertical directions.

As shown in FIG. 7, GPPs 22 overlay at least a portion of SAPs 12 to cover at least a portion of gaps 18 present between SAPs 12 in the first discontinuous layer. Similarly, gaps 19 between GPPs 22 are covered to at least some extent by SAPs 22. Each GPPs 22 has a “T” shape that allows a portion of each GPPs 22 to extend into gap 18 between SAPs 12 while also including a portion that directly overlays a surface of SAPs 12. As will be described below, such a configuration may increase the ease with which GPPs 22 are attached to SAPs 12. The thickness of first and second discontinuous armor layers formed by SAPs 12 and GPPs 22, respectively, may be substantially the same or may be different from one another.

FIGS. 9A and 9B are conceptual diagrams illustrating GPP 22a of FIG. 7 from a perspective view and side view, respectively. As shown, GPP 22a has a “T” shape as shown in FIG. 7. In some examples, a “T” shape can provide improved low angle performance in an armor assemblies designed to stop knife attacks. FIGS. 8A and 8B are conceptual diagrams illustrating another example GPP 22d from a perspective view and side view, respectively. Unlike that of GPP 22a, GPP 22d has an elongated flat shape rather than a “T” shape. GPP 22a may be used in addition to or alternatively to that of GPP 22d in assembly 30 to at least partially cover gaps 18 between SAPs 12. However, the flat, elongated shape of GPP 22d does not allow for a portion of GPP 22d to be extending into gap 18 in the first discontinuous armor layer. Other geometries for GPPs are contemplated.

Some examples GPPs such as GPPs having a “T” shape include a vertical portion. The vertical portion may give the GPP substantially greater strength against bending under an applied force or impact because of the relatively large moment of inertia and higher bending modulus exhibited by the GPP about a horizontal bending axis, e.g., in the plane of FIG. 11 below. Additionally, GPP embodiments incorporating a vertical portion may tend to lock the vertical portion in place in the gap between adjacent SAPs. In one embodiment, the length of a GPP may be larger than its width and the height of the vertical portion may be approximately equal to the width of the GPP. In other embodiments, the height of the vertical portion may be less than the width of the GPP, and in still other embodiments the height of the vertical portion may be greater than the width of the GPP. In one embodiment, the length of the GPP is at least 50% larger than its width.

FIGS. 10A and 10B are conceptual diagrams illustrating an example assembly including SAPs 12a, 12b and GPPs 22a coupled to each other via an example rope 14. FIG. 10A illustrates a side view of SAPs 12a, 12b and GPPs 22a, and FIG. 10B illustrates a cross-sectional view along a plane that intersects apertures 16 in SAPs 12a, 12b, and apertures 32 in GPP 22a. As shown, a portion of “T” shaped GPP 22a extends into gap 18 between SAPs 12a, 12b. Rope 14 forms a secure loop that extends through apertures 16 in SAPs 12a, 12b and apertures 32 in GPP 22a to attach GPP 22a and SAPs 12a, 12b to each other. In this manner, rope 14 may attach individual armor plates in the same discontinuous layer (SAPs 12a, 12b) to one another in the horizontal direction as well as individual armor plates that are in other discontinuous layers in the vertical direction. As described above, coupling elements 14 may couple armor plates that are in the same discontinuous armor layer, in different discontinuous armor layers, or both.

FIG. 11 is a conceptual diagram illustrating an alternate example assembly including SAPs 12a, 12b and GPPs 22a coupled to each other via an example rope 14. SAPs 12a, 12b and GPP 22a are shown along a cross-section similar to that shown in FIG. 10B. As shown in FIG. 11, the shape and relative configuration of GPP 22a and SAPs 12a, 12b is substantially the same or similar to that shown in FIGS. 10A and 10B. However, apertures 32 in GPP 22a extend through GPP 22a in substantially the same direction as apertures 16 extend through SAPs 12a, 12b, rather than in substantially orthogonal directions. In other examples, apertures 16, 32 may extend through GPP 22a and/or SAP along an angular path that is neither substantially orthogonal nor substantially parallel to the surface plane of the first and/or second discontinuous layer. When assembled as shown in FIG. 11, apertures 32 are approximately aligned in the horizontal direction with apertures 16 of SAPs 12a, 12b, and rope 14 forms a secure loop through each aperture to attached GPP 22a to SAP 12a, 12b.

FIGS. 40A and 40B are conceptual diagrams illustrating a bullet 80 impacting an example armor assembly at a portion similar to that shown in FIG. 10B. As shown, when bullet 80 impacts GPP 22a, the example armor assembly is self-tightening or self-enhancing in the sense that when GPP 22a is pushed down by bullet 70, first and second SAPs 12a, 12b, which support GPP 22a, approach each other and tighten the grip on GPP 22a. As will be described below, in a three-layer armor assembly, when a bullet impacts on an isolated hole cover, e.g., IHC 46 shown in FIG. 26, there is a self-enhancing effect where the bullet pushes on IHC 46 which tends to pull adjacent SAPs closer to each other.

FIGS. 12A and 12B are conceptual diagrams illustrating example GPP 22a from perspective and side-views, respectively. As shown, GPP 22a has a “T” shape, and includes a plurality of apertures 32 extending through a portion of GPP 22a in a manner consistent with the example shown in FIGS. 10A and 10B. In FIGS. 12A and 12B, GPP 22a also includes two protrusions 34 on the surface of GPP 22a directly adjacent to the upper surface of SAPs 12a, 12b when inserted into gap 18 as shown, e.g., in FIG. 13 for armor assembly 38. Protrusions 34 allows the contact between GPP 22a and SAPs 12a, 12b to be localized to protrusions 34 rather than along substantially the entire length of gap 18 filled by GPP 22a so as to not restrict air flow through the first and second discontinuous layers through gap 18. FIG. 14 shows example air flow 36 through the armor assembly of FIG. 13. Such airflow allows for breathability in the example in which armor assembly forms a portion of body armor. Adequate airflow and moisture passage across body armor may be important for human comfort. Ample air passage through the armor of the present invention can be achieved due to the nature of the design. Protrusions 34 of GPP 22a provides additional space between GPP 22a and SAPs 12a, 12b for air or moisture to pass through. Alternatively or additionally, SAPs 12a, 12b may include protrusions to provide for separation between GPP 22a and SAPs 12a, 12b.

In some examples, the configuration of multiple discontinuous layer armor assemblies, such as one or more of those examples armor assemblies described in this disclosure, may be such that one or gaps are formed in the armor assembly which extend along a substantially continuous, nonlinear path through all of the individual discontinuous armor layers of an armor assembly. In this manner, the air flow through one or more continuous gaps through the armor assembly may provide for a relatively breathable armor assembly, e.g., in case in which the armor assembly is worn as a body armor. In some examples, the average air flow exhibited throughout the entire armor assembly may be greater than the air flow, if any, through an individual armor plate of the assembly. In this manner, solid armor plates may be used in an example armor assembly while also providing for suitable air flow through the armor assembly as a whole, e.g., via gaps between the solid armor plates.

FIGS. 15A and 15B are conceptual diagrams illustrating an example process for forming example GPP having a “T” shape. As show, multiple layers of high tensile strength yarns or fabrics 43 may be soaked with a properly selected resin and then arranged as shown in FIG. 15A on adjacent molding members 39, 41. Bottom layers of the yarns or fabric are pushed into a cavity between members 39, 41 to form the protruding portion of the “T” shape while top layers of the yarns or fabric extend straight across the “T” shape. The assembly is heated under pressure between members 49, 41, 45, as illustrated in FIG. 15B. The part is removed once the resin is cured resulting in GPP 22a shown in FIG. 16. In some examples, apertures 32 may be drilled or otherwise formed into a portion of GPP 22a to result in a configuration such as that shown in FIG. 10B or 11. In some examples, apertures 32 may be formed through GPP 22a so that ropes can be used to sew together the top layers of yarns or fabric with the bottom layers of yarns or fabric as shown in FIG. 17. The resin used in constructing GPP 22a is selected so that GPP 22a is sufficiently rigid and the resin is also selected to be ductile enough that GPP 22 does not easily fracture under ballistic impact.

FIGS. 18A-E are conceptual diagrams illustrating an example armor plate 22j from various viewpoints. In particular, FIGS. 18A and 18B shows plate 22j from top and bottom views, respectively. FIG. 18C show plate 22j rotated 90 degrees from the top view shown in FIG. 18A along the major axis. FIGS. 18D and 18E show plate 22 from a side view of FIGS. 18A and 18B, respectively. Similar to those other example “T” shaped GPP described above, armor plate 22j may be utilized as a GPP in an armor assembly that covers one or more gap portions between an adjacent discontinuous armor layer formed of SAPs coupled to one another via one or more coupling elements.

As shown in FIGS. 18A and 18B, the top portion or horizontal portion of the “T” shaped plate include a plurality of apertures including example aperture 43b extending all the way through the top portion. As shown in FIG. 18C, the side portion or vertical portion of plate 22j includes a plurality of apertures including example aperture 43a that extends all the way through the side portion. In each case, apertures 43a, 43b may be used to receive a coupling element at the discrete locations along plate 22j to attach plate 22j to other GPPs within the same discontinuous armor layer and/or attach plate 22j to one or more armor plates in a directly or indirectly adjacent discontinuous layer formed of a plurality of plates, such as, e.g., a discontinuous layer including a plurality of SAPs.

FIG. 19 is a conceptual diagram illustrating three example armor plates 12a, 12b, 22j attached to each other via coupling elements 14a-c from a side view. Armor plates 12a, 12b, 22j may be configured relative to each other similar to that shown in FIG. 10A, for example. Armor plates 12a, 12b may form a first discontinuous armor layer of SAPs. Armor plate 22j may be substantially the same as that shown in FIGS. 18A-E, and may form a portion of a second discontinuous armor layer of GPPs that overlies the first armor layer of SAPs such that all or a portion of the gaps between SAPs are covered by the second discontinuous layer of GPPs.

The path of coupling elements 14a-c within plates 12a, 12b, 22j within one or more apertures in plates 12a, 12b, 22j are shown as dashed lines. As shown, coupling elements 14a and 14b are used to attach armor plates 12a, 12b, 22j in a generally vertical direction while coupling element 14 attach armor plates 12a, 12b, 22j in a generally horizontal direction. Coupling element 14c may extend through the same apertures in plates 12a, 12b as that of coupling elements 14a, 14b or may extend through different apertures on plates 12a, 12b that spaced apart from one another on the perimeter of the respective plates.

FIGS. 20A-D are conceptual diagrams illustrating example armor plates 12a, 12b, 22k from various viewpoints. Armor plates 12a, 12b may form a portion of a discontinuous armor layer including a plurality of SAPs. Armor plate 22k may form a portion of another discontinuous armor layer formed of a plurality of GPPs directly adjacent to that the discontinuous armor layer including armor plates 12a, 12b. Armor plate 22k may be substantially the same or similar to that of armor plate 22j of FIGS. 18A-E except that armor plate 22k includes a total of sixteen apertures, e.g., 43c, in the top surface rather than fourteen as shown for armor plate 22j of FIGS. 18A and 18B. FIGS. 20A and 20C illustrates plates 12a, 12b, 22k along cross-section B-B in FIG. 20D, with FIG. 20C being rotated 90 degrees from that shown in FIG. 20A. FIG. 20D is a top-view of plates 12a, 12b, 22k. FIG. 20B is a view of plates 12a, 12b, 22k along cross-section C-C in FIG. 20D.

As shown in FIGS. 20A-D, armor plates 12a, 12b, 22k are attached to each other via coupling element 14d by extending through the apertures (e.g., aperture 43c of plate 22k) of plates 12a, 12b, 22k in both the vertical and horizontal directions for interlayer attachment and intralayer attachment. While the illustrated example includes only a single coupling element 14d to attach plates 12a, 12b, 22k, other examples may include a plurality of coupling elements over a portion an armor assembly formed in part by plates 12a, 12b, 22k.

FIGS. 21A-D are conceptual diagrams illustrating an example armor assembly 42 including multiple example discontinuous armor layers formed of SAPs 12a-d and GPPs 22a-d. In particular, FIGS. 21A and 21C illustrate top and bottom view, respectively, of assembly 42, and FIGS. 21B and 21D illustrates side views. Although not shown for ease of illustration, SAPs 12a-d and GPPs 22a-d may be connected to each other via one or more coupling elements as described above. As before, SAPs 12a-d form a first discontinuous armor layer that is adjacent to a second discontinuous armor layer formed by GPPs 22a-d. GPPs 22a-d have a “T” shape and covers a least a portion of the gaps in the first discontinuous armor layer formed between SAPs 12a-d. Similarly, at least a portion of the gaps in the second discontinuous armor layer formed between GPPs 22a-d are covered by SAPs 12a-d.

Despite the overlaying configuration of GPPs 22a-d and SAPs 12a-d, gap 28 may exist in armor assembly 42. As shown, gap 28 extends through both the first and second discontinuous armor layer along a substantially linear path perpendicular to the surface plane of assembly 42. In some examples, gap 28 may present a weakness in armor assembly 42, and may be covered in some embodiments by one or more armor plates that form a third discontinuous armor layer overlaying the first and second layers of SAPs and GPPs, respectively. As will be described further below, the third discontinuous armor layer is formed of a plurality of individual plates, where individual armor plates are each used to cover a single gap 28.

FIGS. 22A-C are conceptual diagrams illustrating another portion of an example armor assembly 44 including multiple example discontinuous armor layers. FIG. 22A is a plan view of the top surface of armor assembly 44, FIG. 22B is a side view of armor assembly 44, and FIG. 22C is a plan view of the bottom surface of armor assembly 44. Only a portion of SAPs 12a-d are shown in FIG. 22C for ease of illustration. Similar to that described above, SAPs 12-d form a first discontinuous armor layer, and GPPs 22a-d form a second discontinuous armor layer overlaying the first armor layer to at least partially covers gaps between SAPs 12a-d.

Armor assembly 44 also includes armor plate 46 which forms at least a part of a third discontinuous armor layer that overlays a portion of the first and second armor layer, and covers the gap, such as gap 28 shown in FIG. 18A, extending through both the first and second armors layers along a substantially linear path. In this manner, armor plate 46 effectively “plugs” the remaining gap in armor assembly 44 from the first and second discontinuous armor layers. Of course, only a portion of armor assembly 44 is illustrated in FIGS. 22A-C and a number of relatively isolated gaps in the first and second armor layers may be present over the entire assembly requiring a plurality of armor plates 46 to cover substantially all, or at least some, of the gaps. In some examples, armor plate 46 may also be referred to herein as Isolated Hole Cover (IHC) 46.

As the gaps extending through the first and second discontinuous armor layers along a linear path may be relatively isolated in the surface of armor assembly 42, the gap area density of the third discontinuous layer, which includes armor plate 46, required to cover gaps 28 may be relatively high. However, the third discontinuous armor layer may cover more surface area of the first and second layers to provide multiple layers of armor plate at points in an armor assembly to increase the overall degree of protection provided by armor assembly. In some examples, IHC 46 may be formed of the same or similar materials as that of GPPs 22a-d and/or SAPs 12a-d, or may be formed of different materials than that of GPPs 22a-d and/or SAPs 12a-d. Suitable armor materials may include those described in this disclosure for example GPPs and SAPs. IHC 46 may have any suitable thickness and may be the same or different than that of GPPS 22a-d and/or SAPs 12a-d.

Similar to that of SAPs 12a-d, GPPs 22a-d, IHC 46 may include one or a plurality of apertures, e.g., aperture 48a, that allows IHC 46 to be coupled to one or more armor plates of armor assembly 44. As shown in FIGS. 22A and 22C, ropes 14 or other coupling element extends vertically through aligned apertures, including aperture 48a, for example, to connect SAPs 12a-d, GPPs 22a-d and IHC 46 to each other to form the pattern shown in FIGS. 22A-22C. As with the other examples described in this disclosure, such a pattern may be repeated over all or a portion of armor assembly 44. In some examples, IHC 46 may be attached or otherwise fixed in place to cover one or more gaps extending through the first and second discontinuous armor layers of assembly 44 without the use of a coupling element to connect IHC to the adjacent layers.

As illustrated by FIG. 22A-22C, for example, in some embodiments of this disclosure, multiple layer constructions may be used for armor assemblies which provide for substantially 100 percent areal coverage while maintaining flexibility and/or breathability of the armor assembly. Moreover, in some examples, such as the example three discontinuous layer assembly construction shown in FIGS. 22A-22C, an armor assembly may provide for reduced weight, e.g., compared to armor assemblies having one or more continuous layers. For example, for an armor assembly configuration similar to that shown in FIG. 27 below, the armor assembly can have a weight equivalent of approximately 1.23 times the weight of a single, continuous layer of using the same material and thickness of SAPs 12a-12f (ignoring the weight of coupling elements 14). If three substantially identical discontinuous layers of SAPs are used, a weight of approximately 2.56 times the weight of a single full coverage layer of SAP material would be obtained in such an example.

FIGS. 23A-C are conceptual diagrams illustrating an example armor plate 22a from bottom, side and end views, respectively. Armor plate 22a may be the same or substantially similar to that shown in FIGS. 22A-C, and may form a portion of a discontinuous armor layer including a plurality of GPPs. FIGS. 24A and 24B are conceptual diagrams illustrating from side and plan views, respectively, example armor plate 46 from FIGS. 22A-C. As shown, armor plate 22a includes a plurality of apertures, including 43d that may be used to connect armor plate 22a to armor plate 46 using a rope or other coupling element that extends through both apertures 43d, 48a when arranged as shown in FIGS. 22A-C. Although armor plate 46 is shown as having a octagonal shape, other suitable shapes are contemplated.

FIG. 25 is a conceptual diagram illustrating an example portion of example armor assembly 50. Armor assembly 50 includes a first discontinuous layer including SAPs 12a-d and a second discontinuous layer including GPPs 22a-22d which covers at least a portion of the gaps in the first discontinuous layer. As shown, armor assembly 50 may be the same or substantially similar to armor assembly 42 of FIGS. 21A-21D. An example pattern for the plurality of apertures, e.g., apertures 16a, 43a, used to couple the plates in the respective layers to each other, e.g., via a rope or other coupling element, are shown in FIGS. 21A-21D. Other apertures patterns are contemplated. Similar to that of armor assembly 42, armor assembly 50 includes gap 28 which extend through the first and second discontinuous layers along a substantially linear path.

FIG. 26 is a conceptual diagram illustrating an example portion of another example armor assembly 52. Armor assembly 52 is substantially the same or similar to that of armor assembly 50. However, in addition to SAPs 12a-d and GPPs 22a-d, armor assembly 52 includes armor plate or IHC 46 which covers gap 28 that was present in armor assembly 50 in FIG. 25. IHC 46 has a square shape and is directly connected to each of SAPs 12a-d and GPPs 22a-d via coupling element 14 that extend through at least one aperture (not labeled) in each respective plate. For ease of illustration, not all coupling elements are shown in FIG. 26. As shown, SAPs 12a-d, GPPs, 22a, and IHC 46 forms a portion of armor assembly 52 in which substantially no gaps defining a substantially linear path through the respective armor layers exist over the surface of assembly 52.

FIG. 27 is a conceptual diagram illustrating an example portion of example armor assembly 54. The portion of armor assembly shown may be substantially the same or similar to that of the portion of armor assembly 52 shown in FIG. 26. However, the portion of armor assembly 54 illustrated includes SAPs 12a-f, GPPs, 22a-g, and IHCs 46a, 46b. Additionally, IHCs 46a, 46b have an octagonal shape rather than a square shape. Other shapes for IHC plates are contemplated. In some examples, a circular or rectangular armor plate can be used for the IHC.

FIG. 28 is a conceptual diagram illustrating an example portion of another example armor assembly 56. The portion of armor assembly shown may be substantially the same or similar to that of the portion of armor assembly 54 shown in FIG. 27. However, the portion of armor assembly 54 illustrated does not include IHCs covering the gaps in the assembly which define a substantially linear path through both the first and second discontinuous armor layers formed via SAPS 22a-f and GPPs 22a-h. The perimeters of SAPs 22a-f covered by GPPs 22a-h are shown as dashed lines. As shown, for armor assembly 56, coupling elements 14 form a grid pattern which extend over SAPs 12b and 12d.

FIGS. 29A-C are conceptual diagrams illustrating various example discontinuous armor layers on an example portion of example armor assembly 58. In each case, the coupling element(s) used to connect respective armor plates of armor assembly 58 are not shown for ease of illustration. FIG. 29A illustrates a first discontinuous armor layer that include sixteen, square-shaped SAPs, including SAP 12a, arranged in a 4×4 pattern which a plurality of apertures around the perimeter of each SAP. FIG. 29B illustrates the first discontinuous layer of FIG. 29A overlaid with a second discontinuous layer including twenty four, square-shaped GPPs, including GPP 22a, arranged in a pattern that is offset approximately 45 degrees from that of the first discontinuous layer. FIG. 29C illustrates the first and second discontinuous layers of assembly 58 overlaid with a third discontinuous layer including nine, square-shaped IHCs, including IHC 46a arranged in a pattern that is aligned with the first discontinuous layers and offset approximately 45 degrees from that of the second discontinuous armor layer. In the example shown in FIG. 29C, the square-shaped IHCs may be approximately the same size as that of the SAPS, and the GPPs may be approximately half the size of the SAPs.

FIGS. 30A and 30B are conceptual diagrams illustrating various example discontinuous armor layers on an example portion of another example armor assembly 60. In each case, the coupling element(s) used to connect respective armor plates of armor assembly 60 are not shown for ease of illustration. FIG. 30A illustrates the first and second discontinuous layers of assembly 60. Similar to that of armor assembly 58, the first discontinuous layer includes sixteen, square-shaped SAPs, including SAP 12a, arranged in a 4×4 pattern which a plurality of apertures around the perimeter of each SAP. The second discontinuous layer overlaying a portion of the first discontinuous layers includes nine, square-shaped GPPs, including GPP 22a, arranged in a 3×3 pattern. FIG. 30B illustrates the first and second discontinuous layers of assembly 60 overlaid with a third discontinuous layer including eighteen, square-shaped IHCs, including IHC 46a arranged in a pattern that is aligned with the first discontinuous layers and offset approximately 45 degrees from that of the first and second discontinuous armor layers. Each of the configurations illustrated in FIGS. 30A and 30b, as well as the other example configurations, may be repeated as necessary to provide an armor assembly that covers a desired surface area. In the example shown in FIG. 30B, the square-shaped IHCs may be approximately half the size of that of the SAPS and GPPs.

As noted above, the coupling element(s) used to connect the SAPs, GPPs, and IHCs of armor assembly 58 and armor assembly 60 are not shown. However, in these and other examples, such coupling element(s) can extend both horizontally and vertically within the three layer structure, e.g., a coupling element may extend between SAPs, horizontally between GPPs, and vertically between the GPP layer and the SAP layer. The armor plates in FIGS. 29C and 30B include two rows of apertures that allow for additional coupling elements to be used to hold the armor plates together. Tying respective armor plates together both horizontally and vertically can offer improved ballistic performance since a bullet will not be able to penetrate near the boundary of a GPP without bursting ropes and damaging plates.

In some examples, the use of GPPs and IHCs plates in conjunction with SAPs act to reduce the weight of an armor assembly, e.g., as compared to an armor assembly including three continuous armor layers. Moreover, the pattern, shape and other design configurations may be provided to reduce the weight of armor assemblies with three discontinuous layers. As an illustration, if 3×3 inch square plates are used for all three layers in an armor assembly with a pattern similar to that shown in FIG. 29A, with a 0.25 inch gap between the armor plates in each discontinuous layer, each layer covers 85.2% of the total area. The total coverage would then be 255.6%, or just over 2.5 layers of SAP material. With the geometry shown in FIGS. 22A-C with a GPP width of ⅓ of the SAP plate to plate distance (1.08 inches) and a IHC width of half of the SAP plate to plate distance (0.65 inches), the SAP layer has an areal coverage of approximately 85.2%, the GPP layer has an areal cover of approximately 23.7% and the IHC layer has an areal coverage of approximately 14.0%. This results in a total coverage of 122.9%, less than half of coverage, and hence the weight, of using 3 layers of identical square plates. Therefore, using selected patterns and geometries, e.g., as shown in FIGS. 22A-C for the GPP and ICH layers results in a reduction of total guard plate weight by more than 50%. In this manner, some example armor assembly of this disclosure may provide complete coverage using armor plate layers with less than three full coverage layers of plates. For example, in some examples, the GPP layer of plates can cover less than 60 percent, such as, e.g., less than 50 percent, of the total area of the armor assembly and the IHC layer of plates can cover less than 40 percent, such as, e.g., less than 25 percent of the total area of the armor assembly. Thus, the weight of the final body armor assembly is less than an embodiment with three layers of identical plates. In addition, such a configuration of progressively reduced sizes for plates in the upper layers will also improve the overall ability to bend and the flexibility of the three layered plate system of this body armor.

FIG. 31 is a conceptual diagram illustrating an example portion of example armor assemblies 61 from a cross-sectional view. In particular, the cross-section of FIGS. 31-36 are illustrated along a cross-section bisecting an gap portions extending through first discontinuous layer including SAPs 12a, 12b, and second discontinuous layers including GPPs 22a, 22b. As shown, armor assembly 61 also includes IHC 63, which is positioned such that IHC 63 covers or “plugs” the gap in the first and second discontinuous layers. IHC includes first and second hole plugging heads 62a, 62b connected via shaft 64, which runs through the gap portion between the first and second discontinuous layers. In this manner, IHC 63 may take a dumbbell or bobbin type shape. The size of first and second hole plugging heads 62a, 62b connected via shaft 64 are sized such that IHC 63 is secured within assembly 61 and cannot fall through the gap being plugged between the first and second discontinuous layers. As show in FIG. 31, in some examples an IHC, such as, IHC 63 may include both a portion (e.g., head 62a) above the outer surface of the discontinuous layer formed via the GPPs and also a portion (e.g., head 62) below the outer surface of the discontinuous layers formed via the SAPs. In this manner, IHC may be described in some examples as forming two discontinuous layers, where one discontinuous layer is adjacent to the discontinuous layer formed via the GPPs and another discontinuous layer is adjacent to the discontinuous layer formed via the SAPs.

First and second hole plugging heads 62a, 62b may be formed of any suitable hard and/or tough material and may include armor material such as, e.g., those materials described herein. In some examples, shaft 64 connecting heads 62a, 62b may be a rigid member formed of a suitable material, armor or otherwise. In other examples, shaft 64 may include a rope or other coupling member that may be knotted to function as hole plugging heads 62a, 62b. For example, shaft 64 may include one more examples of high-strength rope described above with regard to coupling element 14.

FIGS. 32-34 are conceptual diagrams of example IHCs 63a, 63b, 63c including first and second hole plugging heads 62a, 62b connected to each other via rope shaft 64. Each example IHC 63a, 63b, 63c may be incorporated into an example armor assembly, for example, as shown in FIG. 31. In each case, first and second hole plugging heads 62a, 62b include one or more knots in the rope used for shaft 64. The knots for one or both of heads 62a, 62b may be tied once shaft 64 is inserted in a gap extending through first and second armor layers are shown in FIG. 31. In FIGS. 33 and 34, first and second heads 62a, 62b include semi-sphere shaped and cone-shaped solid head members are engaged by the knots at either end of shaft 64 to assist in securing IHCs 63b, 63c in place within a multiple layer armor assembly as described in this disclosure.

In some examples, the first and/or second hole plugging head of an IHC may include a cap covering the one or more knots at either end of rope shaft of the IHC. FIGS. 35 and 36 are conceptual diagrams illustrating an example portion of example armor assemblies from cross-sectional views. In particular, similar to that of FIG. 31, the cross-section of FIGS. 35 and 36 are illustrated along a cross-section bisecting gap portions extending through first discontinuous layer including SAPs 12a, 12b, and second discontinuous layers including GPPs 22a, 22b of the armor assembly. In each case, IHC 63d, 63e cover or “plugs” the gap between the first and second discontinuous layers.

As shown, for IHC 63d and IHC 63e, each of the first and second hole plugging heads 62a, 62b, respectively, include one or more knots at either end of shaft 64 which are covered by caps 68a, 68b. Caps 68a, 68b may be constructed of any suitably hard or tough material. Example materials may include ceramic, composites, hardened Kevlar® or other tough polymeric materials, including those armor materials described herein. In an alternative embodiment, the area under one or more of caps 68a, 68b covering the knot is filled with a rubbery yet strong glue.

In the example of FIG. 36, first hole plugging head 62a includes ring 66 which extends around the perimeter of the gap filled by IHC 63e to provide additional support for securing IHC 63e in place by preventing the rope knot or other portion of first hole plugging head from pushing through the gap in the first and second discontinuous armor layers, e.g., in the case of impact by a ballistic object. FIG. 38 is a conceptual diagram illustrating ring 66 from a perspective view and may take the form of a washer in some instances. Other examples, ring 66 may have a shape other than that of a circle. FIG. 39 is an example IHC 61f in which both first and second hole plugging heads 62a, 62b include ring 66.

In some examples, an IHC having a bobbin configuration such as IHC 63 of FIG. 31 that is formed of rope rather than a rigid material, especially for that of the shaft 64, may prevent the shaft or other portion of the IHC from becoming a solid, rigid projectile upon direct ballistic impact. FIGS. 39A and 39B are conceptual diagrams illustrating armor assembly 74 with IHC 63g plugging a gap between armor plates 76a, 76b, where IHC 63g includes a rigid shaft. Upon impact by bullet 70, the rigid shaft of IHC 63g may become projectile. Such a scenario may be prevented by the use of a rope-based IHC or other IHC with a flexible shaft rather than substantially rigid shaft. However, in other examples, rigid shaft IHC may also be suitable for use in armor assemblies.

EXAMPLES

Example 1

A variety of example materials were evaluated for use in forming one or more armor plates of an armor assembly according to this disclosure. As described above, a variety of material properties may be analyzed when selecting a material to form armor plates for use in an armor assembly. Tables 1a-d list a variety of example materials and corresponding values for various properties that may be evaluated when selected an armor material. For example, Tables 1a-d include a toughness value for each material. Toughness values (normalized to energy per weight, J/g) were calculated using Equation 1:

T(estimate)=0.5(σ_yield*ε_ultimate)+0.5σ_ultimate(ε_ultimate−ε_yield)  (1)

where T(estimate) is the estimated toughness value, σ_yield is the stress at the yield point on the stress-strain curve, σ_ultimate is the stress at the ultimate strength point on the stress-strain curve, ε_yield is the strain at the yield point on the stress-strain curve, ε_ultimate is the strain at the ultimate strength point on the stress-strain curve.

TABLE 1a
		Ultimate
	Yield	Tensile		Young's			Toughness/
	Stress	Strength	Elongation	Modulus	Density	Toughness	Density
Material	(MPa)	(MPa)	at Break	(MPa)	(g/cm)	(MPa)	(J/g)
Ti Grade 5	1100	1170	0.1	114000	4.43	107.86	24.35
TI Grade 2	340	430	0.28	102000	4.51	107.08	23.74
440 Steel	345	485	0.18	140000	8	74.1	9.26
1340 Steel, oil	814	876	0.21	200000	7.87	175.67	22.32
quenched from
830° C. (1525° F.),
595° C. (1100° F.)
temper
Al 7075-T6	505	570	0.11	72000	2.81	57.13	20.33
or T651
Al 6061-T91	395	405	0.12	69000	2.7	46.84	17.35
Al 7076-T61	470	510	0.14	67000	2.82	66.81	23.69
Al 7475-T61	500	550	0.12	72000	2.8	61.09	21.82
Al 7001-T6	625	675	0.09	71000	2.84	55.53	19.55
or T651
Al 7001-T75	495	580	0.12	71000	2.84	62.48	22
Allvac ® M-252	345	1378	0.5	100000	8.24	428.37	51.99
Nickel				(estimated)
Superalloy,
Heat
Treatment:
1177° C. (2150° F.)
Anneal
Nickelvac ®	414	1035	0.6	100000	9.22	432.56	46.92
L-605 Nickel				(estimated)
Superalloy,
Heat
Treatment:
1204° C. (2200° F.)
Anneal
Gall-Tough ®	414	1110	0.63	100000	8.94	477.76	53.44
Stainless,				(estimated)
Room Temp.

TABLE 1b
		Ultimate
	Yield	Tensile		Young's			Toughness/
	Stress	Strength	Elongation	Modulus	Density	Toughness	Density
Material	(MPa)	(MPa)	at Break	(MPa)	(g/cm)	(MPa)	(J/g)
Haynes ® 188	425	965	0.42	140000	8.94	290.44	32.49
alloy, 10% cold
reduction, 3.2 mm
thick sheet, 1175° C.
for 5 minutes
Haynes ® 25 alloy,	470	1030	0.62	225000	9.13	461.67	50.57
room temperature
after 25% cold
reduction, 1175° C.
anneal for 5 minutes
AISI Type S21900	640	841	0.6	200000	7.83	442.95	56.57
Stainless Steel,
15% final cold
reduction,
stress relieving
heat treatment
705° C. (1300° F.)
for 2 hours, air
cooled

TABLE 1c
		Ultimate
	Yield	Tensile		Young's			Toughness/
	Stress	Strength	Elongation	Modulus	Density	Toughness	Density
Material	(MPa)	(MPa)	at Break	(MPa)	(g/cm)	(MPa)	(J/g)
AISI Type	640	841	0.6	200000	7.83	442.95	56.57
S21904 (Alloy
21-6-9)
Stainless Steel,
15% final cold
reduction,
stress relieving
heat treatment
705° C. (1300° F.)
for 2 hours, air
cooled
Manganese Brass,	683	689	0.6	100000	8.42	409.25	48.62
UNS C66700				(estimated)
Beryllium Copper,	1344	1462	0.48	127500	8.25	665.73	80.7
UNS C17200
Copper,	1379	2141	0.4	100000	8.89	689.24	77.53
UNS C71700				(estimated)
MRC Polymers	53.8	53.8	2	1690	1.1	106.74	97.04
EMAREX 308
High Impact
Modified Nylon
6

TABLE 1d
		Ultimate
	Yield	Tensile		Young's			Toughness/
	Stress	Strength	Elongation	Modulus	Density	Toughness	Density
Material	(MPa)	(MPa)	at Break	(MPa)	(g/cm)	(MPa)	(J/g)
Ensilon 6/6	85.49	85.49	0.9	2827	1.14	75.65	66.36
Xenoy 1103	52	50	1.5	1900	1.2	75.82	63.18
Xenoy 1101	53	59	1.2	2040	1.21	66.43	54.9
Xenoy 5720	50	50	1.65	1720	1.17	81.77	69.89
Lexan 141	62	69	1.3	2340	1.2	84.24	70.2
304 steel	215	505	0.7	196000	8	251.72	31.47
Kevlar	3620	3620	0.04	70300	1.44	37.12	25.78
302 Steel	255	585	0.57	193000	7.86	239.01	30.41

Example 2

A sample sheet of body armor was constructed according to the armor assembly embodiment shown in FIG. 22A-C using approximately 3×3 inch square, 20 ply HB50 Dyneema SAP plates. For the GPPs armor plates, approximately 2 inch wide HB50 Dyneema armor plates with “T” shapes, such as, e.g., those as shown in FIGS. 16 and 17 were used. These GPP plates with 20 plies had a thickness of approximately 5 mm. For the IHC armor plates, HB50 20 ply Dyneema, octagonally shaped IHCs (similar to that shown in FIGS. 24A and 24B were attached over the holes. The Dyneema plates were manufactured by Tencate. The rope coupling element used to connect the plates in the armor assembly was Spectra 1.6 mm diameter cord from RW Rope Warehouse. The sample armor assembly successfully protected against a 44 Magnum Semi Jacketed hollow point at NIJ Level IIIA. This is a Level IIIA Protection Level according to the National Institute of Justice Ballistic Resistance of Body Amor NIJ Standard-0101.06.

Various embodiments of the invention have been described. These and other embodiments are within the scope of the following claims.

Claims

1. An armor assembly comprising:

a plurality of armor plates; and

at least one coupling element that couples the plurality of armor plates to each other, wherein the plurality of armor plates are coupled to each other via the at least one coupling element at discrete locations on each armor plate to form a discontinuous armor layer.

2. The armor assembly of claim 1, wherein the plurality of plates forming the discontinuous layer includes a first plurality of plates forming a first discontinuous layer and a second plurality of plates forming a second discontinuous layer overlaying at least a portion of the first discontinuous layer.

3. The armor assembly of claim 2, wherein the first plurality of plates define a first gap portion in the first discontinuous layer, wherein the second plurality of plates forming the second discontinuous layer overlays at least a portion of the first gap portion.

4. The armor assembly of claim 2, wherein the plurality of plates forming the discontinuous layer includes a third plurality of plates forming a third discontinuous layer overlaying at least a portion of the second discontinuous layer.

5. The armor assembly of claim 4, wherein the second plurality of plates define a second gap portion in the second discontinuous layer, wherein the third plurality of plates forming the third discontinuous layer overlays at least a portion of the second gap portion.

6. The armor assembly of claim 5, wherein the first, second, and third discontinuous layers combine to form a continuous layer with substantially no gaps extending through the continuous layer along a substantially linear path.

7. The armor assembly of claim 2, wherein the first plurality of plates of the first discontinuous layer and the second plurality of plates of the second discontinuous layer are mechanically coupled to each other via the at least one rope.

8. The armor assembly of claim 1, wherein the plurality of armor plates comprising one or more of aramid, polyethylene, ceramic, carbon nanotubes, or metallic alloy.

9. The armor assembly of claim 1, wherein the at least one coupling element comprises one or more of aramid, polyethylene, nylon, or metallic wire.

10. The armor assembly of claim 1, wherein each of the plurality of armor plates includes at least one coupling aperture, wherein the at least one rope extends through the at least one coupling aperture of the plurality of plates to mechanically couple the plurality of plates to each other.

11. The armor assembly of claim 1, wherein each of the plurality of armor plates includes a plurality of coupling apertures dispersed around a perimeter of the armor plate.

12. The armor assembly of claim 1, wherein the armor assembly may substantially conform to a surface having a radius of curvature greater than 30 mm.

13. The armor assembly of claim 1, wherein the plurality of armor plates comprise a ceramic material and the at least one coupling elements comprise polyethylene or aramid fiber ropes.

14. The armor assembly of claim 1, wherein the plurality of armor plates comprise multiple layers, wherein respective layers include unidirectional fibers held together in a binder.

15. The armor assembly of claim 14, wherein the unidirectional fibers comprise polyethylene or aramid.

16. The armor assembly of claim 1, wherein a thickness the first plurality of plates is between approximately 2 mm and approximately 30 mm.

17. The armor assembly of claim 1, wherein the armor assembly may substantially conform to a surface having a radius of curvature less than 300 mm.

18. An armor assembly comprising:

a first discontinuous armor layer including of a first plurality of armor plates;

a second discontinuous armor layer including of a second plurality of armor plates;

a third discontinuous layer armor including of a third plurality of armor plates; and

at least one coupling element that couples the first, second, and third plurality of armor plates to each other to form at least a portion of the armor assembly.

19. The armor assembly of claim 18, wherein the first, second, and third plurality of armor plates are coupled to each other via the at least one coupling element at discrete locations on respective armor plates.

20. The armor assembly of claim 18, wherein the second discontinuous layer is between the first and third discontinuous layers.

21. The armor assembly of claim 18, wherein the second plurality of armor plates covers less than about 60 percent of a total area covered by the armor assembly and the third plurality of armor plates covers less than about 40 percent of the total area covered by the armor assembly.

22. The armor assembly of claim 18, wherein the second plurality of plates covers gaps between the first plurality of plates, and the third plurality of plates covers gaps extending through the first and second plurality of plates.

23. The armor assembly of claim 18, wherein the first, second and third discontinuous layers are adjacent to each other and are positioned relative to each other such that no gap exists in the armor layers defining a substantially linear path through all of the discontinuous layers.

24. The armor assembly of claim 18, wherein at least one of the first, second, and third plurality of armor plates forming the first, second and third arrays of armor plates have a shape that is non-identical from the other of the first, second, and third plurality plates.

25. The armor assembly of claim 24, wherein the at least one coupling element traverses substantially vertically through the first and second discontinuous layers armor plates to connect the first and second plurality of plates together, and wherein the at least one coupling element traverses substantially vertically through the second and third discontinuous layers of armor plates to connect the second and third plurality of plates together.

26. The armor assembly of claim 18, wherein the first, second, and third discontinuous armor layers define one or more continuous pathways configured to allow air flow through the armor assembly.

27. A method comprising coupling a plurality of armor plates to each other via at least one coupling element, wherein the plurality of armor plates are coupled to each other via the at least one coupling element at discrete locations on each armor plate to form a discontinuous armor layer.

28. The method of claim 27,

wherein the plurality of armor plates comprise a first, second, and third plurality of armor plates, and the discontinuous armor layer comprises first, second, and third discontinuous armor layers,

wherein coupling the plurality of armor plates to each other via at least one coupling element comprising coupling the first, second, and third plurality of armor plates to each other via the at least one coupling element to form the first, second, and third discontinuous armor layers, and

wherein the first armor layer includes the first plurality of armor plates, the second armor layer includes the second plurality of armor plates, and the third armor layer includes the third plurality of armor plates.

29. The method of claim 27, wherein first, second, and third discontinuous layers combine to form a continuous layer with substantially no gaps extending through the continuous layer along a substantially linear path.