The presently-disclosed subject matter relates to a composite armor panel. In particular, the presently-disclosed subject matter relates to a composite armor panel that is comprised of a first layer, composed of a matrix of an elastomeric material and a crushed aggregate material, and a second backing layer.
For the past several decades, military and civilian researchers have been searching for materials that will provide effective, lightweight protection against armor piercing rounds. Ceramic and KEVLAR® materials have been shown to provide a substantial amount of protection when applied to vehicles or body armor. (KEVLAR® is a registered trademark of E.I. du Pont de Nemours and Company of Wilmington, Del.) However, while these materials are effective, they are expensive and are thus typically reserved for critical applications, and not for structures such as airports, banks, shopping malls, financial institutions, and schools.
Previously, a matrix of bitumen and stone, known as “plastic armour,” was identified as a low-cost material that that could provide the necessary protection for these structures. Plastic armour is a wafer consisting of at least two inches of a bitumen-granite matrix overlaying a thin steel plate, and is capable of preventing many armor-piercing projectiles from piercing its steal plate. Nevertheless, because of its composition, it is not economically feasible or practical to incorporate plastic armour into many civilian structures.
Thus, there remains a need for an armor panel that is both economically feasible to produce and practical to incorporate into civilian structures, but yet is still capable of providing the necessary protection for these structures.
The presently-disclosed subject matter relates to a composite armor panel that makes use of an elastomeric material and a crushed aggregate material to provide a composite armor panel that is capable of being inexpensively manufactured and incorporated into common building structures, yet is still able to provide protection for the structure as well as its occupants.
In some embodiments, a composite armor panel is comprised of two layers: a first layer, composed of a matrix of an elastomeric material and a crushed aggregate material; and a second backing layer. The elastomeric material of the first layer can be selected from a variety of materials including rubber or plastic. Similarly, the crushed aggregate material can also be selected from a variety of materials, including, granite, limestone, ceramic, silicon carbide, or combinations thereof. In one embodiment, the elastomeric material is rubber, and the crushed aggregate material is granite.
Depending upon the intended application, the ratio of elastomeric material to aggregate material can be varied, and/or the thickness of the matrix can be increased to provide a first layer with tunable properties and with desired performance characteristics. In some embodiments, the first layer of the panel is comprised of an amount of the elastomeric material that is equal to or greater than about 60% by weight of the first layer. For example, in certain embodiments, the first layer includes about 75% by weight of the elastomeric material and about 25% by weight of the crushed aggregate material. As another example, in other embodiments, the first layer includes about 90% by weight of the elastomeric material and about 10% by weight of the crushed aggregate material. As yet another example, in some embodiments, to produce an armor panel with tunable properties and with desired performance characteristics, the thickness of the first layer of the armor panel is varied from about 0.5 inches to about 1.5 inches. Of course, varying the thickness of the armor panel can be done with and without varying the amount of elastomeric material and crushed aggregate material in the armor panel.
In some embodiments, to provide additional strength to an exemplary armor panel, a composite armor panel is provided that incorporates one or more geogrids into the matrix of the first layer. When more than one geogrid is incorporated into a matrix of an exemplary armory panel, each geogrid is typically spaced at a predetermined distance from each adjacent geogrid, such that the crushed aggregate material of the matrix is held in place throughout the matrix.
As noted, an exemplary composite armor panel further includes a second backing layer. In some embodiments, the second backing layer is in the form of a steel plate that provides a further barrier to prevent projectiles or the like from penetrating through an exemplary armor panel. In other embodiments, the second backing layer is a geomembrane that reduces the overall weight of the armor panel, but yet still provides a second backing layer with both high tear resistance and high deformation resistance.
Further provided are methods for making a composite armor panel. In some embodiments, an exemplary armor panel is made by creating a mixture of an amount of an elastomeric material and an amount of a crushed aggregate material. The mixture is then placed in a mold. The mold is then exposed to an elevated temperature and an elevated pressure for a predetermined time period, such that a matrix, composed of the elastomeric material and the crushed aggregate material, is formed. The mold and the matrix are then allowed to cool prior to removing matrix from the mold. In some embodiments, a backing layer is then attached to the resultant matrix to produce an armor panel that includes an additional protective barrier.
In certain embodiments, to produce an exemplary armor panel, the elastomeric material and the crushed aggregate material are exposed to an elevated temperature of about 130° C. to about 160° C. and an elevated pressure of about 6000 lbs/in2 for about 90 to about 180 minutes to thereby produce the armor panel. In some embodiments, the elastomeric material and the crushed aggregate material are exposed in a stepwise manner to elevated temperatures and elevated pressures for varying time periods, such that the elastomeric materials and the crushed aggregate materials are exposed to a series of elevated temperatures and elevated pressures for successive time periods to thereby produce a desired composite armor panel.
The presently-disclosed subject matter includes a composite armor panel that is capable of being inexpensively manufactured and incorporated into common building structures to provide protection for the structure as well as its occupants.
Referring first to
Various elastomeric materials can be used to construct the composite armor panel 10. In some embodiments, the elastomeric material 22 comprises a rubber or a plastic. For example, suitable elastomeric materials include natural rubber, neoprene, styrene-butadiene rubber (SBR), nitrile, ethylene propylene diene M-class rubber (EPDM), or other elastomers or plastics (such as those with a cross-linked structure) that will maintain their morphology over long periods of time and through applications of heat and stress.
With respect to the crushed aggregate materials, a variety of crushed aggregate materials can be combined with the elastomeric materials to produce a suitable matrix. In some embodiments, the crushed aggregate material 24 is selected from granite, limestone, ceramic, silicon carbide, other alumino-silicate materials, or combinations thereof. Of course, other crushed aggregate materials can also be used without departing from the spirit and scope of the presently-disclosed subject matter.
In many cases, the selection of an appropriate aggregate material is dependent, at least in part, on its hardness characteristics with respect to the elastic modulus of the surrounding elastomeric material in the matrix. Additionally, a particular aggregate material can also be chosen for a particular application based on the strength, hardness, and durability of the particular aggregate material, such that the selection of the aggregate material relates to the impact energy that must be resisted in a specific application. In other words, a particular aggregate material can, in some instances, be chosen based on the mass of the projectile that will impact the aggregate material, the velocity at which the projectile will impact the aggregate material, and the distance the projectile must travel before it impacts the aggregate material and the panel. For example, it has been experimentally observed that particles of crushed granite material having an average diameter of approximately ⅜ inch are sufficient to prevent a bullet from penetrating the backing layer 30 of an exemplary panel when a 9-mm handgun was fired at the panel from a range of 10 yards and impacted the panel with an energy of 350 foot-pounds. Of course, the selection and size of other aggregate materials for a particular application can readily be determined through routine experimentation. In some embodiments, the size of a particular aggregate material is on the same scale as the size of the projectile that must be resisted by an exemplary armor panel. For instance, to adequately resist the impact of a 9-mm bullet, aggregate material particles having an average diameter of approximately ⅜ inch can be incorporated into an exemplary armor panel.
Referring now to
Referring still to
Furthermore, and without wishing to be bound by any particular theory, it is believed that the geogrid 40 optimally improves the strength and deformation resistance properties of the first layer 120 if the geogrid 40 is placed in the center or latter half of the first layer 120 (i.e., closest to the second backing layer 130). For example, as shown in
Referring now to
Referring again to
Further provided, in some embodiments of the presently-disclosed subject matter, are methods for making a composite armor panel. In one exemplary implementation, an elastomeric material is first provided and is cut to a size and gradation that is similar to, or smaller, than the individual particles of the crushed aggregate material that is selected to be combined with the elastomeric material and used produce a first layer of the armor panel. Once the elastomeric material is cut, a mixture is created with an amount of the elastomeric material and an amount of crushed aggregate. The mixture is then placed into a mold of a desired size and shape alone or with a geogrid that has been cut to the shape of the mold. Depending upon the particular elastomeric material used to produce the armor panel, the mold can first be pre-treated with an agent (e.g., talc) that allows the elastomeric material and crushed aggregate material to later be easily released from the mold. However, regardless of whether a releasing agent is used, once the elastomeric material and aggregate material, with or without one or more geogrids, are placed in the mold, the mold is then placed between steel plates and is loaded onto a machine that exposes the mold to elevated temperatures while simultaneously engaging the steel plates and compressing the mold, such that the mold is also exposed to an elevated pressure. This simultaneous exposure of the mold to an elevated temperature and pressure serves to melt the elastomeric material and produce a matrix of elastomeric material and crushed aggregate material of sufficient density that is able to withstand an impact by a projectile, such as a bullet, without losing its shape or integrity.
After a predetermined amount of time has passed and the matrix of elastomeric material and crushed aggregate material has been formed, the mold is then removed from the machine and allowed to cool. Once the mold has cooled, the resulting matrix of elastomeric material and crushed aggregate material can then be removed from the mold and affixed to a second backing layer, such as by using a suitable adhesive or other means for securing two layers together.
In some embodiments, the step of exposing the elastomeric material and crushed aggregate material in the mold to an elevated temperature and an elevated pressure comprises exposing the mold to a series of elevated temperatures and elevated pressures. In some embodiments, the series of elevated temperatures and pressures can be selected based on the desired thickness of the first layer of the armor panel that is being produced. For example, in one exemplary implementation, a first layer of an exemplary armor panel with a thickness of 0.5 or 1-inch is made by exposing the elastomeric and crushed aggregate material to a temperature of 130° C. for 15 minutes under a load of 6000 lbs/in2, followed by exposing the elastomeric and crushed aggregate material to a temperature of 150° C. for 15 minutes and 160° C. for 60 minutes under the 6000 lbs/in2 load. In another exemplary implementation, a first layer of an armor panel with a thickness of 1.5-inches is made by exposing the elastomeric and crushed aggregate material to a temperature of 130° C. for 30 minutes under a load of 6000 lbs/in2, followed by exposing the elastomeric material and crushed aggregate material to a temperature of 150° C. for 30 minutes and 160° C. for 120 minutes under the 6000 lbs/in2 load. Of course, armor panels of other thicknesses can also be made in accordance with the presently-disclosed subject matter and the elevated temperatures and pressures, as well as the time periods required to produce these other armor panels, that are required to produce these panels of varying thickness can be readily determined using only routine experimentation.
Indeed, it is contemplated that the shape, thickness, density, elastomer material properties, aggregate material properties, and other factors and characteristics of an exemplary armor panel can readily be tailored to meet desired performance characteristics and intended applications. For example, depending upon the desired performance characteristics and the intended application, the ratio of elastomeric material to aggregate material can be varied, the composite thickness can be modified, and/or the backing layer thickness can be increased to meet a desired performance characteristic or intended application.
With respect to the ratio of elastomeric material to the crushed aggregate material, in some embodiments, this ratio can be varied to produce armor panels of tunable properties. By increasing the amount of crushed aggregate material in the first layer of the panel relative to the amount of elastomeric material, a composite armor panel can be produced that is more resistant to penetration by a projectile, such as a bullet. It has been experimentally observed that by increasing the crushed aggregate content of the first layer of the panel, once a bullet penetrates the first layer, the bullet shatters a larger amount of stone, and thus dissipates more energy as it passes through the first layer of the panel. In some embodiments of the presently-disclosed composite armor panels, the first layer of the panel is comprised of an amount of elastomeric material that is equal to or greater than about 60% by weight of the first layer. In some embodiments, the first layer includes about 75% by weight of the elastomeric material (e.g., rubber) and about 25% by weight of the crushed aggregate material (e.g., granite). In other embodiments, the first layer includes about 90% by weight of the elastomeric material and about 10% by weight of the crushed aggregate material. Of course, other amounts and ratios of elastomeric material to aggregate material can be used. However, preferred ratios will typically include less aggregate material than elastomeric material for weight savings, and because it has been experimentally observed that, although greater penetration resistance is obtained with larger proportions of aggregate material (see
As a further refinement, and as discussed above, the thickness of the first layer of the panel can also be varied to provide a panel with tunable properties. By increasing the thickness of the first layer, an armor panel can be provided that also increases the penetration resistance of the panel to projectiles. Of course, increasing the thickness of the first layer of the panel will also increase the weight of the panel. As such, to the extent varying the thickness of the first layer is desired, a particular thickness of the first panel can be selected such that the thickness of the particular panel will be suitable for an intended application or will produce a desired level of penetration resistance. Additionally, the preferred thickness of the first layer can be selected with respect to the ratio of elastomeric material to aggregate material, along with the intended application for the panel. In some embodiments, the thickness of the first panel is about 0.5 to 1.5 inches as it has been determined that panels of such thickness are capable of providing a desired level of penetration resistance without an excessive increase in the weight of the panel.
The above-described composite armor panels, which include a matrix composed of an elastomeric material and a crushed aggregate material, can easily be adapted for use in common building structures. Furthermore, because of the materials that are used to produce the composite armor panels, the panels provide an economic means to safely protect many common civilian structures that could not otherwise be protected. Thus, the composite armor panels of the presently-disclosed subject matter provide convenient alternatives to current armor systems, with the added benefit that the panels can be adapted for a variety of applications, thus making them suitable as a means to protect many different structures.
The presently-disclosed subject matter is further illustrated by the following specific but non-limiting examples.
To examine the ability of an elastomer-stone matrix, backed by a steel plate, to prevent bullet penetration, a number of experiments were undertaken. As an initial point of reference, a thin steel plate (14 gauge thickness) was first shot with a 9 mm handgun at range of 10 yards. Based on preliminary calculations, it was estimated that the energy at impact was about 350 foot-pounds and, thus, the bullet easily penetrated the steel plate.
To then assess the effectiveness of a composite armor panel with a first layer composed of a matrix of an elastomeric material and a crushed aggregate material, and a second backing layer in the form of a thin steel plate (14 gauge thickness), several prototypes, including varying amounts of stone aggregates, were then tested in a firing range with a single shot from a 9-mm handgun at a range of 10 yards. Referring again to
To examine the effect of incorporating geogrids within the elastomer-stone matrices, several additional prototypes that incorporated geogrids were also developed and tested as described above. By including the geogrid in the test samples, the “dimple” in the steel plate was noticeably shallower, but had a much greater diameter. Further, with the inclusion of the geogrid, it was evident that significantly less strength and deformation was required from the steel plate.
An armor panel was also developed that contained a geogrid layer, but where the steel plate was replaced with a geomembrane. The 40-mm thick geomembrane was a high-density polyethylene (HDPE) material that provided both tear resistance and high deformation upon testing. While the 9-mm projectile at 10 yards penetrated the matrix, stone crushing was observed, and the impact energy was distributed over a larger area due to the geogrid. Thus, the combination of geogrid and geomembrane backing appeared as a viable alternative that would significantly reduce composite weight.
To further examine the effect of varying the composition of the first layer of an armor panel and the effect of varying the number of geogrids included in the first layer, armor panels, with steel backing layers, were created that were composed of either 90% rubber and 10% granite or 75% rubber and 25% granite. These armor panels included between zero to three geogrids, and varied in thickness from 0.5 inches to 1.0 inches. Armor panels with first layers comprised of 50% rubber and 50% granite were unable to maintain their integrity. Testing of the armor panels was conducted on a 200-kip universal testing machine that fired a metal rod into the armor panels and provided a reproducible impact. In testing each of the armor panels, an initial test was performed in the center of each panel and four additional were performed immediately above, below, and to either side of the initial test.
The testing of the armor panels with a 0.5 inch thickness revealed that the armor panels that included 25% granite were able to withstand a larger load with less deformation of the panel as compared to a panel including 10% granite. Further, it was observed that the armor panels were able to withstand a larger load at the site of the initial test than those of the exterior tests without a change in the amount of deformation observed in the panel. Without wishing to be bound by any particular theory, it is believed that the surrounding area of armor panel provided strength to the central area of the armor panel.
The testing of the armor panels with a 1-inch thickness revealed overall that the load that could be withstood by the panels was greater for the initial tests than for surrounding tests and also again revealed that the armor panels that included 25% granite were able to withstand a larger load with less than or the same amount of deformation of the panel as compared to a panel including 10% granite. For example, as shown in
One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the presently-disclosed subject matter. This detailed description, and particularly the specific details of the exemplary embodiments and implementations disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the presently-disclosed subject matter.
This application claims priority to U.S. Application Ser. No. 61/228,762 filed on Jul. 27, 2009, the entire disclosure of which is incorporated herein by this reference.
Number | Date | Country | |
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61228762 | Jul 2009 | US |