Shape-effect composite armor system

Abstract

An armor system for protecting an object from the impact of a projectile. A core layer of hardened metal or ceramic balls supported in a softer material, wherein the surfaces of the balls are in contact with adjacent ball surfaces and the sizes of the balls are selected with respect to the anticipated shape of the projectile being armored against. Inward and outward facing reinforced layers at the surfaces of the core layer. The reinforced layers including a resin base and fibers therein. A backing plate may back the core layer on the rear surface.

1 . Armor system for application to an object to be armored, wherein the armor system is intended to stop passage of a projectile, the armor system comprising:
 a core layer comprising:   a tightly arrayed pattern of a layer of hardened balls in the core layer, wherein the balls have a diameter of about one to two times the diameter of a projectile to be armored against and the balls have a surface hardness of about the same hardness or harder than an impact surface of the projectile to be armored against;   a material much softer than the balls disposed at the core layer and surrounding the balls for holding the balls in a layout in the core layer;   the core layer having opposite surfaces;   a reinforced layer at least one of the surfaces of the core layer for reinforcing the armor.   
     
     
         2 . The armor system of  claim 1 , wherein the reinforced layer is on one of the opposite surfaces of the core layer which is outward of the object to be armored and faces toward the projectile to be armored against. 
     
     
         3 . The armor system of  claim 2 , further comprising another reinforced layer on the opposite surface of the core layer inward toward the object to be armored also for reinforcing the armor. 
     
     
         4 . The armor system of  claim 3 , further comprising a backing plate between the core layer and the reinforced layer at the surface of the core layer away from the projectile, wherein the backing plate is configured to prevent the balls moving out of the core layer. 
     
     
         5 . The armor system of  claim 3 , wherein the inward reinforced layer has a shape selected to correspond to a shape of a surface of an object being armored by the armor system. 
     
     
         6 . The armor system of  claim 3 , wherein the reinforced layer comprises fibers in a random array and supported in a resin. 
     
     
         7 . The armor system of  claim 1 , wherein the balls in the core layer are hardened steel balls. 
     
     
         8 . The armor system of  claim 1 , wherein the balls in the core layer are hardened ceramic balls. 
     
     
         9 . The armor system of  claim 1 , wherein each ball has an outer surface and the array of balls is tight such that the outer surface of each ball is in touching contact with the outer surfaces of adjacent balls in the core layer. 
     
     
         10 . The armor system of  claim 1 , wherein the armor is of reduced areal density by having removed from the balls a fraction of the material of each of the balls, wherein the removal comprises at least one of a flat formed on a rear surface of the ball facing away from the side thereof to be impacted by the projectile and a hollowed area formed in a rear center of the ball. 
     
     
         11 . The armor system of  claim 1 , further comprising a plurality of axial reinforcements extending across at least the reinforced layer to be impacted by the projectile and optionally extending into the core layer. 
     
     
         12 . The armor system of  claim 11 , wherein each ball has an outer surface and the array of balls is tight such that the outer surface of each ball is in touching contact with the outer surfaces of adjacent balls in the core layer. 
     
     
         13 . The armor system of  claim 12 , further comprising axial reinforcements located to extend into the core layer into spaces surrounded by adjacent contacting balls. 
     
     
         14 . The armor system of  claim 11 , wherein the axial reinforcements are at approximately 1 inch centers apart. 
     
     
         15 . The armor system of  claim 11 , wherein the axial reinforcements are of a material of high strength. 
     
     
         16 . The armor system of  claim 15 , wherein the reinforcements are of steel wire. 
     
     
         17 . The armor system of  claim 1 , wherein the core layer is so configured and of such material as to be bonded to a polymer based composite armor. 
     
     
         18 . The armor system of  claim 1 , wherein the at least one reinforced layer is positioned on a rear surface of the core layer away from impact from the projectile and backing the core layer, and the at least one reinforcement layer is configured, shaped and positioned to restrict movement of individual ones of the balls rearwardly, with respect to the rear surface of the core layer, as a result of impact by the projectile on the armor system from a direction of an opposite front surface of the core layer. 
     
     
         19 . The armor system of  claim 1 , wherein the material in the core layer surrounding the balls therein comprises a reinforced thermoset or a thermoplastic material. 
     
     
         20 . The armor system of  claim 17 , wherein the material surrounding the balls in the core layer comprises a fiberglass reinforced epoxy, or a fiberglass reinforced polycarbonate, or a low-density metal or aluminum.