Method of Layering Composite Sheets to Improve Armor Capabilities

Abstract

According to one embodiment, an armor system comprises a plurality of polylithic composite armor panels. Each of the polylithic composite armor panels comprising a plurality of layers. The plurality of layers comprise at least two layers having a different Young's modulus. Each of the plurality of layers comprising a plurality of sheets. The plurality of sheets comprise one or more fibers. The plurality of sheets have one or more respective weave characteristics.

1 . An armor system comprising:
 a plurality of polylithic composite armor panels;   each of the polylithic composite armor panels comprising a plurality of layers;   the plurality of layers comprising at least two layers having a different Young's modulus;   each of the plurality of layers comprising a plurality of sheets;   the plurality of sheets comprising one or more fibers; and   the plurality of sheets having one or more respective weave characteristics.   
     
     
         2 . The armor system of  claim 1 , wherein the one or more fibers have a type comprising an e-glass fiber, an s-glass fiber, an aramid fiber, a carbon nanotube, a carbon fiber, an aluminum fibers and combinations thereof. 
     
     
         3 . The armor system of  claim 1 , wherein the weave characteristic comprises a direction of weave, a fineness of mesh, or a weave pattern. 
     
     
         4 . The armor system of  claim 3 , wherein the direction of weave comprises a [0°/90°] weave, a [0/+45°/−45°/90°]s a weave, and combinations thereof. 
     
     
         5 . The armor system of  claim 3 , wherein the fineness of mesh comprises a finely woven mesh, a coarsely woven mesh, a thick mesh, a medium weave mesh, a thin mesh, intermediates or combinations thereof. 
     
     
         6 . The armor system of  claim 1 , further comprising a resin to bind at least two of the one or more fibers or at least two of the plurality of sheets. 
     
     
         7 . The armor system of  claim 1 , wherein the plurality of polylithic composite armor panels are layered from an outer side of the armor system to an inner side of the armor system, the outer side being the side of initial projectile impact and the inner side being the side farthest away from initial projectile impact. 
     
     
         8 . The armor system of  claim 7 , wherein each of the polylithic composite armor panels comprises at least two layers. 
     
     
         9 . The armor system of  claim 8 , wherein at least a first layer of the two layers comprises sheets having a thicker weave, the first layer located toward the outer side of the armor system; and
 at least a second layer of the two layers comprises sheets having a finer weave, the second layer located toward the inner side of the armor system.   
     
     
         10 . The armor system of  claim 1 , wherein each of the polylithic composite armor panels comprises at least three layers. 
     
     
         11 . The armor system of  claim 10 , wherein:
 at least a first layer of the three layers comprises sheets having a thicker weave, the first layer located toward the outer side of the armor system;   at least a second layer of the three layers comprises sheets having a medium weave, the second layer located toward a middle side of the armor system; and   at least a third layer of the three layers comprises sheets having a fine weave, the third layer located toward the inner side of the armor system.   
     
     
         12 . An armor system of  claim 1 , comprised in a vehicle. 
     
     
         13 . An armor system according to  claim 1 , operable to improve resistance to impact by a shape charge, an explosively formed penetrator (EFP), an improvised explosive device (IED), a ballistic device or a hypervelocity impact. 
     
     
         14 . An armor system comprising:
 a plurality of polylithic composite armor panels;   the plurality of polylithic composite armor panels layered from an outer side of the armor system to an inner side of the armor system, the outer side being located toward an initial projectile impact site and the inner side being located away from the initial projectile impact side;   each of the polylithic composite armor panels comprising a plurality of layers;   each of the plurality of layers comprising a plurality of sheets;   the plurality of sheets comprising one or more fibers;   the plurality of sheets having one or more respective weave directionality and one or more respective weave meshes;   the plurality of sheets comprising one or more different fiber thickness; and   at least one of the polylithic composite armor panels has at least one of the layers comprising thicker fibers toward the outer side of the armor system and finer fibers toward the inner side of the armor system.   
     
     
         15 . The armor system of  claim 14 , wherein each of the polylithic composite armor panels comprises at least two layers. 
     
     
         16 . The armor system of  claim 15 , wherein:
 at least a first layer of the two layers comprises sheets having a thicker weave, the first layer located toward the outer side of the armor system; and   at least a second layer of the two layers comprises sheets having a finer weave, the second layer located toward the inner side of the armor system.   
     
     
         17 . The armor system of  claim 14 , wherein each of the polylithic composite armor panels comprises at least three layers. 
     
     
         18 . The armor system of  claim 17 , wherein:
 at least a first layer of the three layers comprises sheets having a thicker weave, the first layer located toward the outer side of the armor system;   at least a second layer of the three layers comprises sheets having a medium weave, the second layer located toward a middle side of the armor system; and   at least a third layer of the three layers comprises sheets having a fine weave, the third layer located toward the inner side of the armor system.   
     
     
         19 . An armor system comprising:
 a plurality of monolithic composite armor panels;   the plurality of monolithic composite armor panels layered from an outer side of the armor system to an inner side of the armor system, the outer side being located toward an initial projectile impact site and the inner side being located away from the initial projectile impact side;   each of the monolithic composite armor panels comprising a plurality of layers;   each of the plurality of layers comprising a plurality of sheets;   the plurality of sheets comprising one or more fibers having one or more different fiber characteristics;   the plurality of sheets having at least one respective weave directionality;   the plurality of sheets having one or more respective weave meshes; and   at least one of the monolithic composite armor panels having a thicker flexible weave mesh located toward the outer side of the armor system; and   at least a second of the monolithic composite armor panels layers comprising layers having a finer rigid weave mesh located toward the inner side of the armor system.   
     
     
         20 . The armor system of  claim 19 , wherein the monolithic panel has a thickness of less than or equal to 0.5″.