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.

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.