Ceramic armour and method of construction

Abstract

An armor for protection against armor piercing and/or high energy projectiles has a ceramic layer with a confinement layer on a front thereof. The ceramic layer is backed by a first metal layer and the first metal layer in turn is backed by a composite layer. A second optional confinement layer may be included between the ceramic and first metal layers. The composite layer is backed by an optional second metal layer, which in turn is backed by an optional anti-trauma layer. The armor is used to protect personnel and objects such as vehicles.

1 . An armor for protection against armor piercing and/or high energy projectiles comprising:
 a nonporous solid ceramic layer with a first confinement layer bonded to a front surface thereof;   said nonporous solid ceramic layer being backed by a first continuous nonporous solid metal layer of high strength and ductility with a front surface of the first continuous nonporous solid metal layer being bonded to a back surface of the nonporous solid ceramic layer for distributing an impact load from a projectile impacting on said first confinement layer and resulting ceramic debris and for confining the ceramic debris in an impact zone within said nonporous solid ceramic layer; and   said first continuous nonporous solid metal layer being backed by a ballistic composite layer with a front surface of the ballistic composite layer being bonded to a back surface of the first continuous nonporous solid metal layer, said nonporous solid ceramic layer having a thickness in a range from 1 mm to about 40 mm, and the first continuous nonporous solid metal layer having a thickness in a range from about 0.1 mm to about 5 mm.   
     
     
         2 . An armor as claimed in  claim 1  wherein said first nonporous solid metal layer is thinner than said nonporous ceramic layer. 
     
     
         3 . An armor as claimed in  claim 1  including an anti-trauma layer being bonded to a back surface of said ballistic composite layer for reducing blunt trauma and to increase separation between the armor and the torso of a user or object being protected. 
     
     
         4 . An armor as claimed in  claim 1  including a second nonporous solid metal layer of high strength and ductility having a front surface which is bonded to a back surface of said ballistic composite layer. 
     
     
         5 . An armor as claimed in  claim 4  including an anti-trauma layer, said second nonporous solid metal layer being backed by said anti-trauma layer bonded to a back surface of said second nonporous solid metal layer for reducing blunt trauma and to increase separation between the armor and the torso of a user or object being protected. 
     
     
         6 . An armor as claimed in  claim 4  wherein said second nonporous solid metal layer is thinner than said ceramic layer. 
     
     
         7 . An armor as claimed in  claim 1  wherein said nonporous ceramic layer, said first confinement layer, said first nonporous solid metal layer, and said ballistic composite layer have a curvature such that the armor is fitted to a user or object being protected. 
     
     
         8 . An armor as claimed in  claim 1  wherein said first nonporous solid metal layer is a titanium metal layer. 
     
     
         9 . An armor as claimed in  claim 4  wherein said second nonporous solid metal layer is a titanium metal layer. 
     
     
         10 . An armor as claimed in  claim 8  wherein said first nonporous solid metal layer is a titanium alloy containing substantially 6% aluminum. 
     
     
         11 . An armor as claimed in  claim 9  wherein said second nonporous solid metal layer is a titanium alloy containing substantially 6% aluminum. 
     
     
         12 . An armor as claimed in  claim 10  wherein said titanium alloy is Titanium alloy American Society for Testing and Materials B265, Grade 5, with nominal weight contents of 6% Aluminum, 4% Vanadium. 
     
     
         13 . An armor as claimed in  claim 11  wherein said titanium alloy containing said substantially 6% aluminum is Titanium alloy American Society for Testing and Materials B265, Grade 5, with nominal weight contents of 6% Aluminum, 4% Vanadium. 
     
     
         14 . An armor as claimed in  claim 3  wherein said anti-trauma layer is made of a polymeric foam layer. 
     
     
         15 . An armor as claimed in  claim 5  wherein said anti-trauma layer is made of a polymeric foam layer. 
     
     
         16 . An armor as claimed in  claim 14  wherein said polymeric foam layer is about 128 kg/m 3  rigid polyurethane foam having a thickness of about 15 mm. 
     
     
         17 . An armor as claimed in  claim 15  wherein said polymeric foam layer is about 128 kg/m 3  rigid polyurethane foam having a thickness of about 15 mm. 
     
     
         18 . An armor as claimed in  claim 1  wherein said first confinement layer includes a glass or other fiber reinforced polymer layer or other polymeric layer. 
     
     
         19 . An armor as claimed in  claim 1  wherein said first confinement layer includes any one of a glass or other fiber reinforced polymer layer and a polymeric layer not reinforced by fibers. 
     
     
         20 . An armor as claimed in  claim 1  wherein said ballistic composite layer is formed of multiple layers. 
     
     
         21 . An armor as claimed in  claim 20  wherein said multiple layers are multiple layers of ballistic fabric selected from the group consisting of aramid fibers in a polymeric matrix and polyethylene fibers in a polymeric matrix. 
     
     
         22 . An armor as claimed in  claim 1  wherein said ceramic layer is made of any one of boron carbide, silicon carbide and alumina. 
     
     
         23 . An armor as claimed in  claim 1  wherein said nonporous ceramic layer is a single ceramic tile. 
     
     
         24 . An armor as claimed in  claim 1  wherein said nonporous ceramic layer is a mosaic of a plurality of coextensive ceramic tiles. 
     
     
         25 . An armor as claimed in  claim 1  including a second confinement layer located between the nonporous ceramic layer and the first metal layer. 
     
     
         26 . An armor as claimed in  claim 25  wherein said second confinement layer includes any one of a glass or other fiber reinforced polymer layer and a polymeric layer not reinforced by fibers. 
     
     
         27 . An armor as claimed in  claim 26  wherein said second confinement layer is bonded to the ceramic layer and the first nonporous metal layer using any one or combination from the group consisting of thermoplastic and thermoset polymers, microwave joining, and mechanical joining including ultrasonic joining. 
     
     
         28 . An armor as claimed in  claim 1  wherein said first nonporous solid metal layer is equal to, or less than about 20% of the thickness of the ceramic layer. 
     
     
         29 . An armor as claimed in  claim 3  wherein said first confinement layer is similar in thickness to the first nonporous solid metal layer, and wherein said ballistic composite layer is similar in thickness to said nonporous ceramic layer, and wherein said anti-trauma layer is thicker than the ceramic layer. 
     
     
         30 . An armor as claimed in  claim 1  wherein said nonporous solid ceramic layer, said first confinement layer, said first nonporous solid metal layer, and said ballistic composite layer are joined to one another using any one selected from the group consisting of thermoplastic and/or thermoset polymers, microwave joining, direct ceramic-metal joining, and mechanical joining including any one or combination of ultrasonic joining and compression fit, and brazing. 
     
     
         31 . An armor as claimed in  claim 19  wherein said polymeric layer not reinforced by fibers is polycarbonate. 
     
     
         32 . An armor as claimed in  claim 26  wherein said polymeric layer not reinforced by fibers is polycarbonate. 
     
     
         33 . An armor as claimed in  claim 21  wherein said aramid fibers in a polymeric matrix is Kevlar™, and wherein said polyethylene fibers in a polymeric matrix is any one of Dyneema™ and Spectra™. 
     
     
         34 . An armor as claimed in  claim 1  wherein said armor has a variable thickness for providing thicker armor for pre-selected areas to provide higher levels of protection to a user or object to be protected. 
     
     
         35 . An armor as claimed in  claim 14  wherein said polymeric foam layer has a thickness in a range from about 5 mm to about 50 mm. 
     
     
         36 . An armor as claimed in  claim 15  wherein said polymeric foam layer has a thickness in a range from about 5 mm to about 50 mm. 
     
     
         37 . An armor as claimed in  claim 5  wherein said nonporous ceramic layer, said first confinement layer, said first nonporous solid metal layer, said ballistic composite layer, said anti-trauma layer, and said second nonporous solid metal layer have a curvature such that the armor is fitted to a user or object being protected.