Encapsulated Preformed Shapes

Abstract

Anti-ballistic component including encapsulated preformed ceramic shapes are disclosed. Preformed ceramic shapes having a preformed geometry are encapsulated in a metal alloy to stiffen and lighten an anti-ballistic component. The preformed ceramic shapes may be arranged in layers of uniform arrays of preformed ceramic shapes and contained in a porous container to receive the metal alloy during a casting process. A truss structure may be integrated in the preformed ceramic shapes to compartmentalize the preformed ceramic shapes into multiple isolated sub regions to stiffen the anti-ballistic component.

1 . A ballistic-resistant composite component comprising:
 a base metal encapsulating a porous body formed of a plurality of preformed ceramic shapes, the base metal compartmentalizing the plurality of preformed ceramic shapes into at least one sub region, the base metal substantially permeating the porous body, and the preformed ceramic shapes comprising:
 a plurality of elements having a uniform, preformed geometry, the preformed geometry being such that the plurality of preformed ceramic shapes are configured to pack together in uniform way, and 
 a material having a density less than a density of the base metal of the ballistic-resistant composite component. 
   
     
     
         2 . The ballistic-resistant composite component of  claim 1 , wherein each of the plurality of preformed ceramic shapes forming the porous body have substantially the same preformed geometry. 
     
     
         3 . The ballistic-resistant composite component of  claim 2 , wherein the preformed geometry is substantially sphere shaped. 
     
     
         4 . The ballistic-resistant composite component of  claim 3 , wherein the sphere has an outer diameter of about 0.5 inches (1.3 centimeters). 
     
     
         5 . The ballistic-resistant composite component of  claim 2 , wherein the preformed geometry is a cone. 
     
     
         6 . The ballistic-resistant composite component of  claim 2 , wherein the preformed geometry is a jack. 
     
     
         7 . The ballistic-resistant composite component of  claim 1 , wherein the plurality of preformed ceramic shapes forming the porous body comprises a first quantity of the preformed ceramic shapes and a second quantity of the preformed ceramic shapes, and
 wherein each of the preformed ceramic shapes of the first quantity have a first preformed geometry, and each of the preformed ceramic shapes of the second quantity have a second preformed geometry different from the first preformed geometry.   
     
     
         8 . The ballistic-resistant composite component of  claim 1 , further comprising one or more trusses formed integral with the base metal encapsulating the porous body and arranged in the plurality of preformed shapes, wherein the truss structure compartmentalizes the plurality of preformed shapes into a plurality of sub regions to provide for packing the plurality of preformed ceramic shapes together into the uniform array. 
     
     
         9 . The ballistic-resistant composite component of  claim 1 , wherein the base metal is a steel alloy and the plurality of preformed ceramic shapes comprise silicon carbide preformed ceramic shapes, and wherein each silicon carbide preformed shape is encapsulated with a barrier layer. 
     
     
         10 . The ballistic-resistant composite component of  claim 9 , wherein the barrier layer comprises:
 a first layer, encapsulating each silicon carbide preformed shape, to prevent the steel alloy from reacting with the plurality of preformed silicon carbide ceramic shapes during the casting of the steel alloy around the porous body; and   a second layer, disposed between the first layer and each silicon carbide preformed shape, to provide crush protection between the steel alloy and each silicon carbide preformed shape during a cooling of the ballistic-resistant composite.   
     
     
         11 . The ballistic-resistant composite component of  claim 10 , wherein the first layer is a metal film and the second layer is an alumina fiber. 
     
     
         12 . An anti-ballistic armor comprising:
 a base metal cast around an array of solid ceramic tiles, the base metal around the array of solid ceramic tiles defining an encapsulated array, the encapsulated array including a first surface opposite a second surface; and   another base metal cast around a porous body, the other base metal around the porous body defining a backing unit, the backing unit formed integral with the second surface of the encapsulated array, wherein   the porous body is formed of a plurality of preformed ceramic shapes, each preformed ceramic shape including a preformed geometry, and the other base metal substantially permeates the porous body.   
     
     
         13 . The anti-ballistic armor of  claim 12 , further comprising a truss structure arranged in the porous body to stiffen the backing unit. 
     
     
         14 . The anti-ballistic armor of  claim 13 , wherein the truss structure is formed integral with the other base metal. 
     
     
         15 . The anti-ballistic armor of  claim 13 , wherein the truss structure is a separate unit formed of a pre-cast metal unit. 
     
     
         16 . The anti-ballistic armor of  claim 12 , wherein the base metal is different from the other base metal. 
     
     
         17 . The anti-ballistic armor of  claim 12 , wherein the base metal is the same as the other base metal. 
     
     
         18 . A method of forming an anti-ballistic composite assembly, the method comprising:
 casting a metal around a porous body formed of a plurality of preformed ceramic shapes having a preformed geometry and a density less than a density of the base metal, the metal around the porous body defining a backing unit,   compartmentalizing the plurality of preformed ceramic shapes into at least one sub region with the base metal,   wherein the plurality of preformed ceramic shapes displace the metal cast around the porous body to lighten the backing unit.   
     
     
         19 . The method of  claim 18 , further comprising:
 casting the metal around an array of solid ceramic tiles, the metal around the array of solid ceramic tiles defining an encapsulated array to provide protection against ballistic projectiles, the encapsulated array including a first surface opposite a second surface, and   wherein the backing unit is cast integral with the first surface, or the second surface, of the encapsulated array to stiffen the encapsulated array.   
     
     
         20 . The method of  claim 18 , further comprising forming the porous body including:
 arranging, in a porous container, the plurality of preformed ceramic shapes into one or more layers of arrays of preformed ceramic shapes.   
     
     
         21 . The method of  claim 20 , further comprising arranging, in the porous container, the plurality of preformed ceramic shapes to include one or more channels having a length greater than a width and/or a depth, the one or more channels to receive the metal cast around the porous body, the metal received in the one or more channels defining a truss structure, and
 wherein the truss structure stiffens the backing unit.   
     
     
         22 . A ballistic-resistant composite component comprising:
 a base metal encapsulating a porous body formed of a plurality of preformed ceramic shapes configured to interlock, the base metal substantially permeating the porous body, and the preformed ceramic shapes comprising:
 a plurality of elements having a uniform, preformed geometry, the preformed geometry being such that the plurality of preformed ceramic shapes are configured to pack together and interlock in uniform way, and 
 a material having a density less than a density of the base metal of the ballistic-resistant composite component.