Multi-layer multi-impact ballistic body armor and method of manufacturing the same

Abstract

Multi-impact multi-layer body armor is presented. A first layer is a single layer of front covering material. A second layer, is a ballistic ceramic plate formed of a plurality of curved smaller ceramic tiles that are bonded together using a structural adhesive. A third layer formed of one or a plurality of aramid layers such as Kevlar® XP. A fourth layer formed of a rigid backing plate, formed of ultra-high molecular weight polyethylene such as Spectra Shield®. A fifth layer is a single layer of rear covering material. Thus, an improved body armor is presented which is inexpensive to produce, light, durable and can sustain multiple impacts.

What is claimed: 
     
         1 . Body armor, comprising;
 an armor plate;   the armor plate formed of a plurality of small ceramic tiles;   wherein at least one layer of structural adhesive is placed over the ceramic tiles;   wherein the plurality of small ceramic tiles are formed into a rigid monolithic piece by activating the at least one layer of structural adhesive;   wherein after the at least one layer of structural adhesive is activated and the small ceramic tiles are formed into a rigid monolithic piece, the rigid monolithic piece is coated using at least one layer of binder;   at least one layer of ballistic material;   a rigid backing plate;   wherein the at least one layer of ballistic material is positioned behind the armor plate and in front of the rigid backing plate;   wherein the rigid backing plate is positioned behind the at least one layer of ballistic material;   wherein the at least one layer of ballistic material is formed of an aramid-type material;   wherein the armor plate provides protection to ballistic impacts;   wherein when the multi-layer multi-impact ballistic armor is struck by a projectile, the armor plate serves to absorb and disperse energy from the projectile as the stricken small ceramic tile or tiles break upon impact;   wherein when the multi-layer multi-impact ballistic armor is struck by a projectile, the at least one layer of ballistic material serves to absorb and disperse energy from the projectile;   wherein when the multi-layer multi-impact ballistic armor is struck by a projectile, the rigid backing plate serves to absorb and disperse energy from the projectile and to prevent or reduce back face deformation;   wherein when the multi-layer multi-impact ballistic armor is struck by a projectile, the combination of the at least one layer of structural adhesive and the at least one layer of binder help to maintain the integrity of the armor plate.   
     
     
         2 . The body armor of  claim 1 , wherein the plurality of small ceramic tiles are aligned in a plurality of rows;
 wherein the plurality of rows are stacked;   wherein the plurality of small ceramic tiles are arranged in edge-to-edge engagement with one another:   
     
     
         3 . The body armor of  claim 1 , wherein the plurality of small ceramic tiles are arcuately curved. 
     
     
         4 . The body armor of  claim 1 , wherein the at least one layer of structural adhesive is placed over a front side and a back side of the arranged small ceramic tiles. 
     
     
         5 . The body armor of  claim 1 , the at least one layer of structural adhesive partially or fully penetrates seams between small ceramic tiles thereby improving bonding between adjacent small ceramic tiles. 
     
     
         6 . The body armor of  claim 1 , wherein the at least one layer of structural adhesive is applied as a film. 
     
     
         7 . The body armor of  claim 1 , wherein the at least one structural adhesive is an epoxy-type material. 
     
     
         8 . The body armor of  claim 1 , wherein the plurality of small ceramic tiles and the at least one layer of structural adhesive are placed under a vacuum as part of the forming process which forms the armor plate out of the plurality of small ceramic tiles. 
     
     
         9 . The body armor of  claim 1 , wherein the plurality of small ceramic tiles and the at least one layer of structural adhesive are placed in a mold and heated as part of the forming process. 
     
     
         10 . The body armor of  claim 1 , wherein the plurality of small ceramic tiles and the at least one layer of structural adhesive are placed in a mold and pressed as part of the forming process. 
     
     
         11 . The body armor of  claim 1 , wherein the at least one layer of binder is spayed on the armor plate. 
     
     
         12 . The body armor of  claim 1 , wherein the at least one layer of binder encapsulates the armor plate. 
     
     
         13 . The body armor of  claim 1 , wherein the at least one layer of binder is formed of a polyuria-type material or polyurethane-type material. 
     
     
         14 . The body armor of  claim 1 , wherein the at least one layer of binder is formed of a polyurethane elastomer material. 
     
     
         15 . The body armor of  claim 1 , further comprising a second-binder covering the binder, wherein the second-binder is formed of a different material than the binder. 
     
     
         16 . The body armor of  claim 1 , wherein the small ceramic tiles are formed of silicon carbide (SiC). 
     
     
         17 . The body armor of  claim 1 , wherein the at least one layer of binder helps to prevent or reduce spalling or fragmentation. 
     
     
         18 . The body armor of  claim 1 , wherein the rigid backing plate is formed of a plurality of pressed layers of ultra-high molecular weight polyethylene. 
     
     
         19 . The body armor of  claim 1 , wherein the at least one layer of structural adhesive is harder and more brittle than the at least one layer of binder. 
     
     
         20 . The body armor of  claim 1 , wherein the at least one layer of binder is more flexible than the at least one layer of structural adhesive. 
     
     
         21 . A multi-layer multi-impact ballistic body armor formed of a plurality of layers, comprising:
 an armor plate;   the armor plate formed of a plurality of small ceramic tiles;   at least one layer of structural adhesive;   the at least one layer of structural adhesive positioned over the plurality of small ceramic tiles which holds the plurality of small ceramic tiles into a rigid monolithic piece;   at least one layer of binder;   the at least one layer of binder positioned over the at least one layer of structural adhesive;   at least one layer of ballistic material;   the at least one layer of ballistic material positioned behind the armor plate;   a rigid backing plate;   the rigid backing plate positioned behind the at least one layer of ballistic material;   a covering material covering the armor plate, the at least one layer of ballistic material and the rigid backing plate;   wherein the plurality of small ceramic tiles are formed of silicon carbide (SiC);   wherein the plurality of layers provide protection to ballistic impacts;   wherein when the armor plate is struck by a projectile the combination of the at least one layer of structural adhesive and the at least one layer of binder helps to maintain the integrity of the armor plate.   
     
     
         22 . The body armor of  claim 21 , wherein when activated the at least one layer of structural adhesive at least partially penetrates seams between small ceramic tiles thereby improving bonding between adjacent small ceramic tiles; 
     
     
         23 . The body armor of  claim 21 , wherein the at least one layer of ballistic material is formed of an aramid-type material. 
     
     
         24 . The body armor of  claim 21 , wherein the at least one layer of structural adhesive is applied as a film. 
     
     
         25 . The body armor of  claim 21 , wherein the at least one layer of binder is sprayed on. 
     
     
         26 . The body armor of  claim 21 , wherein the rigid backing plate is formed of an ultra-high molecular weight polyethylene. 
     
     
         27 . The body armor of  claim 21 , wherein the structural adhesive is a thermosetting material. 
     
     
         28 . The body armor of  claim 21 , wherein the structural adhesive is an epoxy-type material. 
     
     
         29 . The body armor of  claim 21 , wherein the at least one layer of structural adhesive is harder and more brittle than the at least one layer of binder. 
     
     
         30 . The body armor of  claim 21 , wherein the at least one layer of binder is more flexible than the at least one layer of structural adhesive. 
     
     
         31 . The body armor of  claim 21 , wherein the at least one layer of binder is formed of a polyurethane elastomer material. 
     
     
         32 . Multi-layer multi-impact ballistic body armor formed of a plurality of layers, comprising:
 a second layer, wherein the second layer is an armor plate;   a third layer, wherein the third layer is a ballistic material;   a fourth layer, wherein the fourth layer is a rigid backing plate;   a fifth layer, wherein the fifth layer is a rear cover material;   wherein the armor plate is formed of a plurality of small ceramic tiles;   wherein the plurality of small ceramic tiles are placed in edge-to-edge engagement;   wherein at least one layer of structural adhesive is placed over the armor plate;   wherein when activated the at least one layer of structural adhesive bonds the plurality of small ceramic tiles into a single unitary and rigid armor plate;   wherein at least one layer of binder is placed over the at least one layer of structural adhesive;   wherein the at least one layer of ballistic material is positioned behind the armor plate and in front of the rigid backing plate;   wherein the rigid backing plate is positioned behind the ballistic material;   wherein the ballistic material is formed of an aramid-type material.   
     
     
         33 . The body armor of  claim 32 , wherein the at least one layer of binder is formed of a polyurethane elastomer material. 
     
     
         34 . The body armor of  claim 32 , wherein the structural adhesive is an epoxy-type material. 
     
     
         35 . The armor of  claim 32 , wherein the plurality of small ceramic tiles are formed of silicon carbide (SiC). 
     
     
         36 . A method of manufacturing a multi-layer multi-impact ballistic body armor comprising the steps of:
 placing at least one layer of structural adhesive over a front side and a back side of the a plurality small ceramic tiles;   activating the at least one layer of structural adhesive by applying heat thereby forming a rigid monolithic armor plate out of the plurality of small ceramic tiles and the at least one layer of structural adhesive;   applying at least one layer of binder over the rigid monolithic armor plate formed of the plurality of small ceramic tiles and the activated at least one layer of structural adhesive;   placing at least one layer of ballistic material behind the armor plate;   placing a rigid backing plate behind the at least one layer of ballistic material;   covering the combined rigid monolithic armor plate, the at least one layer of ballistic material, and the rigid backing plate with a covering material;   wherein the combination of the at least one layer of structural adhesive and the at least one layer of binder helps to maintain the structural integrity of the rigid monolithic armor plate upon ballistic impact.   
     
     
         37 . The method of  claim 32 , wherein the step of activating the at least one layer of structural adhesive by applying heat further comprises simultaneously applying pressure. 
     
     
         38 . The method of  claim 32 , wherein the step of activating the at least one layer of structural adhesive by applying heat further comprises simultaneously applying vacuum. 
     
     
         39 . The method of  claim 32 , wherein the plurality of small ceramic plates are formed of silicon carbide (SiC). 
     
     
         40 . The method of  claim 32 , wherein the at least one layer of structural adhesive is applied as a film. 
     
     
         41 . The method of  claim 32 , wherein the at least one layer of binder is sprayed on. 
     
     
         42 . The body armor of  claim 32 , wherein the at least one layer of binder is formed of a polyurethane elastomer material.