WO2010082970A2

WO2010082970A2 - Reactive topologically controlled armors for protection and related method

Info

Publication number: WO2010082970A2
Application number: PCT/US2009/061888
Authority: WO
Inventors: Haydn N. G. Wadley
Original assignee: University Of Virginia Patent Foundation
Priority date: 2008-10-23
Filing date: 2009-10-23
Publication date: 2010-07-22
Also published as: WO2010082970A3

Abstract

An armor system incorporates electromagnetic concepts into a robust, structurally efficient armor panel and exploits synergies between the elements of the system to reduce its aerial density. The electromagnetic concept provides capitatively charged electrodes whose rapid shorting by high aspect projectiles provides a reactive means for the defeat of hypervelocity, high aspect ratio metallic projectiles, such as metallic "jets" formed by shaped charges. In combination with the electromagnetic concept, the system exploits topology optimization of cellular core sandwich panels to provide efficient load supporting structures, provide high structural efficiency, and provide good environmental protection. The multifunctional system results in a low aerial density armor solution that can be easily tailored to match a wide variety of threat scenarios. The system can be fabricated in a variety of complex shapes including cylinders, hemispheres, beams and plates.

Description

Reactive Topologically Controlled Armors for Protection and Related Method

RELATED APPLICATIONS The present application claims priority from U.S. Provisional Application Serial

No. 61/107,810, filed October 23, 2008, entitled "Reactive Topologically Controlled Armors for Cylindrical and Spherical Structure Protection and Related Method;" the disclosure of which is hereby incorporated by reference herein in its entirety.

The present application is also related to PCT International Application No. PCT/US2008/071848, filed on July 31 , 2008, entitled "Hybrid Periodic Cellular Material Structures, Systems, and Methods for Blast and Ballistic Protection" and PCT International Application No. PCT/US2008/073377, filed August 15, 2008, entitled "Synergistically-Layered Armor Systems and Methods for Producing Layers Thereof;" the disclosures of which are hereby incorporated by reference herein in their entirety.

SUMMARY OF INVENTION

Armor systems are often forced to make detrimental tradeoffs between providing adequate blast and ballistic protection and providing lightweight, high structural efficient systems. Modern weapons and their improvised variants require armor systems that can defeat a wide variety of threats including high-explosive, high velocity projectiles, blasts creating overpressure waves, and conventional projectiles from small arms. Other more dangerous threats include anti-armor weapons that either fire linear heavy metal penetrators or explode shaped charges on an armor surface creating a linear "jet" of molten metal, either of which can easily penetrate most armor systems. Traditional solutions to defeating these types of threats may include increasing thickness or adding heavy materials, which decrease the structural efficiency of the armor and can often make the armor too heavy and thick for practical use. Increasing thickness is often made even more impractical as certain projectiles formed by shaped charges from rocket propelled grenades have been known to penetrate several meters of solid steel.

According to an aspect of an embodiment of the present invention, a reactive electromagnetic armor system exploiting topology optimization of cellular core sandwich panels is provided. The system generally includes top and bottom layers of chargeable conductive materials separated by a dielectric core lattice structure forming a super capacitor. The super capacitor structure is generally situated between top and bottom insulating projectile arresting layers which may be comprised of ballistic grade ceramic tiles. The dielectric lattice core may include a first open-cell lattice structure layer, a second open-cell lattice structure layer, and an intermediate panel in mechanical communication with both open-cell lattice structures. Additionally, the lattice core may form a sandwich panel by including a first layer panel in mechanical communication with the first open-cell lattice structure and a second layer panel in mechanical communication with the second open-cell lattice structure. A filler portion is also included which conforms to the voids created by the open-cell lattice structures. In addition, the armor system might include top and bottom metal face sheets on the exterior of the structure to provide further protection and insulation.

When a hypervelocity, high aspect ratio metallic projectile, such as a metal "jet" created by a shaped charge, penetrates the armor system it may penetrate far enough to span the super capacitor structure. When this happens, an active circuit is formed when the projectile closes the connection between the two charged layers and results in the discharge of a large amount of electrical energy through the projectile. A large enough amount of electrical discharge can cause the projectile to disperse or vaporize. Thus the armor system provides, among other things, an electromagnetic, non-explosive means to defeat a certain class of ballistic threats including elongated solid penetrators and metal jets created by shaped charges. An optional fragment catching layer such as a ballistic fiber composite (spall shield) may also be added to the armor system to catch debris and other fragments resulting from the dispersed projectile's radially expanding debris cloud. The open-cell lattice structures mentioned may include a variety of different lattice truss topologies some of which include hexagonal, pyramidal, corrugated, tetrahedral, three-dimensional Kagome, and other Trusscore™ truss arrangements. Additionally, the open-cell lattice structures and attached panels may be formed using fiber glass composites and 3D weaving techniques to create delamination resistant sandwich panel structures with corrugated or pyramidal lattice truss cores. These low density structures provide number of advantages and particularly have a very low through thickness electrical conductivity and high electrical breakdown field strength. They are therefore ideal for supporting very large electric field gradients. Furthermore, the filler portion, conforming to the voids of the open-cell lattice truss cores, may be filled with a variety of materials, such as closed cell syntactic foams or ceramic inserts, to enhance blast responses or to increase ballistic resistance.

The multifunctional concept is specially intended as a high structural efficiency system for the protection of flat, cylindrical or hemispherical structures. An aspect of an embodiment of the present invention provides that the corrugated and lattice truss cores can be flexed to create a cylindrical form prior to the attachment of their face sheets. The use of slightly curved ceramic tiles then allows the cylindrical analogue of a planar design to be fabricated. Lattice truss structures can also be bent in two directions creating the novel opportunity of making hemispherical analogues of the armor system. The curvature of the faces may add additional energy absorbing mechanisms which are likely to enhance the blast mitigating response of the structure (it requires in plane compression of the faces as well as core crushing). Thus an aspect of an embodiment of the present invention provides a protection concept that can be formed to multiple desired shapes. An aspect of an embodiment of the present invention itself exhibits a number of novel and non obvious features, elements, and characteristics by providing an armor system that incorporates electromagnetic concepts into a robust, structurally efficient armor panel and exploits synergies between the elements of the system to reduce its aerial density. Ballistic resistant ceramic tiles used as insulators are able to defeat significant ballistic threats at low aerial density. Crushable materials used to form the dielectric lattice cores of the super capacitor may be used to reduce impulse transfer and peak transmitted pressures from shock wave interactions. The cellular core sandwich panel design has high structural efficiency and good environmental protection.

The multifunctional system results in a low aerial density armor solution that can be easily tailored to match a wide variety of threat scenarios. The system can be easily fabricated in a variety of complex shapes including cylinders, hemispheres, beams and plates. An aspect of an embodiment of the present invention also includes a method of manufacturing and using the invention. Besides the armor system's reactive ability to defeat certain classes of hypervelocity, high aspect ratio metallic projectiles, protection may also be provided against a wide variety of different classes of threats including, but not limited thereto, small arms, fragment threats, explosive blast loading, and various combinations thereof.

An aspect of various embodiments of the present invention may be utilized for a number of products and services, such as but not limited thereto, the following: used for any lightweight armor on land, sea or air. An aspect of various embodiments of the present invention may be utilized for tank armor plating structure, a land craft/vehicle/robot, air vehicle/craft/robot, space vehicle/craft/robot or water vehicle/craft (or ship)/ robot plating structure (for example: siding panels, face plates, floor plates, infrastructure, frames or any of the components of the vehicle, craft, ship, or robot). The armor system may disposed on or as part of the exterior of the of the vehicle, craft , ship or robot. The armor may disposed on or as part of the interior of the of the vehicle, craft ship, or robot. The armor may disposed on or as part of both the interior an exterior of the of the vehicle, craft, ship, or robot. The armor system discussed herein may disposed on or adjacent to of the exterior of the personnel (i.e., person or animal). The armor system discussed and disclosed herein may be utilized for building structures, equipment, or housings. The armor system discussed and disclosed herein may be utilized for roadways, bridges, tunnels, air craft runways or landing pads. The system can be made from materials with very high corrosion resistance in salt water environments An embodiment provides an armor system that utilizes electromagnetic concepts into a robust, structurally efficient armor panel and exploits synergies between the elements of the system to reduce its aerial density. The electromagnetic concept provides capacitively charged electrodes whose rapid shorting by high aspect projectiles provides a reactive means for the defeat of hypervelocity, high aspect ratio metallic projectiles, such as metallic "jets" formed by shaped charges. In combination with the electromagnetic concept, the system exploits topology optimization of cellular core sandwich panels to provide efficient load supporting structures, provide high structural efficiency, and provide good environmental protection. An embodiment of the multifunctional system results in a low aerial density armor solution that can be easily tailored to match a wide variety of threat scenarios. An embodiment of the system can be fabricated in a variety of complex shapes including cylinders, hemispheres, beams and plates.

An aspect of an embodiment provides a synergistically- layered armor system for mitigating blast pressure and ballistic threats. The system may comprise: 1) a super capacitor, wherein the capacitor comprises: a top chargeable electrically conductive layer, a bottom chargeable electrically conductive layer, and a dielectric core, wherein the core comprises a lattice structure disposed between the top conductive layer and the bottom conductive layer; 2) a top insulating projectile arresting layer in mechanical communication with the super capacitor distal from the bottom conductive layer; and 3) a bottom insulating projectile arresting layer in mechanical communication with the super capacitor distal from the top conductive layer. Further, the super capacitor provides an active circuit reactive to a conductive projectile that spans across the super capacitor.

An aspect of an embodiment provides a method of making a synergistically- layered armor system for mitigating blast pressure and ballistic threats. The method may comprise: 1) providing a super capacitor, wherein the capacitor comprises: a top chargeable electrically conductive layer, a bottom chargeable electrically conductive layer, and a dielectric core, wherein the core comprises a lattice structure disposed between the top conductive layer and the bottom conductive layer; 2) providing a top insulating projectile arresting layer in mechanical communication with the super capacitor distal from the bottom conductive layer; 3) providing a bottom insulating projectile arresting layer in mechanical communication with the super capacitor distal from the top conductive layer; and 4) providing an active circuit reactive to a conductive projectile that spans across the super capacitor. The invention itself, together with further objects and attendant advantages, will best be understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a part of the instant specification, illustrate several aspects and embodiments of the present invention and, together with the description herein, serve to explain the principles of the invention. The drawings are provided only for the purpose of illustrating select embodiments of the invention and are not to be construed as limiting the invention.

Figure 1 provides a schematic perspective view of a basic armor concept where armor layers create a super capacitor sandwiched between insulating armor plates as an aspect of an embodiment of the invention. The insulating armor plates may be hard dense ballistic ceramic tiles such as boron carbide or other desired materials. Figure 2 provides a schematic perspective view showing a projectile, which upon penetrating and fully spanning the super capacitor in the armor system, creates an active circuit, discharging large amounts of current through the projectile and thus dispersing and vaporizing the projectile as an aspect of an embodiment of the invention. Figure 3 provides a schematic perspective view of a planar two layer armor system with a cellular core and ballistic filler comprising the dielectric core of the super capacitor as well as a fragment catching layer and top and bottom metal face sheets as an aspect of various embodiments of the invention. Figure 4 provides a schematic perspective view of a sandwich panel with 3D weave composite faces woven into a corrugated core structure as forming a dielectric core of the super capacitor as an aspect of an embodiment of the invention. The composite faces and corrugated core may be S2 glass/epoxy or other desired weavable composite materials. The space between the cells may be filled with high density PVC foam or other desired material.

Figure 5 provides a schematic perspective view of a two core layer sandwich panel structure with a pyramidal truss topology core which would form a dielectric core of a super capacitor as an aspect of an embodiment of the invention.

Figure 6 provides a schematic perspective cross-sectional view of a portion of an armor system where the corrugated truss cores are bent transversely to their corrugations enabling the fabrication of reactive concepts in a cylindrical form as an aspect of an embodiment of the invention. Hot pressed ceramic tiles or other desired materials with hexagonal (or square) shapes can be used to create curved systems.

Figure 7 provides a schematic perspective cross-sectional view of a hemispherical implementation of a reactive topological armor system as an aspect of an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION An aspect of various embodiments of the current invention provides, among other things, core combinations of armor design which exploits the use of topology optimization of cellular core sandwich panels with an integrated super capacitor providing an active circuit reactive to a projectile that penetrates the said super capacitor. The structural components provide, among other things, a light weight solution to various blast and ballistic threats. In combination with these structural advantages, an aspect of an embodiment of the present invention provides a solution for defeating long metal penetrators and metal "jets" produced by shaped charges through an electromagnetic projectile defeating concept. Turning now to the drawings, the illustration in Figure 1 provides an example of an embodiment of the electromagnetic projectile defeating concept. As here embodied, the armor system 100 comprises a super capacitor 110 which includes a top chargeable electrically conductive layer 120, a bottom chargeable electrically conductive layer 122 and a lattice structure forming the dielectric core 130 disposed between said top and bottom conductive layers. The electrically conductive layers may comprise of thin metallic foils so as to minimize thickness and weight. The super capacitor 110 is sandwiched in between top 140 and bottoml42 insulating projectile arresting layers so as to protect and insulate the active armor element. An exemplary material for the insulating projectile arresting layers 140 142 is ceramic tile made OfB₄C (boron carbide), and other possible materials include, but not limited thereto, hard ballistic substrates and related ceramic tiles. Using ballistic grade ceramic tiles provides the beneficial effect of also enhancing its small arms and fragment projectile impact resistance as well as enhancing the resistance and electrical breakdown field strength of the armor. The ballistic grade ceramic tiles are able to defeat significant ballistic threats at low aerial density.

In Figure 2 a projectile 250 is seen penetrating an embodiment of the armor system 200. After the projectile penetrates the top insulating projectile arresting layer 240 the projectile will form an active circuit reactive to said projectile when it fully penetrates and therefore spans the super capacitor 210. Once this active circuit is closed by the projectile 250, all the electrical power stored in the super capacitor 210 will be discharged through the projectile 250, as designated "I" for current, resulting in the projectile 250 being vaporized or dispersed. As Figure 2 demonstrates, an embodiment of the present armor system 200 can comprise of a plurality of super capacitor and insulating layers in order to provide maximum protection for projectiles that can penetrate multiple armor layers. Thus an embodiment of the invention provides an armor system with capitatively charged electrodes whose rapid shorting by high aspect projectiles provides a reactive means for the defeat of certain classes of ballistic threats, particularly impeding the penetration of the structure by hypervelocity, high aspect ratio metallic projectiles. The application of like (repulsive) charges to the foils also creates electrostatic mechanisms to limit or control the collapse of the structure under blast/shock loading scenarios.

Turning to Figure 3, Figure 3 provides a more detailed depiction of an embodiment of the full armor system 300. In addition to the insulating layers 340 342, and super capacitor 310, a top metal face sheet 360 is added as an outer layer to provide additional protection against ballistic threats. A bottom metal face sheet 362 can also be attached. An exemplary material for the metal face sheets 360 362 is steel rolled homogenous armor (RHA), and other possible materials include, but not limited thereto, titanium, stainless steel, or any combination thereof.

Still referring to Figure 3, the depiction also provides an example of an embodiment of the lattice sandwich structure which forms the dielectric core 380. The sandwich structure provides an inner core comprising of a first open-cell lattice structure 383 and a second open-cell lattice structure 384 attached to and divided by an intermediate panel 385. The sandwich structure is then completed by attaching a first layer panel 381 to the first open-cell lattice structure 383, and attaching a second layer panel 382 to the second open-cell lattice structure 384. This sandwich structure forms the dielectric core 380 and is further sandwiched between the top and bottom conductive layers 381 382 to form the super capacitor 310. The inner and outer layers provide a sandwich panel design that has high structural efficiency and good environmental protection capabilities.

Additionally, a filler portion 386 is formed and conforms to the voids created between the either the first open-cell lattice structure 383 or second open-cell lattice structure 384. These filler portions can be filled with materials such as, but not limited to closed cell polymer or syntactic foams to enhance blast responses or with ceramic inserts to increase ballistic resistance. Other materials used to fill the filler portions 386 might include elastomers, polyurethane, polyeuria, polymer or other desired filler material or any combination thereof.

Furthermore, as depicted in Figure 3, the multilayer armor system 300 provides the opportunity to sequentially reduce the length of incident projectile as the projectile passes through each super capacitor 310 layer.

Still referring to Figure 3, a fragment catching layer 365 is provided which may be positioned behind the structure and can be used to arrest a radially expanding debris cloud created by the projectile dispersion or protect against other threats. The fragment catching layer may comprise of a ballistic fiber composite (spall shield). Materials for the fragment catching layer may comprise of, but are not limited thereto, Kevlar, Dynema fabric, aramid fabric, glass fiber composites, Polyphenylenebenzobisoxazole (PBO), or any combination thereof. The polyethylene systems are lowest in density (they have a density about 2% less than that of fresh water).

In total, Figure 3 shows an exemplary embodiment of the invention which provides a planar multifunctional electromagnetic armor with efficient structural load support capabilities and resistance to both explosive blast loading and small arms threats.

Figure 4 illustrates one particular example of one possible embodiment of a dielectric core 480 of the super capacitor. This embodiment presents a delamination resistant sandwich panel structure with corrugated lattice truss cores built out of glass fiber based composites. The first layer panel 481, intermediate panel 485, and first open- cell lattice structure 483 are built with fiber based composites and woven together using 3D weaving techniques. As illustrated, the first open-cell lattice structure 483 might comprise of two layers of 54 oz. E-glass. The first layer panel 481, and intermediate panel 485 might comprise of lOOoz. S2-glass. In addition, Figure 4 also illustrates the use of a double Kevlar straight stitch 490 which provides a mechanism for attaching the open-cell lattice structure 483 to the first 481 and intermediate 485 panels. Furthermore, the filler portion 486 is filled with closed cell PVC foam. The structure illustrated in Figure 4 would have a very low through thickness electrical conductivity and high electrical breakdown field strength. It is therefore ideal for supporting very large electric field gradients. These low density structures have been blast loaded and found to reduce the impulse transferred from a buried mine blast by about 30%. It should be appreciated that the open-cell lattice structures may be made with a variety crushable materials and could comprise of ballistic polymer fiber based composites, ballistic glass fiber based composites such as S2-glass and E-glass, or any combination thereof. Different combinations will enable customization of the system in order to respond to different combinations and classes of blast and ballistic threats. These crushable materials can reduce impulse transfer and peak transmitted pressures from shock wave interactions caused by various blasts.

Figure 5 illustrates another example of a possible embodiment of a dielectric core 580 as part of the super capacitor structure. The figure more clearly depicts use of a two core open-cell sandwich structure. As illustrated, the first open-cell lattice structure 583 and the second open-cell lattice structure 584 are separated by and attached to an intermediate panel 585. This structure is attached to a first layer panel 581 and a second layer panel 582 to form the full sandwich panel structure. The filler portion 586 is also pointed out as the void created by the open-cell lattice structures. Merely by way of example, the open-cell lattice structures in the embodiment illustrate a pyramidal truss topology. The figure illustrates the general use of topology optimization of cellular core sandwich panels to create efficient load supporting structures. These types of structures, integrated into the armor system, offer significant mass efficiency over conventional vehicle armors.

It should be particularly appreciated that the open-cell lattice structures as disclosed throughout may comprise of a variety of cellular truss topologies. Some examples of preferred cellular truss structures include, but are not limited to, honeycomb structures such as hexagonal cell, square cell, cylindrical, and triangular cell, or any combination thereof. Other example of preferred cellular truss structures include, but are not limited to, the following corrugation type structures: triangular, diamond, multi- layered, flat-top and Navtruss® corrugation arrangements, or any combination thereof. Even further, other examples of preferred cellular truss structures include, but are not limited to the following truss arrangements: tetrahedral, pyramidal, three-dimensional Kagome, or any combination thereof. It should further be appreciated that the open-cell lattice structures may also comprise of at least one of the following structures: textile weave structure, woven wire mesh, or multilayer textile weave structure or any combination thereof. It should also be appreciated that the sandwich panel structure may comprise of only one open cell lattice structure without an intermediate panel. Moreover, a sandwich panel structure may comprise of more than one and without an intermediate panel between some or all occurrences. Further yet, any of the panels or structures may be laterally coupled next to one another (i.e., side -by-side, for example) Referring to Figure 5, examples of preferred materials for the elements 581 582

583 584 585 which make up the sandwich panel include, but are not limited to: steel, aluminum alloy (such as 6061 T6 aluminum alloy), titanium, magnesium alloy, or any combination thereof.

Figure 6 illustrates an embodiment of the multifunctional electromagnetic armor system 600 adapted to a cylindrically shaped structure 601. The multifunctional concept is specially intended as a high structural efficiency system for the protection of flat, cylindrical or hemispherical structures. As Figure 6 shows, the corrugated and lattice truss cores, forming the dielectric core of the super capacitor 610, can be flexed and bent transversely to their corrugations enabling the fabrication of relative concepts with a cylindrical form prior to the attachments of the top 660 and bottom 662 metal face sheets. The use of hot pressed ceramic tiles with hexagonal (or square) shapes or other slightly curved ceramic tiles for the top 640 and bottom 642 insulating layers further allows the cylindrical analogue of the planar design to be fabricated. It should be appreciated that slightly curved panels and panels with hexagonal or square shapes can be fabricated from a variety of ceramics and used to create the curved analogue of the design. Other materials that can be bent or specifically shaped can also be substituted to create non- planar surfaces. It should be appreciated that any of the components of the various embodiments of the armor system disclosed herein may be bent, flexed, contoured and shaped as desired or required for a given application. Moreover, various shapes, sizes, thicknesses, and volumes may be employed and considered within the context of the invention. Figure 7 illustrates another exemplar embodiment of the multifunctional electromagnetic armor system 700 adapted to a hemispherical structure 701. The figure shows that lattice truss structures forming the dielectric core 780 of the super capacitor 710 may be also bent in two direction creating the novel opportunity of making hemispherical analogues of this protection concept. As mentioned previously, hot pressed tiles in hexagonal shapes which comprise the insulating projectile arresting layers 741 are identified to show how hemispherical shapes may be achieved. It should be appreciated that these concepts may be adapted to create armor systems in a wide variety of non-planar shapes including, but not limited to desired shapes including curved, planar, multifaceted, substantially planar, or a protection concept having a plurality of curves. We note that this curvature of the faces adds additional energy absorbing mechanisms which are likely to enhance the blast mitigating response of the structure (it requires in plane compression of the faces as well as core crushing).

It should be appreciated that the various embodiments of the present invention or any sub-combination thereof may be fabricated utilizing a number of manufacturing methods. For instance, some exemplary manufacturing methods of the armor system or any components thereof may include the following methods or combination thereof: brazing, welding, soldering, 3D weaving, and near neat shape or net shape fabrication using techniques such as extrusion or casting. For example, a method may produce the truss core structures using extrusion that provide very good nodal strength and resultant performance.

In summary, an aspect of an embodiment or various embodiments of the present invention comprises, among other things, a novel, very low aerial density multifunctional reactive armor (and related method of use and manufacture) with the capability of defeating a wide range of projectile and blast threats to structures with a planar, cylindrical or hemispherical geometry.

An aspect of various embodiments of the present invention may provide a number of novel and nonobvious features, elements and characteristics, such as but not limited thereto, the following: the armor incorporates electromagnetic concepts into a robust, structurally efficient armor panel and exploits synergies between the elements of the system to reduce its aerial density.

An aspect of various embodiments of the present invention may provide a number of advantages, such as but not limited thereto, the following: this reactive, multifunctional system results in a low aerial density armor solution that can be easily tailored to match a wide variety of threat scenarios. It can be fabricated in a variety of complex shapes including cylinders, hemispheres, beams and plates.

An aspect of various embodiments of the present invention may be utilized for a number of products and services, such as but not limited thereto, the following: used for any lightweight armor on land, sea or air. The present invention may be made from materials with very high corrosion resistance in salt water environments.

It should be appreciated that various aspects of embodiments of the present method, system, devices, article of manufacture, and compositions may be implemented with the following methods, systems, devices, article of manufacture, and compositions disclosed in the following U.S. Patent Applications, U.S. Patents, and PCT International Patent Applications and are hereby incorporated by reference herein:

International Application No. PCT/US2009/034690 entitled "Method for Manufacture of Cellular Structure and Resulting Cellular Structure," filed February 20, 2009. U. S. Utility Patent Application Serial No. 12/408,250, filed March 20, 2009, entitled "Cellular Lattice Structures with Multiplicity of Cell Sizes and Related Method of Use." U.S. Application No. 12/479,408 entitled "Manufacture of Lattice Truss Structures from

Monolithic Materials," filed June 5, 2009.

PCT International Application No. PCT/US2008/071848, filed on July 31, 2008, entitled "Hybrid Periodic Cellular Material Structures, Systems, and Methods for Blast and Ballistic Protection,"

PCT International Application No. PCT/US2008/073377, filed August 15, 2008, entitled "Synergistically-Layered Armor Systems and Methods for Producing Layers

Thereof,"

PCT International Application No. PCT/US02/17942, entitled "Multifunctional Periodic Cellular Solids And The Method of Making Thereof," filed June 6, 2002, and corresponding U.S. Application No. 10/479,833, entitled "Multifunctional Periodic

Cellular Solids And The Method of Making Thereof ," filed on December 5, 2003. PCT International Application No. PCT/US03/16844, entitled "Method for Manufacture of Periodic Cellular Structure and Resulting Periodic Cellular Structure," filed May 29, 2003, and corresponding U.S. Application No. 10/515,572, entitled

"Multifunctional Periodic Cellular Solids And The Method of Making Thereof ," filed

November 23, 2004. PCT International Application No. PCT/US04/04608, entitled "Methods for Manufacture of Multilayered Multifunctional Truss Structures and Related Structures There from," filed February 17, 2004, and corresponding U.S. Application No. 10/545,042, entitled

"Methods for Manufacture of Multilayered Multifunctional Truss Structures and

Related Structures There from," filed August 11, 2005. PCT International Application No. PCT/US01/22266, entitled "Method and Apparatus

For Heat Exchange Using Hollow Foams and Interconnected Networks and Method of Making the Same," filed July 16, 2001, and corresponding U.S. Application No.

10/333,004, entitled "Heat Exchange Foam," filed January 14, 2003. PCT International Application No. PCT/USOl/25158 entitled "Multifunctional Battery and Method of Making the Same", filed August 10, 2001, and corresponding U.S.

Application Nos. 10/110,368, entitled "Multifunctional Battery and Method of Making the Same", filed July 22, 2002, and 11/788,958, entitled "Multifunctional

Battery and Method of Making the Same", filed April 23, 2007. PCT International Application No. PCT/US03/27606, entitled "Method for Manufacture of Truss Core Sandwich Structures and Related Structures Thereof," filed September 3, 2003, and corresponding U.S. Application No. 10/526,296, entitled "Method for Manufacture of Truss Core Sandwich Structures and Related Structures Thereof," filed March 1, 2005.

PCT International Application No. PCT/USOl/17363, entitled "Multifunctional Periodic Cellular Solids And The Method of Making Thereof," filed May 29, 2001 , and corresponding U.S. Application No. 10/296,728, entitled "Multifunctional Periodic Cellular Solids And The Method of Making Thereof ," filed November 25, 2002.

PCT International Application No. PCT/US2007/012268, entitled "Method and Apparatus for Jet Blast Deflection", filed May 23, 2007 and corresponding U.S.

Application No. 12/301,916, entitled "Method and Apparatus for Jet Blast Deflection," filed November 21, 2008. PCT International Application No. PCT/US03/23043 and corresponding U.S. Application

Serial No. 10/522,068, filed January 21, 2005, entitled "Method for Manufacture of Cellular Materials and Structures for Blast and Impact Mitigation and Resulting

Structure."

PCT International Application No. PCT/US2003/027605 and corresponding U.S. Application Serial No. 10/526,416, filed March 2, 2005, entitled "Blast and Ballistic Protection Systems and Methods of Making Same."

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Unless clearly specified to the contrary, there is no requirement for any particular described or illustrated activity or element, any particular sequence or such activities, any particular size, speed, material, duration, contour, dimension or frequency, or any particularly interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. It should be appreciated that aspects of the present invention may have a variety of sizes, contours, shapes, compositions and materials as desired or required. In summary, while the present invention has been described with respect to specific embodiments, many modifications, variations, alterations, substitutions, and equivalents will be apparent to those skilled in the art. The present invention is not to be limited in scope by the specific embodiment described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those of skill in the art from the foregoing description and accompanying drawings. Accordingly, the invention is to be considered as limited only by the spirit and scope of the following claims, including all modifications and equivalents. Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of this application. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Unless clearly specified to the contrary, there is no requirement for any particular described or illustrated activity or element, any particular sequence or such activities, any particular size, speed, material, dimension or frequency, or any particularly interrelationship of such elements. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all sub ranges therein. Any information in any material (e.g., a United States/foreign patent, United States/foreign patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render invalid any claim herein or seeking priority hereto, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein.

Claims

CLAIMS: We claim:

1. A synergistically-layered armor system for mitigating blast pressure and ballistic threats, said system comprising: a super capacitor, wherein said capacitor comprises: a top chargeable electrically conductive layer, a bottom chargeable electrically conductive layer, and a dielectric core, wherein said core comprises a lattice structure disposed between said top conductive layer and said bottom conductive layer; a top insulating projectile arresting layer in mechanical communication with said super capacitor distal from said bottom conductive layer; a bottom insulating projectile arresting layer in mechanical communication with said super capacitor distal from said top conductive layer; and wherein said super capacitor provides an active circuit reactive to a conductive projectile that spans across said super capacitor.

2. The system of claim 1, further comprising: a fragment catching layer disposed in mechanical communication with said top insulating projectile arresting layer or said bottom insulating projectile arresting layer.

3. The system of claim 2, wherein said fragment catching layer comprises at least one of the following: Kevlar, Dynema fabric, aramid fabric, glass fiber composites, Polyphenylenebenzobisoxazole (PBO), or any combination thereof.

4. The system of claim 1, wherein said top insulating projectile arresting layer comprises a ballistic substrate.

5. The ballistic substrate of claim 4, wherein said ballistic substrate comprises ballistic grade ceramic tiles.

6. The system of claim 5, wherein said ballistic grade ceramic tiles comprises at least of Boron Carbide.

7. The system of claim 5, wherein said ceramic tiles can be slightly curved to allow multiple armor system shapes.

8. The system of claim 5, wherein said ceramic tiles can be formed into different shapes.

9. The system of claim 5 wherein said desired shape is at least one of polygonal, hexagonal, or square.

10. The system of claim 9, wherein: said coupling is provided by an extrusion process.

11. The system of claim 9, wherein: said coupling is provided by fasteners.

12. The system of claim 11, wherein: said fasteners comprises bolts, rivets, screws, or the like.

13. The system of claim 9, wherein: said coupling is provided by an extrusion process and machining process.

14. The system of claim 1 , wherein said bottom insulating projectile arresting layer comprises a ballistic substrate.

15. The system of claim 14, wherein said ballistic substrate comprises ballistic grade ceramic tiles.

16. The system of claim 15, wherein said ballistic grade ceramic tiles comprises at least of Boron Carbide.

17. The system of claim 1 , further comprising a top metal face sheet in mechanical communication with said top insulating projectile arresting layer distal from said super capacitor.

18. The system of claim 17, wherein said top metal face sheet comprises at least one of rolled homogeneous armor, titanium, stainless steel, or any combination thereof.

19. The system of claim 1 , further comprising a bottom metal face sheet in mechanical communication with said bottom insulating projectile arresting layer distal from said super capacitor.

20. The system of claim 19, wherein said bottom metal face sheet comprises at least one of rolled homogeneous armor, titanium, stainless steel, or any combination thereof.

21. The system of claim 1 , wherein said top chargeable electrically conductive layer comprises metallic foil.

22. The system of claim 1, wherein said bottom chargeable electrically conductive layer comprises metallic foil.

23. The system of claim 1, wherein said dielectric lattice core comprises: a first open-cell lattice structure layer, a second open-cell lattice structure layer, and an intermediate panel disposed between said first open-cell lattice structure and said second open-cell lattice structure layer.

24. The system of claim 23, wherein said dielectric lattice core further comprises: a first layer panel in mechanical communication with said first open-cell lattice structure layer distal from said second open-cell lattice structure layer; and a second layer panel in mechanical communication with said second open- cell lattice structure layer distal from said first open-cell lattice structure layer.;

25. The system of claim 24, wherein said dielectric lattice core further comprises: a filler portion disposed between voids created between: either said first open-cell lattice structure or said second open-cell lattice structure, or both said first open cell lattice structure or said second open-cell lattice structure; and wherein said filler portion conform to the void created by said open cells of said first and second open cell lattice structures.

26. The system of claim 23, wherein at least one of said first open-cell lattice structure, said second open-cell lattice structure, said intermediate panel, said first layer panel, or said second layer panel comprise of crushable materials.

27. The system of claim 26, wherein said crushable materials comprises ballistic fiber based composite materials.

28. The system of claim 27, wherein said ballistic fiber based composite materials comprises at least one of ballistic polymer fiber based composites, ballistic glass fiber based composites, or any combination thereof.

29. The system of claim 27, wherein said first open-cell lattice structure, second open-cell lattice structure, said intermediate panel, said first layer panel, or said second layer panel are woven together using 3D fiber weaving processes.

30. The system of claim 23, wherein at least one of said first open-cell lattice structure or second open-cell lattice structure is at least one of the following honeycomb type structures: hexagonal cell, square cell, cylindrical, and triangular cell, or any combination thereof.

31. The system of claim 23, wherein at least one of said first open-cell lattice structure or second open-cell lattice structure is at least one of the following corrugation type structures: triangular, diamond, multi-layered, flat-top and Navtruss® corrugation arrangements, or any combination thereof.

32. The system of claim 23, wherein at least one of said first open-cell lattice structure or second open-cell lattice structure is at least one of the following truss arrangements: tetrahedral, pyramidal, three-dimensional Kagome, or any combination thereof.

33. The system of claim 23, wherein at least one of said first open-cell lattice structure or second open-cell lattice structure is at least one of the following structures: textile weave structure, woven wire mesh, or multilayer textile weave structure or any combination thereof.

34. The system of claim 23, wherein said first open-cell lattice structure layer or a second open-cell lattice structure layer, or both said first open-cell lattice structure layer or a second open-cell lattice structure layer comprises the following: steel, aluminum alloy, titanium, magnesium alloy, or any combination thereof.

35. The system of claim 23, wherein said intermediate panel, said first layer panel, or said second layer panel, or all of said intermediate panel, said first layer panel, or said second layer panel comprises the following: steel, aluminum alloy, titanium and magnesium alloy, or any combination thereof.

36. The system of claim 23, wherein said filler portion comprises at least one of: elastomer, polyurethane, polyeuria, polymer or other desired filler material or any combination thereof.

37. The system of claim 23, wherein said filler portion comprises closed cell polymer foams.

38. The system of claim 23, wherein said filler portion comprises closed cell syntactic foams.

39. The system of claim 23, wherein said filler portion comprises ceramic inserts for ballistic protection.

40. The system of claim 1 , wherein said system may be fabricated or bent so as to be any desired shape.

41. The system of claim 40, wherein said desired shape comprises a shape that is at least one of curved, planar, multifaceted, substantially planar, or has a plurality of curves.

42. The system of claim 1, wherein said system comprises at least one of: a tank armor plating structure, a land, air, space or water vehicle/craft plating structure (for example: siding panels, face plates, floor plates).

43. The system of claim 1 , wherein said system is an assembly affixed to the exterior of a vehicle, water craft, air craft, or space craft.

44. A method of riding or driving said vehicle or said craft of claim 43.

45. The system of claim 1 , wherein said system is an assembly affixed to the a surface of a vehicle, water craft, air craft, or space craft.

46. A method of riding or driving said vehicle or said craft of claim 45.

47. A method of manufacturing the system of claim 1 , wherein: said super capacitor, said core, said inner core, said first insulating panel, said second insulating panel, said top face plate, and said bottom face plate are provided for: coupling them together to form said system.

48. The method of claim 47, wherein said coupling comprises at least one of the following: bonding, adhesives, diffusion bonding, brazing, soldering, or resistance/electron/laser welding.

49. The s of claim 47, wherein: said coupling comprises a metallurgical bond such as at least one of the following: welding, friction stir welding, or diffusion bonding.

50. A method of making a synergistically-layered armor system for mitigating blast pressure and ballistic threats, said method comprising: providing a super capacitor, wherein said capacitor comprises: a top chargeable electrically conductive layer, a bottom chargeable electrically conductive layer, and a dielectric core, wherein said core comprises a lattice structure disposed between said top conductive layer and said bottom conductive layer; providing a top insulating projectile arresting layer in mechanical communication with said super capacitor distal from said bottom conductive layer; providing a bottom insulating projectile arresting layer in mechanical communication with said super capacitor distal from said top conductive layer; and providing an active circuit reactive to a conductive projectile that spans across said super capacitor.

51. A method of manufacturing the system of claim 50, wherein: said super capacitor, said core, said inner core, said first insulating panel, said second insulating panel, said top face plate, and said bottom face plate are provided by coupling them together to form said system.

52. The method of claim 51 , wherein said coupling comprises at least one of the following: bonding, adhesives, diffusion bonding, brazing, soldering, or resistance/electron/laser welding.