Multi-layer wearable body armor

Patent metadata

Field	Value
Publication number	US-11441875-B2
Application number	US-202117307509-A
Country	US
Kind code	B2
Filing date	May 4, 2021
Priority date	Dec 4, 2018
Publication date	Sep 13, 2022
Grant date	Sep 13, 2022

Abstract

A multi-layer body armor plate includes a strike plate; a mesh layer positioned over the strike plate, the mesh layer having a number of open cells; and an outer skin layer positioned over the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer. The open cells of the mesh layer may entrap air or may be filled with expandable, buoyant foam.

First claim

Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:

1. A multi-layer armor plate comprising:
a strike plate formed of metal matrix composite materials;
a mesh layer positioned over the strike plate, the mesh layer having a number of open cells and comprising metal matrix composite materials; and
an outer skin layer positioned over the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer.

2. The armor plate set forth in claim 1 , wherein the strike plate has a multi-curved profile for conforming to a wearer's torso, an inner face for at least partially covering the wearer's chest, an outer strike face, upper corner concave reliefs for accommodating the wearer's arms, and lower corner concave reliefs for accommodating the wearer's hips and thighs.

3. The armor plate set forth in claim 1 , wherein the strike plate is formed via additive manufacturing methods.

4. The armor plate set forth in claim 1 , wherein the metal matrix composite materials comprise a metal matrix and a nanocellulose supplement.

5. The armor plate set forth in claim 2 , wherein the mesh layer has an inner side positioned on the outer strike face of the strike plate and an outer side, with the open cells formed between the inner side and the outer side.

6. The armor plate set forth in claim 5 , wherein the open cells of the mesh layer entrap air.

7. The armor plate set forth in claim 1 , wherein the outer skin layer is formed of metal matrix composite materials.

8. The armor plate set forth in claim 1 , further comprising expandable, buoyant foam that at least partially fills the open cells of the mesh layer.

9. A multi-layer, wearable body armor plate comprising:
a strike plate formed of metal matrix composite materials and having a multi-curved profile for conforming to the wearer's torso, an inner face for at least partially covering the wearer's chest, an outer strike face, upper corner concave reliefs for accommodating the wearer's arms, and lower corner concave reliefs for accommodating the wearer's hips and thighs;
a mesh layer formed of metal matrix composite materials and having an inner side positioned on the outer strike face of the strike plate, an outer side, a number of open cells formed between the inner side and outer side, and edges between the inner side and the outer side; and
an outer skin layer formed of metal matrix composite materials and positioned over the outer side and the edges of the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer.

10. The body armor plate set forth in claim 9 , wherein the strike plate is formed via additive manufacturing methods and has a thickness of 0.125-0.5 inches.

11. The body armor plate set forth in claim 9 , wherein the metal matrix composite materials of at least one of the strike plate, the mesh layer, or the outer skin layer comprise a metal matrix and a nanocellulose supplement.

12. The body armor plate set forth in claim 9 , wherein the mesh layer has a thickness of 0.125-0.5 inches.

13. The body armor plate set forth in claim 12 , wherein the open cells of the mesh layer entrap air.

14. The body armor plate set forth in claim 9 , further comprising expandable, buoyant foam that at least partially fills the open cells of the mesh layer.

15. A method of forming a multi-layer, wearable body armor plate comprising:
depositing metal matrix composite materials via additive manufacturing to form a strike plate having an inner face and an outer strike face;
depositing additional metal matrix composite materials via additive manufacturing to form a mesh layer over the strike plate, the mesh layer having an inner side positioned on the outer strike face of the strike plate, an outer side, a number of open cells formed between the inner side and outer side, and edges between the inner side and the outer side; and
depositing additional material via additive manufacturing to form an outer skin layer over the outer side and the edges of the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer.

16. The method as set forth in claim 15 , wherein the metal matrix composite materials of at least one of the strike plate or the mesh layer comprises a metal matrix and a nanocellulose supplement.

17. The method as set forth in claim 15 , further comprising forming access holes in the mesh layer.

18. The method as set forth in claim 17 , further comprising injecting expandable, buoyant foam in the open cells of the mesh layer.

19. The method as set forth in claim 17 , further comprising sealing the access holes.

20. The method as set forth in claim 15 , wherein the material of the outer skin comprises metal matrix composite materials.

Assignees

• Honeywell Federal Mfg & Tech Llc

Inventors

• Barr Christian G
• Tannehill Justin

Classifications

• F41H5/0457 Primary

  Metal layers in combination with additional layers made of fibres, fabrics or plastics · CPC title

• F41H5/0442 Primary

  Layered armour containing metal (in combination with ceramic layers F41H5/0421; heat treatment of armour plate C21D9/42) · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title