Apparatus for defeating high energy projectiles

Abstract

The disclosed armor system for protecting a vehicle from high energy projectiles includes a leading layer, relative to the projectile trajectory, positioned exterior to the hull; a first plurality of sheet-like layers of a low density material positioned between the leading layer and the hull; and a second plurality of sheet-like high strength metal layers positioned between the leading layer and the hull. The individual ones of the first plurality of high strength metal layers are positioned alternating with, and to the rear of, individual ones of the second plurality of low density material layers. The leading layer can be one of a sheet-like metal layer, a metalicized grid layer, and the outer-most layer of the first plurality of low density materials layers. The materials of the high strength metal layers may be selected from high strength steel and high strength aluminum, and the materials of the low density material may be selected from low density polypropylene composites and R-Glass composites.

1 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including   (a) a leading layer, relative to the expected projectile trajectory;   (b) a first intermediate sheet-like layer of a low density material abutting a rear surface of the leading layer;   (c) a first intermediate sheet-like layer of metal abutting a rear surface of the first intermediate low density material layer;   (d) a second intermediate sheet-like layer of a low density material abutting a rear surface of the first intermediate metal layer;   (e) a second intermediate sheet-like layer of metal abutting a rear surface of the second intermediate low density material layer;   (f) a third intermediate sheet-like layer of a low density material abutting a rear surface of the second intermediate metal layer; and   (g) a third intermediate sheet-like layer of metal positioned between the third intermediate low density material layer and an exterior surface of the vehicle hull, and abutting a rear surface of the third intermediate low density material layer.   
   
   
       2 . The armor system as in  claim 1 , further comprising an interior armor subsystem interior to the vehicle hull, the interior armor subsystem including one or more sheet-like layers of a low density material positioned to the rear of an interior surface of the hull. 
   
   
       3 . The answer system as in  claim 2 , wherein the low density material in the one or more interior low density material layers is selected from members of the group consisting of R-Glass composites, S-Glass composites, E-Glass composites, Kevlar® reinforced polymer, Kevlar® reinforced polyethylene composites, and hybrids of one or more of the group members. 
   
   
       4 . The armor system as in  claim 2 , having a first low density material interior layer of a low density polypropylene composite spaced a predetermined distance from an interior surface of the hull, and a second low density material interior layer of a composite of an aramid and a glass material abutting a rear surface of the first interior low density polypropylene composite layer. 
   
   
       5 . The armor system as in  claim 1 , wherein the leading layer is a sheet-like layer of a high strength aluminum or a metal grid. 
   
   
       6 . The armor system as in  claim 1 , wherein the leading layer is a sheet-like layer of a low density material, and wherein the leading layer also comprises the first intermediate low density material layer. 
   
   
       7 . The armor system as in and  claim 1 , wherein one or more of the leading layer, and the first, second, and third intermediate metal layers is a high strength aluminum, and wherein the low density material of one or more of the first, second, and third intermediate layers of a low density material is a low density polypropylene composite. 
   
   
       8 . The armor system of  claim 7 , wherein the high strength aluminum selected from the group consisting of 7039, 5083, and 2024-T351. 
   
   
       9 . The armor system as in  claim 1 , wherein the third intermediate metal layer also abuts an exterior surface of the vehicle hull. 
   
   
       10 . The armor system as in  claim 1 , wherein the third intermediate metal layer abuts a rear surface of the third intermediate low density material layer and also abuts an exterior surface of the hull; wherein the leading layer and the first, second, and third intermediate layer are a high strength aluminum; wherein the first and second intermediate low density material layer are a low density polypropylene composite; and wherein the third intermediate low density material layer is an R-Glass composite in a phenolic resin. 
   
   
       11 . The armor system of  claim 1 , wherein a fourth intermediate sheet-like layer of a low density material abuts a rear surface of the third metal layer, and wherein a fourth sheet-like metal armor layer abuts an exterior surface of the hull. 
   
   
       12 . The armor system as in  claim 11 , wherein the fourth intermediate low density material layer is spaced a predetermined distance from the fourth intermediate metal layer. 
   
   
       13 . The armor system as in  claim 11 , wherein the fourth intermediate low density material layer also abuts a front surface of the fourth intermediate metal layer. 
   
   
       14 . The armor system as in  claim 11 , wherein the material of the fourth intermediate low density material layer is a low density polypropylene composite, and wherein the metal of the fourth intermediate metal armor layer is a high strength aluminum. 
   
   
       15 . The armor system as in  claim 1 , wherein the third intermediate metal layer is a high strength steel, and wherein the armor system further includes a fourth intermediate sheet-like layer of a high strength steel abutting an exterior surface of the hull. 
   
   
       16 . The armor system as in  claim 15 , wherein the third and fourth intermediate steel layers are spaced apart a predetermined distance. 
   
   
       17 . The armor system as in  claim 15 , further including a fourth intermediate sheet-like layer of a low density material abutting a rear surface of the third intermediate steel layer and abutting a front surface of the fourth intermediate steel layer. 
   
   
       18 . The armor system as in  claim 15  wherein the high strength steels of the third and fourth intermediate steel layers are selected from the group consisting of A514, A517, Weldox®, and Mil A-12560 Rolled Homogeneous Armor. 
   
   
       19 . The armor system as in  claim 1 , wherein the low density materials of the first, second, and third intermediate low density material layers are selected from members of the group consisting of R-Glass composites, S-Glass composites, E-Glass composites, Kevlar® reinforced polymer, Kevlar® reinforced polyethylene composites, and hybrids of one or more of the group members. 
   
   
       20 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured for being mounted sheet like exterior to the vehicle hull, the exterior armor subsystem including   (a) a leading sheet-like layer of a high strength aluminum, relative to the expected projectile trajectory;   (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer;   (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer;   (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer;   (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer;   (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer;   (g) a third intermediate sheet-like layer of a high strength aluminum layer abutting a rear surface of the third intermediate low density polypropylene composite layer;   (h) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer; and   (i) a fourth sheet-like high strength aluminum layer abutting an exterior surface of the hull,   wherein the fourth intermediate low density polypropylene composite layer is spaced a predetermined distance from the fourth intermediate aluminum layer.   
   
   
       21 . The armor system as in  claim 20 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       22 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured for being mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading layer of a high strength aluminum, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer; 
 (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (g) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer; and 
 (h) a fourth intermediate sheet-like high strength aluminum layer abutting a rear surface of the fourth intermediate low density polypropylene composite layer and also abutting an exterior surface of the hull. 
   
   
   
       23 . The armor system as in  claim 22 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       24 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading layer of a high strength aluminum, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer; 
 (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (g) a third intermediate sheet-like layer of a high strength steel abutting a rear surface of the third intermediate low density polypropylene composite layer; and 
 (h) a fourth intermediate sheet-like layer of a high strength steel abutting an exterior surface of the hull, 
 (i) wherein the third and fourth intermediate steel layers are spaced apart a predetermined distance. 
   
   
   
       25 . The armor system as in  claim 24 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       26 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an armor subsystem exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading layer of a high strength aluminum, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a low density polypropylene abutting a rear surface of the leading aluminum layer; 
 (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; and 
 (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (g) a third intermediate sheet-like layer of a high strength steel abutting a rear surface of the third intermediate low density polypropylene composite layer; 
 (h) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate steel layer; and 
 (i) a fourth intermediate sheet-like layer of a high strength steel abutting a rear surface of the fourth intermediate low density polypropylene composite layer and also abutting an exterior surface of the hull. 
   
   
   
       27 . The armor system as in  claim 26 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       28 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading sheet-like layer of high strength aluminum, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer; 
 (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; and 
 (g) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the third intermediate low density polypropylene composite layer and also abutting an exterior surface of the hull. 
   
   
   
       29 . The armor system as in  claim 28 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       30 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading sheet-like layer of a low density polypropylene composite, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the leading low density polypropylene composite layer; 
 (c) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (d) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (e) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (f) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (g) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer; 
 (h) a fourth intermediate sheet-like layer of a high strength steel abutting a rear surface of the third intermediate low density polypropylene composite layer; and 
 (i) a fifth intermediate sheet-like layer of a high strength steel abutting an exterior surface of the hull, 
   wherein the fourth and fifth intermediate steel layers are spaced apart a predetermined distance.   
   
   
       31 . The armor system as in  claim 30 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       32 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading sheet-like layer of a low density polypropylene composite, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the leading low density polypropylene composite layer; 
 (c) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (d) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (e) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (f) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (g) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer; 
 (h) a fourth intermediate sheet-like layer of a high strength steel abutting a rear surface of the third intermediate low density polypropylene composite layer; 
 (i) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the fourth intermediate aluminum layer; and 
 (j) a fifth sheet-like layer of a high strength steel abutting a rear surface of the fourth intermediate low density polypropylene composite layer and also abutting an exterior surface of the hull. 
   
   
   
       33 . The armor system as in  claim 32 , wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       34 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including
 (a) a leading metal grid layer, relative to the expected projectile trajectory; 
 (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading metal grid layer; 
 (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer; 
 (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer; 
 (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer; 
 (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer; 
 (g) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the third intermediate low density polypropylene composite layer; 
 (h) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer; 
 (i) a fourth intermediate sheet-like layer of a high strength steel abutting a rear surface of the fourth intermediate low density polypropylene composite layer; and 
 (j) a fifth intermediate sheet-like layer of a high strength steel abutting an exterior surface of the hull, 
   wherein the fourth and fifth intermediate steel layers are spaced apart a predetermined distance.   
   
   
       35 . The armor system as in  claim 34  wherein one or more of the first, second, third and fourth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       36 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an armor subsystem configured to be mounted exterior to the vehicle hull, the exterior armor subsystem including   (a) a leading metal grid layer, relative to the expected projectile trajectory;   (b) a first intermediate sheet-like layer of a low density material abutting a rear surface of the leading metalized grid;   (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer;   (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer;   (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer;   (f) a third intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the second intermediate aluminum layer;   (g) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the third intermediate low density polypropylene composite layer;   (h) a fourth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the third intermediate aluminum layer;   (i) a fourth intermediate sheet-like layer of a high strength steel abutting a rear surface of the fourth intermediate low density polypropylene composite layer;   (j) a fifth intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the fourth intermediate steel layer; and   (k) a fifth intermediate sheet-like layer of a high strength steel abutting a rear surface of the fifth intermediate low density polypropylene composite layer and also abutting an exterior surface of the hull.   
   
   
       37 . The armor system as in  claim 36 , wherein one or more of the first, second, third, fourth and fifth intermediate low density polypropylene composite layers is Tegris®. 
   
   
       38 . The armor system as in any one of  claims 20 ,  22 ,  24 ,  26 ,  28 ,  30 ,  32 ,  34 , and  36 , further comprising an interior armor subsystem configured for being mounted interior to the vehicle hull, the interior armor subsystem including
 (i) an interior sheet-like layer of low density polypropylene composite spaced a predetermined distance behind an interior surface of the vehicle hull; and   (ii) an interior sheet-like layer of an aramid and glass composite abutting a rear surface of the interior low density polypropylene composite layer.   
   
   
       39 . The armor system as in  claim 38 , wherein the interior layer of a low density polypropylene composite is Tegris®, and the interior layer of an aramid and glass composite is a hybrid composite of Kevlar® and E-Glass®. 
   
   
       40 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured for being mounted exterior to the vehicle hull, the exterior armor subsystem including   (a) a leading sheet-like layer of a high strength aluminum, relative to the expected projectile trajectory;   (b) a first intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer;   (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the first intermediate low density polypropylene composite layer;   (d) a second intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the first intermediate aluminum layer;   (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate low density polypropylene composite layer;   (f) a third intermediate sheet-like layer of R-Glass composite in a phenolic resin abutting a rear surface of the second intermediate aluminum layer;   (g) a third intermediate sheet-like layer of a high strength aluminum layer abutting a rear surface of the third intermediate R-Glass composite in phenolic resin layer and also abutting an exterior surface of the hull.   
   
   
       41 . The armor system as in  claim 40 , wherein one or both of the first and second intermediate low density polypropylene layer is Tegris®. 
   
   
       42 . The armor system as in  claim 40 , further including a sheet-like layer of an R-Glass composite in phenolic resin abutting an interior surface of the hull. 
   
   
       43 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 an exterior armor subsystem configured for being mounted exterior to the vehicle hull, the exterior armor subsystem including   (a) a leading sheet-like layer of a high strength aluminum, relative to the expected projectile trajectory;   (b) a intermediate sheet-like layer of a low density polypropylene composite abutting a rear surface of the leading aluminum layer;   (c) a first intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the intermediate low density polypropylene composite layer;   (d) a intermediate sheet-like layer resin of a R-Glass composite in a phenolic resin abutting a rear surface of the first intermediate high strength aluminum layer;   (e) a second intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the R-Glass composite/phenolic resin layer;   (f) a third intermediate sheet-like layer of a high strength aluminum abutting a rear surface of the second intermediate aluminum layer; and   wherein the third intermediate high strength aluminum layer is spaced from an exterior surface of the hull by a foam layer hull.   
   
   
       44 . The armor system as in  claim 40 , wherein the first intermediate low density polypropylene layer is Tegris®. 
   
   
       45 . The armor system as in  claim 40 , further including an interior armor subsystem comprising in sequence, sheet-like layers of a foam, an aluminum oxide ceramic, and a Kevlar® and E-Glass® hybrid composite, the foam layer abutting an interior surface of the hull. 
   
   
       46 . An armor system for protecting a vehicle from high energy projectiles, the projectile having an expected trajectory and the vehicle having a hull, the system comprising:
 a leading layer, relative to the trajectory, the leading layer positioned exterior to the hull;   a first plurality of sheet-like layers of a low density material positioned between the leading layer and the hull; and   a second plurality of sheet-like high strength metal layers positioned between the leading layer and the hull,   wherein individual ones of the first plurality of high strength metal layers being positioned alternating with, and to the rear of, individual ones of the second plurality of low density material layers.   
   
   
       47 . The armor system as in  claim 46 , wherein the leading layer comprises one of a sheet-like metal layer, a metalicized grid layer, and the outer-most layer of said first plurality of low density materials layers. 
   
   
       48 . The armor system as in  claim 46 , wherein the materials of the high strength metal layers are selected from high strength steel and high strength aluminum, and wherein the materials of the low density material are selected from low density polypropylene composites and R-Glass composites.