Body armor of ceramic ball embedded polymer

Abstract

A body armor composite material is provided to protect a wearer from small-arms projectiles. The material includes a flexible liner, a polymer binder disposed on the liner, and ceramic solids embedded in the binder. The flexible liner conforms to a portion of the wearer and elastically deforms in response to application of mechanical force. The binder can be a polyurea foam. The solids can be spheres arranged in a single-layer pattern substantially parallel to liner.

1 . A body armor composite material for protecting a wearer from small- arms projectiles and shrapnel, said material comprising:
 a flexible liner that conforms to a portion of the wearer and elastically deforms in response to application of mechanical force;   a polymer binder disposed on said flexible liner; and   a plurality of ceramic solids embedded within said polymer binder, said plurality arranged in a single-layer pattern substantially parallel to said liner.   
     
     
         2 . The body armor according to  claim 1 , wherein said ceramic solids are spherical. 
     
     
         3 . The body armor according to  claim 2 , wherein said ceramic solids are between ⅜″ and ¾″ in diameter. 
     
     
         4 . The body armor according to  claim 1 , wherein said ceramic solids are composed of at least one of aluminum oxide (Al 2 O 3 ), silicon carbide (SiC), boron carbide (B 4 C), boron nitride (BN), silicon nitride (Si 3 N 4 ), and zirconium oxide (ZrO 2 ). 
     
     
         5 . The body armor according to  claim 1 , wherein said ceramic solids are composed substantially of aluminum oxide (Al 2 O 3 ). 
     
     
         6 . The body armor according to  claim 1 , wherein said pattern is a hexagonal close packed geometric arrangement in which each non-edge solid has six neighboring solid that share a common plane. 
     
     
         7 . The body armor according to  claim 1 , wherein said binder is a polyurea foam. 
     
     
         8 . The body armor according to  claim 1 , wherein said binder is a polyurethane foam. 
     
     
         9 . The body armor according to  claim 1 , wherein said binder is a rubber foam. 
     
     
         10 . The body armor according to  claim 1 , wherein said binder is an isocyanate foam. 
     
     
         11 . The body armor according to  claim 1 , wherein said binder is between ⅜″ and ¾″ in thickness. 
     
     
         12 . The body armor according to  claim 1 , wherein said liner comprises a weave of aramid fibers. 
     
     
         13 . The body armor according to  claim 12 , wherein said aramid fibers are composed of Kevlar®. 
     
     
         14 . The body armor according to  claim 1 , wherein said liner is a weave of ultra-high-molecular-weight polyethylene (UHMWPE) fibers. 
     
     
         15 . The body armor according to  claim 14 , wherein said UHMWPE fibers are composed of Dyneema® fiber. 
     
     
         16 . The body armor according to  claim 14 , wherein said UHMWPE fibers are composed of Spectra® yarn. 
     
     
         17 . A body armor composite material for protecting a wearer from small- arms projectiles and shrapnel, said material comprising:
 a flexible liner that conforms to a portion of the wearer and elastically deforms in response to application of mechanical force;   a polymer binder disposed on said flexible liner;   a plurality of balls, each said ball being embedded within said polymer binder, said plurality being arranged in a single-layer pattern substantially parallel to said liner, wherein each said ball comprises:   a ceramic solid, and   a high-tensile-strength fiber that securely wraps around said ceramic solid to produce said ball.   
     
     
         18 . The body armor according to  claim 17 , wherein said fiber is composed of an aramid. 
     
     
         19 . The body armor according to  claim 17 , wherein said fiber is composed of UHMWPE. 
     
     
         20 . The body armor according to  claim 17 , wherein each said ceramic solid is composed substantially of aluminum oxide (Al 2 O 3 ).