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 balls embedded in the binder. The flexible liner conforms to a portion of the wearer and elastically deforms in response to application of mechanical force.

1 . A body armor composite material for flexibly conforming to and 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 binder of polyurea foam disposed on said flexible liner; and   a plurality of ceramic balls embedded within said binder, wherein   said plurality is arranged in a hexagonal close-packed single-layer pattern substantially parallel to said liner such that each non-edge ball has six neighboring balls in said pattern.   
     
     
         2 . The body armor according to  claim 1 , wherein each ceramic ball of said plurality is between ⅜″ and ¾″ in diameter. 
     
     
         3 . The body armor according to  claim 1 , wherein said each ceramic ball is 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 ). 
     
     
         4 . The body armor according to  claim 1 , wherein said each ceramic ball is composed substantially of aluminum oxide (Al 2 O 3 ). 
     
     
         5 . The body armor according to  claim 1 , wherein said binder is between ⅜″ and ¾″ in thickness. 
     
     
         6 . The body armor according to  claim 1 , wherein said liner comprises a weave of one of aramid fibers and ultra-high-molecular-weight polyethylene (UHMWPE) fibers. 
     
     
         7 . The body armor according to  claim 1 , wherein a polymer thread wraps said each ceramic ball, said thread being composed of at least one of aramid fibers, UHMWPE fibers and metal. 
     
     
         8 . The body armor according to  claim 1 , wherein said plurality of ceramic balls includes inner and outer facing hexagonal layers, with inner ceramic balls being smaller than outer ceramic balls and each inner ceramic ball being disposed at a joint between adjacent outer ceramic balls. 
     
     
         9 . A small-arms protective insert (SAPI) ballistic panel for disposal in a body armor pocket for flexibly conforming to and protecting a wearer from small-arms projectiles and shrapnel, said plate comprising:
 a flexible liner that conforms to a portion of the wearer and elastically deforms in response to application of mechanical force;   a binder of polyurea foam disposed on said flexible liner; and   a plurality of ceramic balls embedded within said binder, wherein   said plurality is arranged in a hexagonal close-packed single-layer pattern substantially parallel to said liner such that each non-edge ball has six neighboring balls in said pattern.   
     
     
         10 . The SAPI panel according to  claim 9 , wherein each ceramic ball of said plurality is between ⅜″ and ¾″ in diameter. 
     
     
         11 . The SAPI panel according to  claim 9 , wherein said each ceramic ball is 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 ). 
     
     
         12 . The SAPI panel according to  claim 9 , wherein said each ceramic ball is composed substantially of aluminum oxide (Al 2 O 3 ). 
     
     
         13 . The SAPI panel according to  claim 9 , wherein said binder is between ⅜″ and ¾″ in thickness. 
     
     
         14 . The SAPI panel according to  claim 9 , wherein said liner comprises a weave of one of aramid fibers and ultra-high-molecular-weight polyethylene (UHMWPE) fibers. 
     
     
         15 . The SAPI panel according to  claim 9 , wherein a polymer thread wraps said each ceramic ball, said thread being composed of at least one of aramid fibers, UHMWPE fibers and metal. 
     
     
         16 . The SAPI panel according to  claim 9 , wherein said plurality of ceramic balls includes inner and outer facing hexagonal layers, with inner ceramic balls being smaller than outer ceramic balls and each inner ceramic ball being disposed at a joint between adjacent outer ceramic balls.