# US 11,441,875 B2 · Multi-layer wearable body armor

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- Number: US 11,441,875 B2
- Document ID: US11441875B2
- Status: Granted
- Kind: B2
- Application number: 17/307,509
- Filed: 2021-05-04
- Published: 2021-12-23
- Granted: 2022-09-13
- Earliest claimed: 2018-12-04
- Assignees: Honeywell Federal Manufacturing & Technologies, LLC
- Applicants: Honeywell Federal Manufacturing & Technologies, LLC
- Inventors: Christian G. Barr; Justin Tannehill
- Web page: https://patentgrep.com/patent/US11441875B2

## CPC

- F41H 5/0442: {Layered armour containing metal (in combination with ceramic layers F41H5/0421; heat treatment of armour plate C21D9/42)}
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- F41H 5/04: composed of more than one layer {(outerwear resistant to mechanical aggressions A41D31/24; layered products B32B; shaping reinforced articles B29C67/00)}
- F41H 5/0457: {Metal layers in combination with additional layers made of fibres, fabrics or plastics}
- F41H 5/0492: {Layered armour containing hard elements, e.g. plates, spheres, rods, separated from each other, the elements being connected to a further flexible layer or being embedded in a plastics or an elastomer matrix}
- F41H 5/08: for personal use {, i.e. hand held shields}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 15/046: {of foam}
- B32B 15/16: next to a particulate layer
- B32B 2260/025: Particulate layer
- B32B 2264/04: Cellulosic particles, e.g. rayon
- B32B 2307/558: Impact strength, toughness
- B32B 2571/02: defensive, e.g. armour plates or anti-ballistic clothing
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- Y02P 10/25: Process efficiency
- F41H: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## 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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 2)

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.

### Claim 6 (depends on 5)

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

### Claim 7 (depends on 1)

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

### Claim 8 (depends on 1)

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.

### Claim 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.

### Claim 10 (depends on 9)

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.

### Claim 11 (depends on 9)

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.

### Claim 12 (depends on 9)

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

### Claim 13 (depends on 12)

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

### Claim 14 (depends on 9)

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.

### Claim 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.

### Claim 16 (depends on 15)

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.

### Claim 17 (depends on 15)

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

### Claim 18 (depends on 17)

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

### Claim 19 (depends on 17)

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

### Claim 20 (depends on 15)

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