# US 8,464,626 B2 · Multi-layer metal matrix composite armor with edge protection > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,464,626 B2 - Document ID: US8464626B2 - Status: Granted - Kind: B2 - Application number: 12/592,233 - Filed: 2009-11-20 - Published: 2012-07-26 - Granted: 2013-06-18 - Earliest claimed: 2009-11-20 - Assignees: CPS Technologies Corp - Applicants: Richard Adams; Renee MacPherson; Jim Sorensen - Inventors: Richard Adams; Renee MacPherson; Jim Sorensen - Web page: https://patentgrep.com/patent/US8464626B2 ## CPC - F41H 5/0442: {Layered armour containing metal (in combination with ceramic layers F41H5/0421; heat treatment of armour plate C21D9/42)} - 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: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL ## Abstract The armor tile system embodying the principles of the present invention comprises one or more hybrid tiles which can be connected together to cover a protected structure. Various arrays of material layers may be utilized (1×1, 2×2, 4×4, 2×8, etc) within a hybrid tile system and multiple hybrid tiles may be mounted on the area to be protected. Each hybrid tile comprises one or more material layers stacked within a single metal matrix casting. Each material layer within a hybrid tile includes at least one reinforcement insert arranged along a common surface. The reinforcement inserts comprise material types suitable for containment, structural support, and projectile deflection and destruction. The armor tile system of the present invention is created utilizing a molten metal infiltration process. In the preferred embodiment, the reinforcement inserts are arranged along a common surface within each material layer and further positioned within the mold cavity to create a controlled inner seam between adjacent reinforcement inserts to keep the reinforcement inserts from shifting during metal infiltration. The outer periphery of the material layer(s) and the mold cavity inside periphery has a space defining an outer seam. Both the outer and inner seams may further contain a reinforcement material to enhance the effectiveness of the armor system if desired. The mold cavity is infiltrated with liquid metal which solidifies within the materials open porosity thereby binding the layers together to create a coherent integral structure. ## Claims ### Claim 1 A hybrid tile metal matrix composite armor, formed by placing at least one material layer in a closed mold cavity, the outer periphery of the at least one material layer and the mold cavity inside periphery having a space defining an outer seam, comprising: at least one material layer, said at least one material layer comprising at least one first reinforcement insert arranged along a common surface, said at least one first reinforcement inserts comprising a reinforcing material having a fraction of void volume, said first reinforcement inserts having at least one inner seam between a plurality of said at least one first reinforcement inserts; said at least one material layer further comprising an outer seam, said fraction of void volume in said at least one reinforcement material and said inner seam and said outer seam further comprising a metal, said metal infiltrated within said fraction of void volume and within said inner and outer seams, said metal infiltration forming an encapsulating layer within said outer seam. ### Claim 2 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said reinforcement material fraction of void volume ranges from about 0 percent to about 99 percent. ### Claim 3 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, further comprising a second reinforcement insert, said second reinforcement insert positioned in at least one of said at least one inner seam between said plurality of said at least one first reinforcement insert, said second reinforcement insert having a fraction of void volume, said void volume further comprising a metal infiltrated within said void volume. ### Claim 4 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, further comprising a second reinforcement insert, said second reinforcement insert positioned in said outer seam, said second reinforcement insert having a fraction of void volume, said void volume further comprising a metal infiltrated within said void volume. ### Claim 5 (depends on 4) A hybrid tile metal matrix composite armor as in claim 4, wherein said second reinforcement insert is positioned in a portion of said outer seam. ### Claim 6 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said encapsulating layer further includes a plurality of post structures extending outward therefrom. ### Claim 7 (depends on 6) A hybrid tile metal matrix composite armor as in claim 6, wherein said plurality of post structures have variable diameters, lengths, and spacings therebetween. ### Claim 8 (depends on 6) A hybrid tile metal matrix composite armor as in claim 6, further including a backing plate, said backing plate affixed to said plurality of post structures extending outward from said encapsulating layer. ### Claim 9 (depends on 8) A hybrid tile metal matrix composite armor as in claim 8, wherein said backing plate includes top surface mounting recesses, said mounting recesses engaging said plurality of post structures extending outward from said encapsulating layer. ### Claim 10 (depends on 8) A hybrid tile metal matrix composite armor as in claim 8, wherein said plurality of post structures include a fixed length plurality of short and long posts. ### Claim 11 (depends on 10) A hybrid tile metal matrix composite armor as in claim 10, wherein said backing plate includes top surface mounting recesses, said mounting recesses engaging said plurality of long fixed length posts up to a point when said plurality of short fixed length post ends are flush with said backing plate top surface. ### Claim 12 (depends on 11) A hybrid tile metal matrix composite armor as in claim 11, wherein a space exists between said plurality of short fixed length posts ends and said backing plate top surface. ### Claim 13 (depends on 12) A hybrid tile metal matrix composite armor as in claim 12, wherein said space is filled with a reinforcing material. ### Claim 14 (depends on 6) A hybrid tile metal matrix composite armor as in claim 6, wherein said plurality of post structures are a fixed length. ### Claim 15 (depends on 6) A hybrid tile metal matrix composite armor as in claim 6, wherein the space between said plurality of post structures extending outward from said encapsulating layer are filled with a reinforcing material. ### Claim 16 (depends on 6) A hybrid tile metal matrix composite armor as in claim 6, wherein said plurality of post structures have a surface area density from about 2% to about 40% of the surface area of said hybrid tile metal matrix composite armor. ### Claim 17 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said metal matrix composite armor further includes a backing plate, said backing plate spaced away from said encapsulating layer. ### Claim 18 (depends on 17) An integrated layered armor as in claim 17, wherein said spaced away backing plate is substantially parallel to said containment layer. ### Claim 19 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said reinforcing material of said at least one reinforcement insert is a dense material having from zero to a fraction of void volume at said dense material surface and no interconnected void volume within said dense material interior that is connected to said dense material surface, said dense material void volume infiltrated with metal. ### Claim 20 (depends on 19) A hybrid tile metal matrix composite armor as in claim 19, wherein said dense material has a thickness from about 0.02 inches to about 2 inches. ### Claim 21 (depends on 19) A hybrid tile metal matrix composite armor as in claim 19, wherein said dense material comprises a ceramic material selected from the group consisting of aluminum oxide, silicon carbide, boron carbide, silicon nitride and chemical vapor deposit diamond. ### Claim 22 (depends on 19) An integrated layered armor as in claim 19, wherein said dense material comprises a metal material selected from the group consisting of titanium, tungsten, molybdenum, and depleted uranium. ### Claim 23 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said inner seam thickness is from about 0.01 inches to about 0.5 inches. ### Claim 24 (depends on 23) A hybrid tile metal matrix composite armor as in claim 23, wherein said outer seam thickness is at least one half of said inner seam thickness. ### Claim 25 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said at least one reinforcement inserts have equivalent surface areas. ### Claim 26 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said at least one reinforcement insert is at least 0.005 inches thick. ### Claim 27 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said at least one reinforcement insert is at least from about 0.25 inch by 0.25 inch up to the size of said at least one material layer. ### Claim 28 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said hybrid tiles are mounted adjacent to each other. ### Claim 29 (depends on 28) A hybrid tile metal matrix composite armor as in claim 28, wherein said adjacently mounted hybrid tiles are spaced 0 to 0.01 inches apart for optimum ballistic deterrence. ### Claim 30 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said metal infiltrant is selected from the group consisting of aluminum alloys, copper, titanium, magnesium, and ferrous alloys. ### Claim 31 (depends on 1) A hybrid tile metal matrix composite armor as in claim 1, wherein said at least one reinforcement insert comprises a reinforcement material selected from the group consisting of ceramic, glass, or glass-ceramic, including oxides and non-oxide ceramics, graphite and carbon formed materials. ### Claim 32 (depends on 1) An integrated layered armor as in claim 1, wherein said at least one first reinforcement insert comprises a hollow microsphere filler material. ### Claim 33 (depends on 32) An integrated layered armor as in claim 32, wherein said hollow microsphere filler material comprises a plurality of lightweight, inert, hollow spheres filled with air, said spheres being hermetic and strong enough to withstand the pressures and temperatures of metal infiltration casting. ### Claim 34 (depends on 1) An integrated layered armor as in claim 1, wherein said at least one first reinforcement insert comprises a 3-D wire mesh. ### Claim 35 (depends on 34) An integrated layered armor as in claim 34, wherein said 3-D wire mesh is bonded to a backing plate. ### Claim 36 (depends on 35) An integrated layered armor as in claim 35, wherein said 3-D wire mesh is fusion bonded or sintered or woven to join the material layers. ### Claim 37 (depends on 1) An integrated layered armor as in claim 1, wherein said at least one first reinforcement insert comprises a plurality of hard angular faceted particles. ### Claim 38 (depends on 37) An integrated layered armor as in claim 37, wherein said hard angular faceted particles are 0.001 to 1 inch in diameter. ### Claim 39 (depends on 38) An integrated layered armor as in claim 38, wherein said particles are selected from the group consisting of Silicon Carbide, Boron Carbide and Aluminum Oxide. ### Claim 40 (depends on 37) An integrated layered armor as in claim 37, wherein said at least one first reinforcement insert comprising hard angular faceted particles is positioned as the outermost layer of said at least one material layer. ### Claim 41 (depends on 1) An integrated layered armor as in claim 1, wherein said at least one material layer comprises a top layer, a bottom layer and a middle layer, said top layer including a top reinforcement insert, said bottom layer including a bottom reinforcement insert, and said middle layer including a middle reinforcement insert, said top, bottom and middle layer further comprising a metal therein. ### Claim 42 A hybrid tile metal matrix composite armor, formed by placing at least one material layer in a closed mold cavity, the outer periphery of the at least one material layer and the mold cavity inside periphery having a space defining an outer seam, comprising: at least one material layer, said at least one material layer comprising at least one first reinforcement insert arranged along a common surface, said at least one first reinforcement insert comprising a reinforcing material having a fraction of void volume, said first reinforcement insert having at least one inner seam between a plurality of said at least one first reinforcement inserts; said at least one material layer further comprising an outer seam, said at least one inner seam between said plurality of said at least one first reinforcement insert and said outer seam further comprising a second reinforcement insert positioned therein, said second reinforcement insert having a fraction of void volume, said void volume of said first and second reinforcement inserts further comprising a metal infiltrated within said void volume, said metal infiltration forming an encapsulating layer within said second reinforcing material positioned in said outer seam.