# Patent

## Title
Interleaving angled hexagonal tile for flexible armor

## Abstract

An interleaving hexagonal tile (AHT) is provided for incorporation onto a liner in an array for a personnel armor clothing article. The AHT includes a hexagonally-symmetric solid object composed of a homogeneous material. The object includes a geometry that has obverse and reverse planar surfaces parallel to each other. Each planar surface has triangularly disposed terminals. First and second triple sets of oblique surfaces are disposed between the obverse and reverse planar surfaces. A plurality of facets is disposed substantially perpendicular to the planar surfaces. The facets connect between edges of the planar surfaces and adjacent edges of the oblique surfaces. The first and second triple sets of oblique surfaces are disposed to alternate with each other.

## Background
CROSS REFERENCE TO RELATED APPLICATION
The invention is a Continuation-in-Part, claims priority to and incorporates by reference in its entirety U.S. patent application Ser. No. 14/604,644 filed Jan. 23, 2015, issued as U.S. Pat. No. 9,383,172 on Jul. 5, 2016 and assigned Navy Case 103110.


STATEMENT OF GOVERNMENT INTEREST
The invention described was made in the performance of official duties by one or more employees of the Department of the Navy, and thus, the invention herein may be manufactured, used or licensed by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.


BACKGROUND
The invention relates generally to tiles for body armor. In particular, the invention relates to interlocking tiles to provide protection from small arms fire with improved flexibility.
During combat and insurgency patrol, military personnel can be subject to small-arms fire from gun-fired projectile rounds, as well as blast and fragmentation from grenades, designed to attack flesh. Personnel struck by such weapons can suffer serious or even mortal injury. To reduce vulnerability to combatants from such lethal contacts, wearable personnel armor, such as a vest with resistant-fiber mesh, has been developed. Further improvements have integrated high strength intermediary materials to further absorb or deflect kinetic impacts. Such measures have added weight and reduced flexibility for personnel so clad.
Conventional tactical body armor within the United States armed forces consists of small arms protective insert (SAPI) and Enhanced SAPI (ESAPI) ceramic trauma plates. The plates vary in performance where the SAPI plates are capable of defeating M80 ball rounds and the ESAPI is capable of defeating .30 caliber M2AP rounds. The plates are inserted within an interceptor vest which is capable of stopping 9 mm×19 mm handgun bullets. Conventional ESAPI/SAPI plates are comparatively large and bulky, and additionally limit flexibility of the wearer.
SUMMARY
Conventional body armor yield disadvantages addressed by various exemplary embodiments of the present invention. In particular, various exemplary embodiments provide an angled hexagonal tile (AHT) to incorporate as an interleaving arrayed plurality for a personnel armor clothing article. The plurality for the array is adhered onto a liner substrate. The AHT includes a hexagonally-symmetric solid object composed of a homogeneous material. The object includes a geometry that has obverse and reverse planar surfaces parallel to each other and separated by a thickness. Each planar surface has triangularly disposed terminals. Each obverse terminal is angularly offset to an adjacent reverse terminal.
In exemplary embodiments, the terminals on each corresponding planar surface have a length between a vertex at a first terminal and a center-point between second and third terminals. A first triple set of obverse-facing oblique surfaces is disposed between the obverse and reverse planar surfaces. Each obverse-facing oblique surface connects an obverse center-point on the obverse planar surface and a corresponding reverse terminal on the reverse planar surface. A second triple set of reverse-facing oblique surfaces is disposed between the obverse and reverse planar surfaces.
Each reverse-facing oblique surface connects an obverse terminal on the obverse planar surface and a corresponding reverse center-point on the reverse planar surface. A plurality of facets is disposed substantially perpendicular to the planar surfaces. The facets connect between edges of the planar surfaces and adjacent edges of the oblique surfaces. The first and second triple sets of oblique surfaces are disposed to alternate with each other.
In various embodiments, the object is composed of ceramic. In alternate embodiments, the planar surfaces form a contiguous triangular arrangement of hexagons. In other embodiments, these surfaces form a triangular boundary terminated by elongated octagons.



BRIEF DESCRIPTION OF THE DRAWINGS
These and various other features and aspects of various exemplary embodiments will be readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which like or similar numbers are used throughout, and in which:
FIG. 1 is an isometric view of a first tile configuration;
FIG. 2 is an isometric view of an array of first tiles;
FIG. 3 is an isometric view of a second tile configuration;
FIG. 4 is an isometric view of an array of second tiles;
FIG. 5A is an isometric view of a second tile configuration;
FIG. 5B is an elevation view of an array of second tiles;
FIG. 6A is an isometric view of a second tile configuration;
FIG. 6B is an isometric view of an array of second tiles;
FIG. 7 is an isometric view of a second tile configuration;
FIG. 8 is an isometric view of an array of second tiles;
FIG. 9 is an isometric view of a second tile configuration;
FIG. 10 is an isometric view of an array of second tiles;
FIG. 11 is an isometric view of a second tile configuration; and
FIG. 12 is an isometric view of an array of second tiles.



DETAILED DESCRIPTION
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized, and logical, mechanical, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
Exemplary embodiments provide an interlocking tile geometry that improves protection of a surface otherwise vulnerable to kinetic collision, such as from bullet impact. Such tiles can be arranged between substrate layers to provide contiguous yet flexible shock-absorbent material in a wearable clothing article, such as in a jacket to protect the wearer's torso. The layers can represent a variety of woven fabrics, such as aramid Kevlar® and high-modulus polyethylene Spectra®.
The tile design corresponds to a hexagonally symmetric form to represent an angled hexagonal tile (AHT) geometry. The AHTs provide three advantages including: (a) angled interfaces that reduce interstitial vulnerability from conventional tiles, (b) force distribution enhances multi-impact capability by reduced damage propagation, and (c) adhesion to one surface of the AHTs to a flexible fabric facilitates flexibility with an integrated and contiguous area of body protection from blunt force trauma.
FIG. 1 shows an isometric view 100 of a first tile configuration 110 for an AFT. A compass rose 115 shows Cartesian orientation of the first AHT 110 with x and z directions representing the facial x-z plane parallel to the surface to be shielded, and y direction denoting thickness. View 100 shows an obverse planar surface 120 (normal upward relative to y) parallel to a reverse planar surface 125 (normal downward relative to y). These planar surfaces 120 and 125 reveal a contiguous regular tri-hexagonal form.
Triple upward-facing oblique rectangular wedges 130 concatenate alternatingly with counterpart triple downward-facing oblique rectangular wedges 135. Obverse-adjacent triangular edge facets 140, 145, 150 and 155 interweave the wedges 130 and 135 with the obverse surface 120. Similarly, reverse-adjacent triangular edge facets 160, 165, 170 and 175 interweave the wedges 130 and 135 with the reverse surface 125. These triangular facets are substantially perpendicular to the planar surfaces 120 and 125 and thereby at least approximately parallel to y. The planar surfaces 120 and 125 feature three outward obtuse tips 180 flanked by six adjacent obtuse vertices 185, such that three inverse divots 190 are disposed therebetween. Effectively, tips 180 and the divots 190 yield overlapping triangles that form a Star-of-David on the planar surface 120.
Thickness of the tile 110 between the planar surfaces 120 and 125 is denoted as height H and for exemplary personnel armor can vary based on threat assessments. Expected thickness range between 1⁄4 inch and % inch. The example height illustrated in view 100 constitutes 0.50 inch (1.27 cm). Distance along the obverse surface 120 between a first tip 180 and its opposite divot 190 on the obverse surface 120 is denoted as length L, which for exemplary personnel armor can vary between one inch and five inches, depending on requirements. The example length in view 100 measures 1.25 inch (3.175 cm).
The interface angle  between the divot 190 on the obverse surface 120 and the adjacent tip 180 on the reverse surface 125 can vary from forty-five degrees to eighty degrees. The example angle in view 100 is 45° (1⁄4π radian). (By comparison, application Ser. No. 14/604,644 features a 50° angle.) The tips 180 on the obverse surface 120 and the tips 180 on the reverse surface 125 are angularly offset. In the configuration shown, this phase offset is 180° (π radians) between the corresponding obverse and reverse tips 180.
FIG. 2 shows an isometric view 200 of an array 210 of the first AHTs 110 connected together by interleaving facets. The obverse surfaces 120 and select wedges 130 and 135 along the edge are illustrated. Of the seven tiles 110 depicted, the fore unit 220 presents one tip 180 facing right, with aft unit 230, starboard unit 240 and port unit 250 sharing edges, along with a rear unit 260 behind the port unit 250. Edge transitions along the obverse surfaces 120 include corners at tip-to-divot 270, vertex-to-divot 275, and vertices junction 280. Fore and aft units 220 and 230 connect with the tip-to-divot 270.
Fore and port units 220 and 250 connect with the tip-to-divot 275. At their adjacent vertices 185, the port, aft and rear units 230, 250 and 260 connect together at their common junction 280. Similarly, complementary wedges 130 and 135 on adjacent tiles 110 face each other, as do triangular facets 140 with complements 150, along with facets 145 with 155, facets 160 with 170 and facets 165 with 175.
FIG. 3 shows an isometric view 300 of a second tile configuration 310 for the AHT. A compass rose 315 shows orientation of the second AHT 310 similarly as rose 115. View 300 shows an obverse planar surface 320 (normal upward relative to y) parallel to a reverse planar surface 325 (normal downward relative to y). These planar surfaces 320 and 325 reveal a contiguous triple elongated-octagon form. Triple upward-facing oblique hexagonal wedges 330 concatenate alternatingly with counterpart triple downward-facing oblique hexagonal wedges 335.
Obverse-adjacent triangular edge facets 340, 345, 350 and 355 interweave the wedges 330 and 335 with the obverse surface 320. Similarly, reverse-adjacent triangular edge facets 360, 365, 370 and 375 interweave the wedges 330 and 335 with the reverse surface 325. These obverse-adjacent and reverse-adjacent triangular facets are substantially parallel to y, and join at the intersections with their associated wedges 330 and 335. The planar surfaces 320 and 325 feature three outward edges 380 joined at chamfered sides of the facets by three inward edges 390. Effectively, centers of the outward edges 380 and the inward edges 390 yield overlapping triangles that form a Star-of-David on the planar surface 320.
FIG. 4 shows an isometric view 400 of an array 410 of the second AHTs 310. A compass rose 415 shows orientation of the assembly 410 with normal to the planar surfaces 320 parallel to the y-direction. The identified tiles 310 include left upper unit 420, right upper unit 430, center unit 440 and right lower unit 450. Edges of units 430, 440 and 450 join together at a junction point 460 between the edges 380 and 390.
FIG. 5A shows an isometric view 500 of a third tile configuration 510 for the AHT. View 500 shows an obverse planar surface 520 parallel to a reverse planar surface 525. The edges connecting these surfaces include lateral sides 530 and horizontal sides 535. Edges 540 connect the surfaces 520 and 525 along the intersection of the lateral and horizontal sides 530 and 535. Edges 545 connect the surfaces 520 and 525 along the intersection of the lateral sides 530. Corners 550 identify points shared by the obverse planar surface 520, the lateral side 530 and the horizontal side 535. Obverse edges 555 connect the corners 550. Corners 560 identity points shared by the obverse planar surface 520 and the lateral sides 530, and edges 565 connect the corners 550 and 560.
Corners 570 identify points shared by the reverse planar surface 525, the lateral side 530 and the horizontal side 535. Reverse edges 575 connect the corners 570. Corners 580 identity points shared by the reverse planar surface 525 and the lateral sides 530, and edges 585 connect the corners 570 and 580. FIG. 5B shows an elevation view 590 of the third tile configuration 510 with a compass rose 595. The obverse edges 555 are drawn inward compared to the reverse edges 575, so that the obverse surface 520 has greater area than the reverse surface 525.
FIG. 6A shows an isometric view 600 of an array 610 of the third AHTs 510. FIG. 6B shows an isometric view 620 of a single (third AHT 520 (third configuration) in relation to the array's geometry that forms a circular pattern 630, and the sides 585 providing reference curvature 540. The array 610 constitutes a cylindrical ring determined by the pattern 630.
FIG. 7 shows an isometric view 700 of a fourth tile configuration 710 for the AHT having a quasi-prism form. View 700 shows an upper surface 720, a lower surface 730, a front surface 740. View 700 indicates a reverse surface 750 connected to the surfaces 720, 730 and 740 by edge facets 760, 770 and 780. The tile 710 can exhibit exemplary dimensions. This includes width W, length L and thickness T. The width W is defined as the distance between the reverse surface 750 and the corner where surfaces 740, 720 and 730 join together, denoted as 0.3375 inch. The length L is defined as the distance between the upper and lower edge facets 780, and denotes 1.50 inch. The thickness T denotes the minimum distance between the front and reverse surfaces 740 and 750, and denotes 0.0625 inch.
FIG. 8 shows an isometric view 800 of an array 810 of the fourth AHTs 710. The proximal tile 710 shows the reverse surface 750. The exemplary array thickness of 0.40 inch denotes the distance between corners at the reverse surface 750 and the intersection of edges 760 and 780.
FIG. 9 shows an isometric view 900 of a fifth tile configuration 910 for the AHT having a quasi-prism. View 900 shows an upper surface 920, a lower surface 930, a front surface 940. View 900 indicates a reverse surface 950 connected to the surfaces 920, 930 and 940 by edge facets 960, 970 and 980. The tile 910 can exhibit exemplary dimensions. This includes height H and length L. The height H is defined as the distance between the reverse surface 950 and the corner where surfaces 940, 920 and 930 join together, denoted as 0.50 inch. The length L is defined as the distance between the upper and lower edge facets 980, and denotes 1.00 inch.
FIG. 10 shows an isometric view 1000 of an array 1010 of the fifth AHTs 910. The proximal tile 910 shows the reverse surface 950. The exemplary array thickness of 0.40 inch denotes the distance between corners at the reverse surface 750 and the intersection of edges 760 and 780.
FIG. 11 shows an isometric view 1100 of a sixth tile configuration 1110 for the AHT having a quasi-prism form, along with a compass rose 1115. View 1100 shows an obverse surface 1120 and indicates a reverse surface 1130. View 700 indicates corner facets 1140 and 1150 that connect the surfaces 1120 and 1130. The tile 1110 can exhibit exemplary dimensions. This includes length L and interface angle . The length L is defined as the maximum distance between the obverse and reverse surfaces 1120 and 1130, denoting 0.50 inch. The angle θ denotes the arc formed between the reverse surface and the corner facet 1140, denoted as 70° arc.
FIG. 12 shows an isometric view 1200 of an array 1210 of the sixth AHTs 1110 along with a compass rose 1215. The proximal tiles 1110 show the reverse surfaces 1130 together with corner facets 1140 in plane to form a piece-wise contiguous surface. The obverse surface 1120 is shown as providing depth to the tile structure, while corner facets 1150 provide depth-wise interfaces for the tiles 1110.
Arrays 210, 410, 610, 810, 1010 and 1210 enable force absorption from kinetic impact onto respective obverse surfaces 120, 320, 520, 720, 920 and 1120 by momentary flexing, coupled with the plastic deformation of their individual tiles 110, 310, 510, 710, 910 and 1110. In particular, flexing constitutes angular separation of the respective constituent tiles 110 and 310 from their neighbors. For example for view 200, striking the aft unit 230 causes its downward deflection in the −y direction (see rose 115). The adjacent units, including 220, 250 and 260, are constrained laterally by their substrate layers (not shown), and thus deflect by tilting, while maintaining protection against subsequent impacts without serious gaps.
Type of AHT deformation depends on composition material. The AHT can be considered to be a homogeneous substantially isotropic material. Ceramic units, such as boron carbide (B4C), silicon carbide (SiC) and alumina (Al2O3), can fracture under high compressive and shear loads. Ceramic material can also include boron carbide derivatives, such as boron carbide nitride, poly(6-cyclooctenyldecaborane) and poly(6-norbornenyldecaborane). Other more ductile materials (e.g., metals) can plastically deform without shattering, but at lower yield strengths than typical for ceramics.
To enable the development of flexible body armor that reduces blunt force trauma from a projectile strike, reduces vulnerabilities from interstitial joints, benefits from decreased weight, and increases multi-hit capability over conventional designs. The force from bullet impact against an angled hexagonal tile matrix is distributed across multiple tiles while still enabling each individual tile to flex. In addition, the angled sides reduce the vulnerabilities of the joining seams, where the angled joints can either deflect or dissipate incident threats.
Based on desire to reduce weight, increase multi-hit capability, and enhance flexibility, the AHT has been designed to satisfy these requirements. The first AHT design modifies geometry relative to the second AHT design, thereby simplifying the production, lowering the cost, and minimizing the number of interface surfaces to improve the transmission of shock waves across each other, instead of the wearer.
The AHT objects can replace the conventional SAPI/ESAPI plates with the ceramic AHTs, forming equivalent surface area coverage but with fewer gaps for improved bodily protection. Preferably, the ceramic materials are composed of either boron carbide or silicon carbide, and can be manufactured to near theoretical maximum density to provide optimal material properties. Alternative ceramics can be used, including compositions that derive from boron carbide.
The ceramic AHT units are joined together in an array and adhered to a spall liner fabric substrate. After adhesion to the liner, the AHTs 110 and/or 310 can optionally be encapsulated within polyurea foam. This technique is described in U.S. Patent Application Publication 2012/0312150, incorporated by reference in its entirety.
The exemplary AHTs can be integrated into the body armor system similar to the current SAPI/ESAPI plates as inserts. For each exemplary first AHT 110, the six peripheral faces 130 and 135 are angularly disposed in relation to the nominal hexagonal orientation, with each AHT 110 having three positively angled wedges 130 and three negatively angled wedges 135 alternating symmetrically back and forth along the periphery.
The adherence of the reverse surface 125 to the spall liner inhibits lateral tile movement. In response to kinetic impact, the AHTs 110 direct force on each neighboring tile through the angled wedges 130 and 135, enabling the impact energy to be distributed across all of the AHTs 110. The angled wedges also reduce the interstitial vulnerability at seams between tiles 110 by eliminating straight-through points. This similarly applies to the second AHT 310.
While certain features of the embodiments of the invention have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the embodiments.

## Claims

1. An angled hexagonal tile (AHT) for incorporating as an interleaving arrayed plurality into a personnel armor clothing article, said plurality being adhered a liner substrate, said AHT comprising:
a hexagonally-symmetric solid object composed of a homogeneous material, said object including a geometry that has:
obverse and reverse planar surfaces parallel to each other and separated by a thickness, each planar surface having triangularly disposed terminals, each obverse terminal being angularly offset to an adjacent reverse terminal, said terminals on each corresponding said planar surface having a length between a vertex at a first terminal and a center-point between second and third terminals;
a first triple set of obverse-facing oblique surfaces disposed between said obverse and reverse planar surfaces, each obverse-facing oblique surface connecting an obverse center-point on said obverse planar surface and a corresponding reverse terminal on said reverse planar surface;
a second triple set of reverse-facing oblique surfaces disposed between said obverse and reverse planar surfaces, each reverse-facing oblique surface connecting an obverse terminal on said obverse planar surface and a corresponding reverse center-point on said reverse planar surface; and
a plurality of facets substantially perpendicular to said planar surfaces, said facets connecting between edges of said planar surfaces and adjacent edges of said oblique surfaces, wherein said first and second triple sets of oblique surfaces are disposed to alternate with each other.

2. The AHT according to claim 1, wherein said material is a ceramic.

3. The AHT according to claim 2, wherein said material is at least one of boron carbide, silicon carbide and alumina.

4. The AHT according to claim 2, wherein said material is boron carbide.

5. The AHT according to claim 2, wherein said material is a boron carbide derivative.

6. The AHT according to claim 5, wherein said material is at least one of boron carbide nitride, poly(6-cyclooctenyldecaborane) and poly(6-norbornenyldecaborane).

7. The AHT according to claim 2, wherein said material is silicon carbide.

8. The AHT according to claim 2, wherein said material is alumina.

9. The AHT according to claim 1, wherein said terminal is a tip point and said each planar surface forms a contiguous triangular set of regular hexagons.

10. The AHT according to claim 1, wherein said terminal is an outer edge and said each planar surface forms a bounded domain that encompasses a triangular set of elongated octagons.

11. The AHT according to claim 1, wherein said obverse-facing oblique surface interfaces with an opposing reverse-facing oblique surface on a first adjacent AHT in the array, and said reverse-facing oblique surface interfaces with an opposing obverse-facing oblique surface on a second adjacent AHT in the array.

12. The AHT according to claim 1, wherein said length is between one inch and five inches, and said thickness is between 1⁄4 inch and 5⁄8 inch.