Patent ID: 7838079

Claim:
A method for producing an armor system, comprising: forming a core material comprising a front surface, a back surface, at least one side surface, and a thickness between the front surface and the back surface; providing a stream of atomized coating material having a material composition and comprising a liquid fraction and a solid fraction; depositing an initial layer of the coating material having the material composition on at least the front surface and the back surface of the core material by positioning the core material in the stream of atomized coating material wherein the solid fraction of the coating material in the stream of atomized coating material is less than the liquid fraction of the coating material in the stream of atomized coating material on a weight basis; depositing another layer of the same coating material having the material composition on the initial layer of the coating material by positioning the core material in the stream of atomized coating material wherein the solid fraction of the coating material in the stream of atomized coating material is greater than the liquid fraction of the coating material in the stream of atomized coating material on a weight basis; forming the initial layer and the another layer of the coating material to have a first combined thickness on the front surface of the core material; and forming the initial layer and the another layer of the coating material to have a second combined thickness on the back surface of the core material at least about three times the first combined thickness of the initial layer and the another layer of the coating material on the front surface of the core material.