Lightweight, Flexible Ceramic Nanocomposite Polymer Armor Plates for Next Generation Body Armor Navy SBIR FY2009.1 Sol No.: Navy SBIR FY2009.1 Topic No.: N091-005 Topic Title: Lightweight, Flexible Ceramic Nanocomposite Polymer Armor Plates for Next Generation Body Armor Proposal No.: N091-005-0726 Firm: NanoSonic, Inc. P.O. Box 618 Christiansburg, Virginia 24068 Contact: Vince Baranauskas Phone: (540) 953-1785 Web Site: http://www.nanosonic.com Abstract: The objective of this Phase I SBIR program is to develop innovative lightweight, ballistic resistant ceramic nanocomposite armor plates that may be used in place of enhanced small arms protective inserts (E-SAPI) within Interceptor Body Armor (IBA) systems. The proposed lightweight ceramic composite inserts will integrate NanoSonic's pioneering ceramic copolymer materials with shear thickening Kevlarr and Dyneemar fiber reinforced backings to provide protective armor inserts that weigh less than 4.00 lbs, provide enhanced soldier maneuverability and occupy less volume within interceptor vests than E-SAPI plates. This effort will build from NanoSonic's independently validated hybrid nanocomposite armor materials that have demonstrated 1) V50 values > 4,000 ft/s to 3/8" A36 steel plates (MIL-STD-662F), 2) multiple shot protection from 0.50 cal rounds and 3) exceptional flame resistance (time to ignition > 300 seconds and low toxicity smoke). Through these efforts, researchers will develop an array of lightweight armor inserts capable of fragmenting and catching 5.56 mm, 7.62 mm and AP rounds. The potential technological advantages of NanoSonic's lightweight, highly flexible body armor plates includes their ability to protect soldiers from multiple threats (ballistic, fragment and flame), long term environmental durability, tailorable weight and ease of integration within commonly employed composite manufacturing techniques. Benefits: NanoSonic's highly flexible, lightweight ceramic nanocomposite body armor plates have envisioned utility within a broad spectrum of armor ensembles and field protective equipment. By combining the exceptional flexibility, impact durability, flame resistance and mechanical strength of hybrid polysiloxane copolymers with reinforcing, shear thickening Kevlarr and Dyneemar composites, an innovative class of armor capable of defeating a broad spectrum of ballistic, blast and flame threats may be realized. Importantly, researchers will tailor the viscosity, processing window and cure schedule of the proposed armor panels for a graceful transition into commonly employed composite manufacturing techniques (pultrusion, compression molding, resin transfer molding (RTM), vacuum transfer molding (VARTM), prepregging and hand lay-up). Thus, researchers envision facile integration pathways within a broad spectrum of body armor technologies, as well as potential secondary utility for direct application to vulnerable exterior structures of tactical vehicles. The synthetic and manufacturing metrics of the proposed nanocomposite resins will facilitate 55-gallon Phase I scale-up opportunities thus enabling a rapid Phase III transition. Return