SBIR-STTR Award

The ultimate goal of this SBIR project is to develop a smart small arm protection insert embedded with a sensor network capable of self-inspection when interrogated by a separated handheld device. Phase I will focus on two highly innovative and promising technologies: a distributed fiber optic sensor and a conductive paint sensor. The PI’s extensive prior work has proved the concept and demonstrated the advantages of these sensors. In particular, the distributed fiber optic sensor can potentially locate and quantify damage in the inserts, while the conductive paint is likely to provide a simple and cost-effective solution. The Phase-I objective is to demonstrate the technical feasibility of the sensors embedded inside armor inserts for detecting ceramic cracking and delaminations. An innovative interrogation technique is proposed to significantly improve the spatial resolution and accuracy of the fiber optic sensor. Technical obstacles including closed cracks, sensitivity degradation due to bonding and insulation coating will be addressed. Critical issues associated with embedding sensors, such as survivability under the high-temperature and high-pressure manufacturing process of the inserts, will be investigated. Finally, the sensors will be embedded into the current armor inserts for evaluation of their damage detection capability. The ballistic integrity of these inserts will also be verified.

Keywords:
Smart Insert, Damage Detection, Distributed Fiber Optic Sensor, Conductive Paint Sensor, Embedded Sensors, Real-Time, In-Situ

The goal of this SBIR project is to develop a smart small arm protection insert embedded with a sensor network capable of real-time self-inspection when interrogated by a separated handheld device. Phase I successfully developed three distributed sensor technologies and demonstrated their capabilities to detect and locate fine cracks on ceramic-based armor inserts that cannot be found by visual inspection. The primary objective of this Phase II project is to develop the novel conductive sensor (selected from the three technologies) into prototype smart armor inserts. The conductive sensor not only has a high sensitivity and reliability, but also is installed on sides of the armor insert, a significant advantage over other sensors that require surface bonding. The sensor is ultra-thin, lightweight, and the interrogation device can be made as small as a key. The total cost of the sensor and installation will be extremely low. The Phase II work will focus on optimal design of the sensor system, and development of rapid, low-cost sensor fabrication/installation techniques compatible with the current armor insert fabrication processes. Prototype smart armor inserts will delivered to the US Army, and the sensor sensitivity, repeatability, reliability, durability, ease of installation, and ease of operation will be demonstrated.

Keywords:
Smart Armor Insert, Crack Detection, Sensor Tape, Sensor Key, Real-Time, In-Situ, Low-Cost, Inspection