Boron Carbide Sheet Lamination for Lightweight Shock Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shock absorbing members using ceramic materials are often heavy, difficult to scale, and costly, with previous approaches complicating production and increasing weight, which hinders practical application in protective equipment.
Innovation Solution
A shock absorbing member is created by bonding multiple sheet-like ceramic members with a bonding layer containing aluminum, copper, or gold, allowing for efficient energy absorption and reduced weight, featuring a stepwise thickness increase and voids at the bonding interface to enhance shock wave deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective member is made by combining ceramic materials with different properties or same kind with different porosity to achieve intended function, then the member can exhibit desired shock absorption properties, but the production steps become complicated and cost increases
Solution Approach 1:
The ceramic member is divided into multiple thin sheets (5-1000 sheets) with thickness of 0.1 to 50 mm each, which are then laminated and bonded together. This segmentation allows the use of a simpler bonding process while achieving the desired shock absorption function through the layered structure itself.
Solution Approach 2:
The invention changes the bonding parameters by using metal bonding materials (Al, Cu, Ag, Au) and controlling the bonding temperature (600-1600°C) and pressure (30 kPa or less), enabling simplified production while maintaining reliability.
2Reliability
If a protective member combines multiple ceramic materials with different properties to achieve intended function, then the member can exhibit desired shock absorption properties, but the cost increases
Solution Approach 1:
The invention uses sheets containing the same ceramic material (60 mass% or more boron carbide) throughout the laminated structure, eliminating the need for multiple different ceramic materials. This homogeneous approach reduces material costs while maintaining shock absorption performance.
Solution Approach 2:
The invention employs inexpensive metal bonding materials such as aluminum and copper instead of expensive specialized ceramic bonding materials, significantly reducing production cost while achieving reliable bonding between sheets.
3Strength
If a laminated sintered body is produced by sintering under pressurization to achieve structural integrity, then the member can be produced, but it becomes difficult to increase in size
Solution Approach 1:
The invention divides the large-sized member into multiple thin sheets that are bonded together. This allows the production of large-sized shock absorbing members by assembling smaller, manageable sheets without requiring high-pressure sintering of the entire large structure.
Solution Approach 2:
The invention replaces the high-pressure sintering mechanical system with a low-pressure bonding system using metal bonding materials, enabling the production of large-sized members that would be difficult to produce by conventional pressurized sintering.
4Reliability
If a shock absorbing member uses a thick single-layer ceramic structure to absorb shock energy, then the member can provide sufficient protection, but the weight increases
Solution Approach 1:
The invention divides a thick single-layer structure into multiple thin sheets (5-1000 sheets), each contributing to shock absorption. This segmented approach provides sufficient protection while reducing overall weight compared to a solid thick layer.
Solution Approach 2:
The invention creates a composite structure by bonding multiple ceramic sheets with metal bonding materials, achieving a lightweight yet strong shock absorbing member that combines the advantages of ceramic hardness with reduced weight.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lightweight, high-performance shock absorbing member capable of effectively destroying high-speed projectiles, minimizing fragment energy and preventing shock wave transmission, while being cost-effective and easier to produce.
Implementation Method 1
a step of forming the ceramic bonded body by heating the obtained laminated body at a temperature of 600 to 1600°C
Implementation Method 2
at least one metal selected from the group consisting of aluminum, copper, silver, and gold is used as bonding material in the bonding layer
Implementation Method 3
a function of absorbing energy that a high-speed projectile or the like has with a high efficiency
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
A shock absorbing member 50 having a ceramic bonded body 15 having: a plurality of first sheet-like members 5 each having a ceramic containing 60 mass% or more of boron carbide and each having a thickness of 0.1 to 50 mm; and a bonding layer arranged between the first sheet-like members 5 adjacent to each other, the bonding layer bonding surfaces to be bonded facing each other of the first sheet-like members adjacent to each other, wherein the bonding layer has a bonding material containing at least one metal selected from the group consisting of aluminum, copper, silver, and gold.