3D Ceramic Inclusion Composite for Ballistic and EMI Shielding
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Solution Overview
Problem
Current composite structures face challenges in simultaneously achieving structural, ballistic, and electromagnetic performance, with limited success in integrating these functionalities into a single composite structure, often relying on auxiliary or 'parasitic' structures that complicate material interactions and performance.
Innovation Solution
A method involving a preform with substrates and ceramic material deposits, arranged in a layered configuration to form three-dimensional ceramic elements, integrated within a resinous or elastomeric matrix, allowing for geometric shaping to achieve combined structural, ballistic, and electromagnetic functionalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auxiliary or parasitic structures are used to impart armor or electromagnetic character to a structural composite, then electromagnetic or armor-protective performance is enhanced, but device complexity increases and material interactions become problematic
Solution Approach 1:
The patent combines structural, armor-protective, and electromagnetic functionalities into a single integrated composite structure. The composite laminate includes ceramic layers for armor protection, polymer layers for structural support, and conductive layers for electromagnetic shielding, all bonded together as one unit rather than separate auxiliary structures.
Solution Approach 2:
The composite structure is designed to perform multiple functions simultaneously: the ceramic layers provide both structural rigidity and ballistic protection, the polymer layers provide structural support and toughness, and the conductive layers provide electromagnetic interference shielding while being integrated within the same laminate structure.
2Productivity
If multiple functionalities are integrated into a single composite structure, then performance efficiency improves, but manufacturing difficulty increases
Solution Approach 1:
The composite structure is divided into distinct functional layers (ceramic layers, polymer layers, conductive layers) that can be manufactured and prepared separately, then bonded together through lamination. This segmentation allows each layer to be optimized and manufactured independently while achieving integrated multi-functionality in the final structure.
Solution Approach 2:
The patent uses a composite laminate structure combining different materials (ceramics, polymers, conductive materials) in distinct layers. Each material is selected for its specific properties, and the composite structure achieves multi-functionality by leveraging the combined properties of these different materials in a laminated configuration.
3Reliability
If traditional parasitic structures are used for electromagnetic shielding, then electromagnetic performance is achieved, but weight and thickness increase
Solution Approach 1:
The electromagnetic shielding function is merged with the structural and armor layers in a single integrated laminate. The conductive layers are bonded between or within the ceramic and polymer layers, eliminating the need for separate electromagnetic shielding structures and reducing overall weight and thickness.
Data Source
AI summary
According to exemplary inventive practice, ceramic powder or slurry is selectively deposited at many discrete locations on each of many fiberglass fabric substrates. The sizes and/or shapes of the ceramic deposits vary among the substrates. The substrates are selectively ordered and stacked so that perpendicular through-plane alignments of respective ceramic deposits form selected three-dimensional geometric shapes. The resultant stack of substrates, characterized by many three-dimensional ceramic inclusions, is impregnated with an elastomer or an epoxy that binds the ceramic-deposited substrates together, resulting in a finished composite product. Inventive composite structures can be multifariously designed and embodied to afford selected ballistic and/or structural and/or electromagnetic qualities. Another mode of inventive practice provides for incorporation of the above-described inventive composite product as a layer in a multilayer composite system that also includes a high strain-rate-sensitivity-hardening polymer layer, a hybrid composite fabric layer, a ceramic layer, and a polymeric ballistic fabric layer.