Ceramic-Metal Composite Bonding for Lightweight Ballistic Resistance
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Solution Overview
Problem
Existing materials struggle to effectively withstand concentrated impacts and piercing, are fragile, and require careful handling, while also being heavy and costly to maintain.
Innovation Solution
A method involving the use of ceramic and metallic components with a pre-treated surface and a thermosetting polymer adhesive to create a lightweight, high-strength composite material with improved impact resistance and delamination prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic plates are used for ballistic protection, then protective performance is improved, but the material becomes fragile and requires careful handling
Solution Approach 1:
The patent uses composite materials consisting of a ceramic layer bonded to a metallic support plate. The ceramic provides protective performance while the metallic support provides ductility and handling ease. This combination resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent modifies the ceramic material parameters by using sintered nanoparticles instead of conventional ceramic grains. This changes the mechanical properties of the ceramic layer, making it less brittle while maintaining protective performance, thus improving handling ease.
2Reliability
If conventional resistant materials are used, then protective capacity is achieved, but weight is excessive
Solution Approach 1:
The patent employs a composite structure with a thin ceramic layer (providing protection) bonded to a lightweight metallic support plate. This composite approach achieves protective capacity while minimizing weight compared to solid ceramic or solid metal plates of equivalent protection.
Solution Approach 2:
The ceramic layer is applied only where needed for protection (on the impact face), while the rest of the structure uses lightweight metal. This local application of ceramic material provides protective capacity with minimal added weight.
3Strength
If ceramic plates are used for high-speed impact resistance, then impact protection is improved, but the material becomes fragile and prone to delamination
Solution Approach 1:
The patent creates a composite material system where ceramic and metal are bonded through a controlled interface. The metallic support plate provides ductility that prevents catastrophic failure and delamination, while the ceramic layer maintains impact resistance.
Solution Approach 2:
The patent applies a bonding layer (adhesive or metallurgical bond) in advance to prevent delamination before impact occurs. This preliminary bonding action ensures the ceramic layer remains attached to the support plate during high-speed impacts.
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 composite material provides enhanced impact resistance, reduced weight, and improved multi-hit absorption, meeting level 4 ballistic protection standards with reduced material usage and cost.
Implementation Method 1
a thermosetting polymer adhesive to create a lightweight, high-strength composite material
Implementation Method 2
starting plates (13, 14) each made of a material selected from metallic materials such as steel, aluminium, brass, lead, titanium, or ceramic materials such as alumina, boron or silicon oxide
Data Source
Figure 1a~2
Figure 3~4
Figure 5
AI summary
Method for producing a composite resistant material (5), comprising the following steps: preparing at least two component bodies (13, 14, 15, 16) consisting of a material selected from fibre materials such as carbon fibre, aramid fibres, metallic or non-metallic inorganic fibres, ceramic materials such as alumina, boron or silicon carbide, metallic materials such as aluminium, brass, lead, steel, plastic materials such as polyamide, cleaning the outer coupling surface of said bodies (13, 14, 15, 16) preparing at least two adjacent bodies with a free gap (11), coating the clean surface of said bodies (13, 14, 15, 16) with an adhesive; drying said bodies (13, 14, 15, 16); pre-heating said bodies (13, 14, 15, 16) until the reduction of the surface viscosity of said adhesive; coupling said bodies (13, 14, 15, 16) with a thermosetting polymer until filling said gap (11); hardening the polymer and complete activation of the bond of said adhesive with said polymer.