Multi-Layer Composite Armor With Tough Interfaces for Blast Resistance
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Solution Overview
Problem
Existing protective armor materials face challenges in balancing resistance to both penetrating and non-penetrating damage, with fiber-reinforced composites showing severe back projection and insufficient load-carrying capacity after impact, while traditional designs fail to effectively utilize the coupling effect of shock wave diffusion across layers.
Innovation Solution
A multi-phase composite armor material comprising a crack-arresting layer, bullet-breaking layer, energy-absorbing layer, and support layer, bonded with a high-toughness adhesive film layer, where each layer is made of specific materials to stabilize impact, dissipate energy, and provide structural stiffness, enhancing interfacial bonding strength and fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced polymer composites are used for lightweight protection, then weight is reduced and ballistic resistance is improved, but back projection occurs and load-carrying capacity decreases after impact
Solution Approach 1:
The armor is divided into multiple functional layers: a first fiber-reinforced polymer composite layer for initial impact resistance, a metal layer for maintaining structural integrity and load-bearing capacity, and a second fiber-reinforced polymer composite layer for additional ballistic protection. This segmentation allows each layer to perform its specific function, preventing back projection while maintaining reliability after impact.
Solution Approach 2:
The invention uses a composite structure combining different material types (fiber-reinforced polymers and metal) to achieve properties that single materials cannot provide. The fiber-reinforced polymer layers provide lightweight ballistic resistance, while the metal layer provides structural stability and prevents back projection, creating a synergistic effect that resolves the contradiction between weight reduction and reliability maintenance.
2Strength
If single energy dissipation design is used, then penetration resistance is improved, but protection against non-penetrating damage and multiple impacts is insufficient
Solution Approach 1:
The multi-layer composite armor structure serves multiple functions simultaneously: the fiber-reinforced polymer layers provide both penetration resistance and non-penetrating damage protection, while the metal layer provides structural support and load-bearing capacity. This multi-functionality allows the armor to protect against various types of damage including penetration, non-penetration, and multiple impacts, resolving the contradiction between specialized penetration resistance and versatile protection.
3Strength
If high in-plane tensile deformation ability is designed for penetration resistance, then axial tensile properties are fully utilized, but in-plane stiffness is reduced and depression resistance decreases
Solution Approach 1:
Different layers are assigned different mechanical properties suited to their specific functions: the fiber-reinforced polymer layers are designed with high tensile deformation ability to resist penetration, while the metal layer is designed with high in-plane stiffness to resist depression and maintain structural integrity. This local differentiation of material properties allows each layer to excel at its specific function without compromising the other, resolving the contradiction between penetration resistance and depression resistance.
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 armor material achieves high ballistic resistance, low density, and resistance to multiple shots, with improved protection against armor-piercing incendiary ammunition, maintaining structural stability and load-bearing capacity.
Implementation Method 1
adjacent two layers of the crack-arresting layer, the bullet-breaking layer, the energy-absorbing layer, and the support layer are bonded with an adhesive film layer
Implementation Method 2
the bullet-breaking layer is made of ceramic; the bullet-breaking layer is configured for energy dissipation through fragmentation
Implementation Method 3
the energy-absorbing layer is made of an ultra-high molecular weight polyethylene (UHMWPE) fiber composite; the energy-absorbing layer is configured to absorb the residual energy of a bullet
Implementation Method 4
the coupling effect of layer-by-layer diffusion of the shock wave is significant
Data Source
AI summary
A lightweight, ballistic and blast-resistant multi-phase composite armor material based on a high-toughness heterogeneous interfacial layer, including a crack-arresting layer, a bullet-breaking layer, an energy-absorbing layer, and a support layer. The crack-arresting layer, the bullet-breaking layer, the energy-absorbing layer, and the support layer are stacked in sequence from a bullet-accepting side to the inside. Adjacent two layers are bonded with an adhesive film layer. The crack-arresting layer and the support layer are both made of a carbon fiber composite. The bullet-breaking layer is made of ceramic. The energy-absorbing layer is made of an ultra-high molecular weight polyethylene fiber composite. The adhesive film layer is made of a high-toughness heterogeneous interfacial adhesive.