Bonded Hard-Soft Laminate Structure for Impact Debris Suppression
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Solution Overview
Problem
Existing impact-resistant laminated articles have insufficient impact resistance and lack practical utility due to non-bonded or lightly bonded composites, which results in inadequate debris suppression during severe impacts.
Innovation Solution
A laminated article is created by unifying a layer of soft composite material with thermotropic liquid crystal polymer (LCP) fibers and a thermoplastic polymer with a layer of hard composite material containing thermosetting polymers and hard reinforcing fibers, enhancing impact resistance and integrity through bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard composite and soft composite are laminated in a non-bonded or lightly bonded fashion to increase impact strength, then the impact strength is improved, but the laminated article lacks practical utility due to insufficient unity and integrity
Solution Approach 1:
A thermoplastic resin layer is introduced as an intermediary bonding agent between the hard composite layer and soft composite layer. This thermoplastic resin melts during lamination and solidifies to create strong adhesion, serving as a mediator that achieves both strong bonding for practical utility and maintains the impact-absorbing characteristics of the soft composite
Solution Approach 2:
The invention creates a multi-layer composite structure combining hard composite (carbon fiber/epoxy), thermoplastic resin, and soft composite (aramid fiber/ionomer polymer). This composite material approach allows each layer to contribute its specific properties: hard composite for structural strength, thermoplastic for bonding, and soft composite for impact absorption, achieving both high impact strength and practical utility
2Strength
If severe impact is applied to the laminated article, then the impact absorbing ability is activated, but the material scatters and creates debris
Solution Approach 1:
The soft composite layer comprising aramid fibers and ionomer polymer is positioned as an outer layer that absorbs impact energy before it can cause catastrophic failure. This layer acts as a cushion that deforms plastically under impact, preventing the hard composite from shattering into debris while maintaining structural integrity
Solution Approach 2:
The combination of hard composite and soft composite materials creates a gradient structure where the soft outer layer captures and dissipates impact energy through plastic deformation, while the bonded hard composite layer maintains overall structural integrity, preventing debris generation
3Reliability
If the soft composite is made from aramid fibers and ionomer polymer to prevent tearing, then the material integrity is improved, but the impact resistance remains insufficient
Solution Approach 1:
The invention merges the advantages of both hard composite and soft composite materials into a single laminated structure. The hard composite layer provides high impact resistance and structural strength, while the soft composite layer maintains material integrity and prevents tearing, achieving both objectives simultaneously through their synergistic combination
Solution Approach 2:
The multi-layer composite structure allows the hard composite (carbon fiber/epoxy) to provide impact resistance while the soft composite (aramid fiber/ionomer polymer) provides material integrity. The thermoplastic resin bonding layer ensures strong adhesion between these layers, enabling both materials to function at their optimal performance levels
Data Source
AI summary
Provided is a laminated article excellent in impact resistance, and capable of suppressing scattering of a material even when subjected to an impact. The laminated article comprises a layer of a hard composite material comprising at least a hard reinforcing fiber and a thermosetting polymer used as matrix thereof; and a layer of a soft composite material comprising at least a soft reinforcing fiber and a polymer used as matrix thereof, the soft composite layer being laminated to the hard composite layer so as to be unified with each other. The soft reinforcing fiber comprises at least a thermotropic LCP fiber, and the soft composite material comprises a fabric made of the soft reinforcing fiber. The thermotropic LCP fiber may be a multifilament yarn having a single fiber fineness of about 1 to 15 dtex and a total fineness of about 100 to 3,000 dtex.