Multi-layer Composite for High-speed Impact Absorption
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Solution Overview
Problem
Current composite products lack sufficient impact strength and flexibility to effectively absorb and dissipate the energy from high-speed projectiles, and they are not eco-friendly or cost-effective, making them unsuitable for applications in aerospace, automotive, and construction.
Innovation Solution
A composite product is developed with multiple layers, including a thermoset composite layer made from waste hybrid composites or ceramic, a layer of glass fabric impregnated with epoxy resin, and layers of recycled PET bottles felt or HDPE woven bags, arranged in a specific sequence to enhance impact strength and damping behavior while being lightweight and flexible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a honeycomb closed cellular composite product is used to improve impact strength and reduce weight, then impact resistance is enhanced, but the product loses flexibility
Solution Approach 1:
The composite product is divided into multiple functional layers with distinct purposes: layer (a) with voids for impact energy absorption, layer (b) for structural support, layer (c) for flexibility and damping, and layer (d) as a protective outer layer. This segmentation allows each layer to specialize in one function, resolving the contradiction between impact strength and flexibility.
Solution Approach 2:
The invention uses a composite structure combining different materials in each layer: thermoset/composite materials in layer (a), glass fabric with epoxy resin in layer (b), elastomeric adhesive or rubber in layer (c), and composite material in layer (d). This composite approach enables the overall product to exhibit both high impact strength and flexibility simultaneously.
2Strength
If traditional composite products are used to provide structural strength, then strength is maintained, but impact energy dissipation is insufficient
Solution Approach 1:
Layer (a) is designed with voids or cellular structure that acts as a cushioning layer before impact reaches the structural layers. This pre-cushioning mechanism absorbs and dissipates impact energy through void collapse and material deformation, reducing the energy transmitted to the structural components.
Solution Approach 2:
Layer (a) employs porous or cellular composite material that dissipates impact energy through controlled collapse of voids and cellular structures. The porous structure provides multiple deformation mechanisms including void collapse, fiber breakage, and matrix cracking, all of which dissipate impact energy while maintaining structural integrity.
3Ease of manufacture
If waste materials like recycled PET bottles and HDPE bags are used to reduce cost and improve eco-friendliness, then manufacturing cost decreases and environmental impact is reduced, but material performance consistency may be affected
Solution Approach 1:
The invention transforms waste materials from an inconsistent variable into a controlled parameter by specifying detailed processing conditions: compression molding temperature (150-200°C), pressure (10-50 MPa), and time (5-30 minutes). These parameter controls ensure consistent material properties and performance regardless of waste material source variations.
Solution Approach 2:
Different layers are assigned different waste materials based on their specific performance requirements: layer (a) uses compressed waste composite material for impact absorption, layer (c) uses elastomeric adhesive from waste rubber for flexibility, and layer (d) uses waste composite for protective functions. This local quality assignment optimizes performance while utilizing waste materials effectively.
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 product significantly reduces the impact force and damps vibrations and shocks from high-speed projectiles, is lightweight (22-38 kg/m2), flexible, and adaptable to various shapes, while being eco-friendly and cost-effective, making it suitable for high-speed impact applications.
Implementation Method 1
the composite product substantially reduces the impact force of the high-speed projectiles or impactors and damps the vibrations and shock appeared by the impact
Implementation Method 2
damps the vibrations and shock appeared by the impact of the high-speed projectiles or impactors
Data Source
AI summary
A composite product substantially reduced the impact force imposed by hard impactor which travelled at the speed in the range of 400 m/s to 1400 m/s simultaneously damping the vibrations and shocks appeared therein is disclosed. At the same time it is light weight with the weight lower than that of 22 to 38 kg/m2and is flexible to adopt the shape suitable for the end applications. A method of manufacturing the composite product of the invention is also disclosed.