CN116481381A - 一种蜂窝-封装复合增强陶瓷金属装甲及其制备方法 - Google Patents
一种蜂窝-封装复合增强陶瓷金属装甲及其制备方法 Download PDFInfo
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Abstract
本发明涉及轻质防弹装甲及其制备方法,具体涉及一种蜂窝‑封装复合增强陶瓷金属装甲及其制备方法,解决了现有的防弹装甲连接强度小、防护不均匀、受到弹丸打击时损伤区域大,或者是UHMWPE难以有效固定的技术问题。本发明提供的蜂窝‑封装复合增强陶瓷金属装甲以一体化蜂窝网格金属点阵为框架和背板,在蜂窝网格结构的网格孔内镶嵌陶瓷块,其外部为交替正交缠绕的双股超高分子量聚乙烯纤维增强复合材料预浸料,可限制损伤区域,增强结构一体性和防护均匀性,有效提升抗侵彻性能。本发明还提供一种蜂窝‑封装复合增强陶瓷金属装甲的制备方法,内部采用铣削成型,外部采用双股预浸料交替正交缠绕后一体热压成型,工艺简单且成本低廉,易于规模化生产。
Description
技术领域
本发明涉及轻质防弹装甲及其制备方法,具体涉及一种蜂窝-封装复合增强陶瓷金属装甲及其制备方法。
背景技术
随着时代的发展特别是战争形态的演进,单纯依靠装甲尺寸和质量的增加进行防护已不能满足新形势下的防护要求,装甲防护设计正朝着新概念、新原理、新结构和新材料等方向发展,装甲系统也从传统均质装甲转向复合装甲。针对防护需求的多样化,装甲需要兼具低密度、高性能、多功能等特点,还需要具备模块化装配功能以适应复杂表面和低损伤区域,使装甲具备抗多次打击的防护能力等特性。
传统的陶瓷/金属双层装甲在受到弹丸打击时,作为迎弹面的整块陶瓷发生脆性断裂,会产生快速扩展且贯穿整个表面的裂纹。同时,陶瓷与金属间连接方式为胶粘,其连接强度的不足会导致陶瓷受到弹丸打击后严重剥落。马赛克装甲通过减小陶瓷的尺寸,将整块陶瓷替换为马赛克状排列的拼接陶瓷。这种拼接陶瓷结构虽然可以一定程度上限制损伤区域的扩展,但是具有拼接缝隙脆弱、陶瓷剥落严重及防护性能不均匀等缺点。因此,有必要提出一种改进的设计方案,以避免当前拼接装甲的固有缺点。
为适应现代战争的需求,在现有技术中,研究者开发了大量的纤维增强复合材料,其中,超高分子量聚乙烯纤维增强复合材料(以下简称UHMWPE)因其良好的抗侵彻性能和低密度的特点,被越来越多地应用于轻质防弹装甲中。但在实际应用中,一方面由于UHMWPE的低摩擦系数及较低的表面粗糙度,导致UHMWPE很难与其他材料有效结合;另一方面,由于UHMWPE的大变形能量耗散方式,在受到冲击时UHMWPE的边界难以进行有效夹持,使其在装甲系统中与其他材料脱离,从而导致装甲防护性能的降低。因此,UHMWPE的有效固定成为了装甲防护性能充分发挥的关键。
发明内容
本发明的目的是解决现有的防弹装甲连接强度小、防护不均匀、受到弹丸打击时损伤区域大,或者是UHMWPE难以有效固定的技术问题,而提供一种蜂窝-封装复合增强陶瓷金属装甲及其制备方法。
为实现上述目的,本发明采用的技术方案为:
一种蜂窝-封装复合增强陶瓷金属装甲,其特殊之处在于:包括内装甲和对内装甲进行封装的外装甲;
所述内装甲包括一体化蜂窝网格金属点阵,以及与所述一体化蜂窝网格金属点阵的蜂窝网格适配的陶瓷块;
所述一体化蜂窝网格金属点阵为采用金属材料一体成型的多边形蜂窝网格结构;所述多边形蜂窝网格结构包括背板,以及设置在背板上的多边形蜂窝网格;
所述多个陶瓷块分别镶嵌在多边形蜂窝网格的每个网格孔内;
所述外装甲为双股交替正交缠绕在内装甲表面的预浸料,所述双股交替正交缠绕是指由两张预浸料以相互垂直并且交替的方式进行缠绕,所述预浸料为超高分子量聚乙烯纤维增强复合材料预浸料。
进一步地,所述超高分子量聚乙烯纤维增强复合材料预浸料的叠层方式为[(90/0)2(90/0)2]N。
进一步地,所述一体化蜂窝网格金属点阵为采用金属材料一体成型的四边形蜂窝网格结构或者六边形蜂窝网格结构,工艺简单、结构强度大。
本发明还提供一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,用于制造上述的蜂窝-封装复合增强陶瓷金属装甲,其特殊之处在于,包括以下步骤:
S1、制备长为l,宽为w,厚度为h的金属板,清洗金属板,去除其表面的油污和锈迹;
S2、将步骤S1得到的金属板进行铣削处理,得到一体化蜂窝网格金属点阵,所述一体化蜂窝网格金属点阵的蜂窝网格结构中每个网格孔的边长为d,间距为t、深度为h1,其中,h1<h,h-h1为背板厚度;
S3、选取陶瓷原料,并对其进行粗处理,随后再进行精细研磨,制得边长为d,厚度为h1的陶瓷块;
S4、将步骤S3制备的陶瓷块涂覆胶粘剂后,分别嵌入一体化蜂窝网格金属点阵1蜂窝网格结构的每个网格孔内,得到具有蜂窝/陶瓷复合结构的内装甲;
S5、沿纤维分布的平行方向或垂直方向裁剪两卷宽度分别为l和w的预浸料;
S6、利用所述两卷宽度分别为l和w的预浸料对步骤S4得到的内装甲以相互垂直并且交替的方式进行缠绕封装;
S7、将经步骤S6封装的内装甲放入热压模具中,进行热压固化成型,得到蜂窝-封装复合增强陶瓷金属装甲。
进一步地,所述步骤6具体为:
将宽度为l的预浸料一端沿内装甲的宽度方向固定于内装甲上,宽度为w的预浸料一端沿内装甲的长度方向固定于内装甲上,所述两卷宽度分别为l和w的预浸料在内装甲上交替正交缠绕各N圈,使每卷预浸料的外层纤维方向均平行或垂直于内装甲的蜂窝/陶瓷复合结构的边缘;
所述N不小于2。
进一步地,所述步骤S1中还包括:
为防止外部预浸料受内装甲边缘剪切作用提前失效,无法充分变形吸能,清洗前对所述金属板的边缘做倒角处理,所述金属板的边缘倒角半径为1~3mm。
进一步地,步骤S2中,所述蜂窝网格的边长d大于拟防护的入射弹丸直径,间距t为拟防护的入射弹丸直径的10%~15%,深度h/2≤h1≤2h/3。
进一步地,步骤S7中,所述进行热压固化成型的具体步骤为:
将经步骤S6封装的内装甲依次通过模具预热、加热加压、保温保压、冷却保压和卸载出模进行热压固化成型。
进一步地,所述步骤S7具体为:
S7.1、将经步骤S6封装的内装甲放入热压模具后进行合模,将热压模具预热至100℃,且在不施加压力的情况下保持100℃的温度5~10min,使经封装的内装甲的温度均匀;
S7.2、将热压模具的加热温度设定为120℃,压力增加至不小于16.5MPa;
S7.3、保持步骤S7.2设定的温度与压力20~30min;
S7.4、使热压模具停止加热,压力保持不变,对经封装的内装甲进行冷却;
S7.5、当经封装的内装甲的温度低于60℃时,将压力卸载,得到蜂窝-封装复合增强陶瓷金属装甲。
进一步地,所述步骤S7.1中,由于预浸料受热后的粘性,为方便成型后卸载出模,将经步骤S6封装的内装甲放入热压模具后,在经封装的内装甲与热压模具间插入厚度不超过1mm的耐高温材料。
与现有技术相比,本发明具有的有益技术效果如下:
1、本发明提供的蜂窝-封装复合增强陶瓷金属装甲,内部采用蜂窝网格结构,可阻断裂纹的扩展、加强各组分间的连接、减少结构中防护薄弱的区域,能保持撞击点周边陶瓷与背板间的有效连接,有效支撑和约束陶瓷,并通过塑性变形耗散能量;外部使用UHMWPE进行封装,通过UHMWPE大变形能量耗散方式吸收能量,一体封装后的UHMWPE具有自固定效果,有效提升了UHMWPE的材料防护效力,避免了自由边界及螺栓固定边界导致的防护性能降低,提升了等质量下装甲可承受的弹道极限速度;由于蜂窝-封装的联合强化作用,使装甲结构具备限制损伤区域、增强结构一体性和防护均匀性等性能;同时,在面密度无明显增加的情况下,有效提升了装甲结构的抗侵彻性能。
2、本发明提供的蜂窝-封装复合增强陶瓷金属装甲为一个模块,实际使用中可单模块使用,或多模块集合使用。
3、本发明提供的蜂窝-封装复合增强陶瓷金属装甲制备方法采用内部框架铣削成型,外部双股交替正交缠绕后一体热压成型的制备方法,工艺简单且成本低廉,易于对不同规格尺寸的轻质复合装甲进行规模化生产。
4、本发明提供的蜂窝-封装复合增强陶瓷金属装甲制备方法中边缘倒角取1~3mm,可防止外部UHMWPE受内装甲边缘剪切作用提前失效,无法充分变形吸能。
5、本发明提供的蜂窝-封装复合增强陶瓷金属装甲制备方法中,在蜂窝-封装复合增强陶瓷金属板与热压模具间插入厚度不超过1mm的耐高温材料,方便加热成型后卸载出模。
附图说明
图1为本发明提供的蜂窝-封装复合增强陶瓷金属装甲实施例的结构示意图;
图2a为本发明实施例中一体化蜂窝网格金属点阵铣削及陶瓷块镶嵌示意图Ⅰ;
图2b为本发明实施例中一体化蜂窝网格金属点阵铣削及陶瓷块镶嵌示意图Ⅱ;
图2c为本发明实施例中一体化蜂窝网格金属点阵铣削及陶瓷块镶嵌示意图Ⅲ;
图3为本发明实施例中双股交替正交缠绕封装形式示意图;
图4为本发明实施例的热压成型温度-压力时程曲线图;
图5a为本发明提供的蜂窝-封装复合增强陶瓷金属装甲实施例与传统陶瓷/金属双层板的入射速度-剩余速度曲线图;
图5b为本发明提供的蜂窝-封装复合增强陶瓷金属装甲实施例与传统陶瓷/金属双层板的抗弹性能对比图;
图6a为在受到入射速度相同的弹丸打击时UHMWPE封装单增强装甲的损伤区域示意图;
图6b为在受到入射速度相同的弹丸打击时本发明提供的蜂窝-封装复合增强陶瓷金属装甲实施例的损伤区域示意图;
附图标记说明如下:
1-一体化蜂窝网格金属点阵,2-陶瓷块,3-外装甲,4-铣刀,5-预浸料,6-陶瓷/金属双层装甲,7-弹丸入射方向。
具体实施方式
为使本发明的目的、优点和特征更加清楚,以下结合附图和具体实施例对本发明提出的一种蜂窝-封装复合增强陶瓷金属装甲及其制备方法作进一步详细说明。
一种蜂窝-封装复合增强陶瓷金属装甲,包括内装甲和对内装甲进行封装的外装甲3,内装甲和外装甲3通过不同方式进行一体化增强。
如图1所示,内装甲包括一体化蜂窝网格金属点阵1,以及与一体化蜂窝网格金属点阵1的蜂窝网格结构中网格孔适配的多个陶瓷块2。一体化蜂窝网格金属点阵3作为内装甲的框架和背板,为采用金属材料一体成型的四边形蜂窝网格结构或者六边形蜂窝网格结构,多边形蜂窝网格结构包括背板,以及设置在背板上的多边形蜂窝网格,多个陶瓷块2分别镶嵌在多边形蜂窝网格结构中的每个网格孔内。外装甲3为双股交替正交缠绕在内装甲表面的预浸料5,双股交替正交缠绕是指由两张预浸料5以相互垂直并且交替的方式进行缠绕,本实施例中,预浸料5选用超高分子量聚乙烯纤维增强复合材料预浸料。超高分子量聚乙烯纤维增强复合材料预浸料的叠层方式为[(90/0)2(90/0)2]N。超高分子量聚乙烯纤维,又称高强高模聚乙烯纤维,由分子量在100万~500万的聚乙烯纺出,是目前世界上比强度和比模量最高的纤维具有纤维密度低,断裂伸长低、断裂功大等性能,具有很强的耐化学腐蚀、耐磨性和很强的能量吸收能力。
在实际使用时,整个装甲可以采用一个蜂窝-封装复合增强陶瓷金属装甲模块,也可以采用多模块集合使用。
本实施例还提供一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,用于制备上述的蜂窝-封装复合增强陶瓷金属装甲,包括以下步骤:
S1、经线切割得到如图2a所示的长宽均为112mm,厚度为10mm的6061-T6铝合金板,并对其边缘做倒角处理,其边缘倒角半径为2mm,清洗去除6061-T6铝合金板表面的油污和锈迹后,放入烘干机内烘干备用。
S2、如图2b所示,将步骤S1得到的6061-T6铝合金板利用铣刀4进行铣削处理,得到一体化蜂窝网格金属点阵1,其中,一体化蜂窝点阵1中蜂窝网格结构的每个网格孔边长d大于入射弹丸的直径,间距t为入射弹丸直径的10%~15%,深度h/2≤h1≤2h/3,h-h1为背板厚度。本实施例中,蜂窝网格边长d为20mm,间距t为2mm,深度h1为5mm。
S3、选取陶瓷原料,通过金刚石砂轮切割、砂轮表面抛光对其进行粗处理,随后通过研磨机精细研磨,制得边长d为20mm,厚度h1为5mm的陶瓷块2。
S4、如图2c所示,将步骤S3制备的陶瓷块2涂覆双组分环氧树脂结构胶粘剂后,分别嵌入一体化蜂窝网格金属点阵1中蜂窝网格结构的每个网格孔内,得到具有蜂窝/陶瓷复合结构的内装甲。
S5、沿纤维分布的平行方向或垂直方向裁剪两卷宽度w为112mm的预浸料5,预浸料5的叠层方式为[(90/0)2(90/0)2]N,即采用四层纤维分布依次正交的超高分子量聚乙烯纤维增强复合材料。
S6、利用步骤S5获得的两卷宽度w为112mm的预浸料5对步骤S4得到的内装甲进行封装,将两卷预浸料5的一端分别沿内装甲的长度方向和宽度方向固定于内装甲上,两卷预浸料5在内装甲上交替正交缠绕各8圈,使每卷预浸料5的外层纤维方向均平行或垂直于蜂窝/陶瓷复合结构的边缘,其中,装甲内部112mm边长平面外侧的超高分子量聚乙烯纤维增强复合材料的叠层方式为[(90/0)2(90/0)2]8。
S7、采用具有水冷系统的热压模具对经步骤S6封装的内装甲进行热压固化成型,如图4所示,为本实施例的热压成型温度-压力时程曲线图,具体步骤如下:
S7.1、将经步骤S6封装的内装甲放入热压模具,在经封装的内装甲与热压模具间插入厚度不超过1mm的耐高温材料,将热压模具预热至100℃,且在不施加压力的情况下保持100℃的温度10min,使经封装的内装甲的温度均匀;
S7.2、将热压模具的加热温度设定为120℃,压力增加20MPa;
S7.3、保持步骤S7.2设定的温度与压力30min;
S7.4、使热压模具停止加热并打开水冷系统,保持20MPa的压力不变,对经封装的内装甲进行冷却;
S7.5、当经封装的内装甲的温度低于60℃时,将压力卸载,得到蜂窝-封装复合增强陶瓷金属装甲。
本发明将金属点阵材料与UHMWPE同时引入到装甲的设计中,并通过联合的一体化成型工艺,使得装甲结构在实现限制损伤区域、增强结构一体性和防护均匀性的同时,有效提升了抗侵彻性能。
在相同实验条件下,对本实施例提供的蜂窝-封装复合增强陶瓷金属装甲与传统陶瓷/金属双层装甲6做对比研究,经多次实验得到如图5a所示的入射速度-剩余速度曲线图。
从图中可以看出,在弹丸入射速度相同的情况下,对于弹丸击穿装甲的剩余速度,本实施例提供的蜂窝-封装复合增强陶瓷金属装甲小于传统陶瓷/金属双层装甲6。同时,对于弹丸击穿装甲的极限速度,即剩余速度为零时装甲所能承受的弹丸入射速度,本实施例提供的蜂窝-封装复合增强陶瓷金属装甲大于传统陶瓷/金属双层装甲6。
对实验数据进行统计,得到如图5b所示的本实施例提供的蜂窝-封装复合增强陶瓷金属装甲与传统陶瓷/金属双层装甲6的抗弹性能对比图。本实施例提供的蜂窝-封装复合增强陶瓷金属装甲较传统陶瓷/金属双层装甲6,质量增加约13.68%,极限速度提升约29.64%,在提升装甲抗弹性能方面具有明显优势。图5b中阴影部分分别为质量增加与极限速度增加比例,结果表明,本实施例提供的蜂窝-封装复合增强陶瓷金属装甲在面密度无明显增加的情况下,有效提升了抗侵彻性能。
经实验研究发现,蜂窝-封装复合增强陶瓷金属装甲较陶瓷/金属双层装甲6,质量增加约13.68%,极限速度可提升约29.64%,在提升装甲抗弹性能方面具有明显优势,且损伤区域的大幅降低。
如图6a所示,为在受到入射速度相同的弹丸打击时采用UHMWPE封装单增强装甲的损伤区域示意图。在传统的陶瓷/金属双层装甲6外部增加UHMWPE封装,得到UHMWPE封装单增强装甲,对其与本发明提供的蜂窝-封装复合增强陶瓷金属装甲进行损伤区域研究,经实验,得到分别如图6a和图6b所示的在受到入射速度相同的弹丸打击时为UHMWPE封装单增强装甲和蜂窝-封装复合增强陶瓷金属装甲的损伤区域示意图,其弹丸入射方向7相同。结果表明,在受到入射速度相同的弹丸打击时,蜂窝-封装复合增强陶瓷金属装甲得出损伤区域远小于UHMWPE封装单增强装甲,并且极限速度有明显提升。由于蜂窝-封装的联合强化作用,使得本发明提出的装甲结构具备限制损伤区域、增强结构一体性和防护均匀性等性能。
同时,在其他试验中表明,具有相同的UHMWPE封装的装甲,与无封装装甲相比,其极限速度有明显提升,且UHMWPE封装相较于不同的装甲内部结构具有明显的协同增强效应,在装甲抗侵彻性能上有明显优势。并且根据装甲内部结构的不同,其防护性能也有明显不同。
最后应说明的是:以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述实施例所记载的技术方案进行修改,或者对其中部分或者全部技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明技术方案的范围。
Claims (10)
1.一种蜂窝-封装复合增强陶瓷金属装甲,其特征在于:包括内装甲和对内装甲进行封装的外装甲(3);
所述内装甲包括一体化蜂窝网格金属点阵(1),以及与所述一体化蜂窝网格金属点阵(1)的蜂窝网格结构中网格孔适配的多个陶瓷块(2);
所述一体化蜂窝网格金属点阵(1)为采用金属材料一体成型的多边形蜂窝网格结构,所述多边形蜂窝网格结构包括背板,以及设置在背板上的多边形蜂窝网格;
所述多个陶瓷块(2)分别镶嵌在多边形蜂窝网格的每个网格孔内;
所述外装甲(3)为双股交替正交缠绕在内装甲表面的预浸料(5),所述双股交替正交缠绕是指由两张预浸料(5)以相互垂直并且交替的方式进行缠绕,所述预浸料(5)为超高分子量聚乙烯纤维增强复合材料预浸料。
2.根据权利要求1所述的一种蜂窝-封装复合增强陶瓷金属装甲,其特征在于:所述超高分子量聚乙烯纤维增强复合材料预浸料的叠层方式为[(90/0)2(90/0)2]N。
3.根据权利要求2所述的一种蜂窝-封装复合增强陶瓷金属装甲,其特征在于:所述一体化蜂窝网格金属点阵(1)为采用金属材料一体成型的四边形蜂窝网格结构或者六边形蜂窝网格结构。
4.一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,用于制造如权利要求1-3任一所述的蜂窝-封装复合增强陶瓷金属装甲,其特征在于,包括以下步骤:
S1、制备长为l,宽为w,厚度为h的金属板,清洗金属板,去除其表面的油污和锈迹;
S2、将步骤S1得到的金属板进行铣削处理,得到一体化蜂窝网格金属点阵(1),所述一体化蜂窝网格金属点阵(1)的蜂窝网格结构中每个网格孔的边长为d,间距为t、深度为h1,其中,h1<h,h-h1为背板厚度;
S3、选取陶瓷原料,并对其进行粗处理,随后再进行精细研磨,制得边长为d,厚度为h1的陶瓷块(2);
S4、将步骤S3制备的陶瓷块(2)涂覆胶粘剂后,分别嵌入一体化蜂窝网格金属点阵(1)的蜂窝网格结构中每个网格孔内,得到具有蜂窝/陶瓷复合结构的内装甲;
S5、沿纤维分布的平行方向或垂直方向裁剪两卷宽度分别为l和w的预浸料(5);
S6、利用所述两卷宽度分别为l和w的预浸料(5)对步骤S4得到的内装甲以相互垂直并且交替的方式进行缠绕封装;
S7、将经步骤S6封装的内装甲放入热压模具中,进行热压固化成型,得到蜂窝-封装复合增强陶瓷金属装甲。
5.根据权利要求4所述的一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,其特征在于,所述步骤6具体为:
将宽度为l的预浸料(5)一端沿内装甲的宽度方向固定于内装甲上,宽度为w的预浸料(5)一端沿内装甲的长度方向固定于内装甲上,所述两卷宽度分别为l和w的预浸料(5)在内装甲上交替正交缠绕各N圈,使每卷预浸料(5)的外层纤维方向均平行或垂直于内装甲的蜂窝/陶瓷复合结构的边缘;
所述N不小于2。
6.根据权利要求5所述的一种蜂窝-封装复合增强陶瓷金属装的制备方法,其特征在于,所述步骤S1中还包括:
清洗前对所述金属板的边缘做倒角处理,所述金属板的边缘倒角半径为1~3mm。
7.根据权利要求6所述的一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,其特征在于,步骤S2中,所述蜂窝网格的边长d大于拟防护的入射弹丸直径,间距t为拟防护的入射弹丸直径的10%~15%,深度h/2≤h1≤2h/3。
8.根据权利要求4-7任一所述的一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,其特征在于,步骤S7中,所述进行热压固化成型的具体步骤为:
将经步骤S6封装的内装甲依次通过模具预热、加热加压、保温保压、冷却保压和卸载出模进行热压固化成型。
9.根据权利要求8所述的一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,其特征在于,所述步骤S7具体为:
S7.1、将经步骤S6封装的内装甲放入热压模具后进行合模,将热压模具预热至100℃,且在不施加压力的情况下保持100℃的温度5~10min,使经封装的内装甲的温度均匀;
S7.2、将热压模具的加热温度设定为120℃,压力增加至不小于16.5MPa;
S7.3、保持步骤S7.2设定的温度与压力20~30min;
S7.4、使热压模具停止加热,压力保持不变,对经封装的内装甲进行冷却;
S7.5、当经封装的内装甲的温度低于60℃时,将压力卸载,得到蜂窝-封装复合增强陶瓷金属装甲。
10.根据权利要求9所述的一种蜂窝-封装复合增强陶瓷金属装甲的制备方法,其特征在于,所述步骤S7.1中,将经步骤S6封装的内装甲放入热压模具后,在经封装的内装甲与热压模具间插入厚度不超过1mm的耐高温材料。
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