Structural panel insert having encapsulated filler materials

摘要

A structural insert according to the present invention can be utilized in a Metal Matrix Composite (MMC) structure such as an armor structure having one or more material layers with each material layer having at least one structural insert arranged along a common surface. Utilizing a polygonal or HoneyComb Core, a reinforcement material containing a fraction of high volume hollow microspheres with interior voids can be utilized and placed within the inserts cellular structure to decrease the weight of the armor system. Subsequent to metal infiltration, the metal encapsulates the micro-spheres within the cells of the cellular structure, forming pockets of micro-spheres therein. These encapsulated hollow microspheres comprise a ceramic or glass wall around an interior void having a wall thickness that reinforces the void wall surface. The encapsulating metal further bonds to the walls of the cellular structure increasing the crush strength of the cell wall. In one embodiment, having the entire cellular structure filled with micro-spheres, the combination of microsphere diameter, face-sheet type and thickness, and core thickness, combined with the increased bonding effect of the encapsulated spheres to the cell walls, has demonstrated superior energy absorption characteristics.

主权项

1. A structural insert for a composite armor, comprising:
a top and bottom facesheet reinforcement layer, said top and bottom facesheet having a thickness of at least 0.5 mm, and further comprising aluminum and ceramic fiber wherein said ceramic fiber is between 3 and 60 percent volume; at least one cellular structure arranged in a common plane, said cellular structure further arranged in one or more stacked layers, said cellular structure disposed between said top and bottom facesheet, said cellular structure having a plurality of interior openings and an external surface, said plurality of interior opening having oppositely faced sides between which said plurality of openings extend, said cellular structure being at least 10 times the thickness of one of said said top and bottom facesheets; a first filler material placed within said plurality of openings of said at least one cellular structure to provide crush absorption within said cellular structure, wherein said first filler material comprises a plurality of high volume hollow microspheres with a mean diameter of less than 100 microns; and a metallic material infiltrating said plurality of interior openings of said cellular structure, said metallic material bonding to said plurality of microspheres and forming an encapsulating containment wall around said first filler material in each of said plurality of openings, said containment wall having an external surface bonding to said oppositely faced sides between which said plurality of openings extend, said metallic material extending outward to encapsulate said cellular structure and said top and bottom face sheets, said metallic material forming an encapsulating barrier.