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<p>Ceramic/metal composite armor faces limitations in lightweighting, environmental adaptability, and multi-impact resistance. This study proposes a bio-inspired gradient-structured modified polyurethane (PU)/ceramic composite armor. The PU matrix, modified via dynamic covalent disulfide (S-S) bonds, exhibits excellent self-healing (&gt;&#xa0;95% recovery) and toughness (&gt;&#xa0;300% elongation). A double-sided PU/ceramic sandwich structure was developed to leverage synergistic energy dissipation through ceramic fragmentation and polymeric tensile delay. Ballistic impact tests and explicit dynamic simulations (deviation &lt; 2%) were performed. Results show the double-sided design achieved a specific energy absorption (SEA) of 20.02&#xa0;J·m<sup>2</sup>/kg and a ballistic limit (V<sub>50</sub>) of 493.10 m/s at an areal density of 45.35&#xa0;kg/m<sup>2</sup>, yielding an 11-18% improvement over conventional systems. Furthermore, the composite maintained structural integrity after 3000-h salt spray and − 50&#xa0;°C impact evaluations. Energy dissipation analysis quantified that the ceramic layer accounts for 70% of energy absorption via fragmentation, while the PU layer contributes 30% through fibrillation-induced stretching. This research provides a material–structure integration strategy for next-generation intelligent, lightweight, and durable protective systems.</p>

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Bionic Gradient Modified Polyurethane/Ceramic Composite Armor: Achieving High Impact Resistance and Lightweighting via Self-Healing Interlayer and Synergistic Energy Dissipation Mechanism

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Xue Gao,
  • Feng Zhao,
  • Zhonghua Du,
  • Qican Xu

摘要

Ceramic/metal composite armor faces limitations in lightweighting, environmental adaptability, and multi-impact resistance. This study proposes a bio-inspired gradient-structured modified polyurethane (PU)/ceramic composite armor. The PU matrix, modified via dynamic covalent disulfide (S-S) bonds, exhibits excellent self-healing (> 95% recovery) and toughness (> 300% elongation). A double-sided PU/ceramic sandwich structure was developed to leverage synergistic energy dissipation through ceramic fragmentation and polymeric tensile delay. Ballistic impact tests and explicit dynamic simulations (deviation < 2%) were performed. Results show the double-sided design achieved a specific energy absorption (SEA) of 20.02 J·m2/kg and a ballistic limit (V50) of 493.10 m/s at an areal density of 45.35 kg/m2, yielding an 11-18% improvement over conventional systems. Furthermore, the composite maintained structural integrity after 3000-h salt spray and − 50 °C impact evaluations. Energy dissipation analysis quantified that the ceramic layer accounts for 70% of energy absorption via fragmentation, while the PU layer contributes 30% through fibrillation-induced stretching. This research provides a material–structure integration strategy for next-generation intelligent, lightweight, and durable protective systems.