Aug 19, 2025

US12391022 - Composite structure and method of manufacture

A composite structure comprises a plurality of first layers each comprising graphene; and a plurality of second layers each comprising an aerogel, wherein the first and second layers alternate in the composite structure. A method for manufacturing a composite structure comprising first and second layers comprises providing a plurality of the second layers, each second layer comprising an aerogel, providing a plurality of first layers, each layer comprising graphene; and arranging the first and second layers so that the layers form a composite structure in which the plurality of first and second layers alternate.

Assignee: GRAPHENE COMPOSITES LTD
Inventors: Sandy Winthrop Chen
Filing date: 2018-02-22

The patent describes a protective armor article featuring a composite structure made of alternating layers of graphene and aerogel, with specific materials and bonding methods outlined for enhanced protection. It includes a protective exterior layer and a fastening element to secure the composite layers, optimizing the balance between weight and strength.

Claim 1

A protective armor article comprising a composite structure, the composite structure comprising: a plurality of graphene layers; and a plurality of aerogel layers; wherein the graphene layer and the aerogel layer are directly bonded in an alternating structure; wherein at least one of the graphene layers comprises graphene in the form of graphene platelets and the graphene platelets are dispersed in a polymer matrix; wherein the polymer matrix comprises a polymer selected from polyurethane, polyethylene, polypropylene, polyester, polyamide, polyimide, epoxy resin or combinations thereof; a protective layer, wherein the protective layer is provided as an exterior layer to the alternating graphene and aerogel layers and comprises one or more of aromatic polyamide fibres, boron fibres, ultra-high molecular weight polyethylene, and poly (p-phenylene-2,6-benzobisoxazole) (PBO), including combinations thereof; wherein a fastening element is provided to secure the graphene layers and aerogel layers together when the composite structure is positioned in the protective armor article; and wherein the graphene is provided in each of the graphene layers in an amount of from 0.1 wt % to 5 wt % graphene and wherein the polymer is provided in each of the graphene layers in an amount of from 95 wt % to 99.9 wt %. a plurality of graphene layers; and a plurality of aerogel layers; wherein the graphene layer and the aerogel layer are directly bonded in an alternating structure; wherein at least one of the graphene layers comprises graphene in the form of graphene platelets and the graphene platelets are dispersed in a polymer matrix; wherein the polymer matrix comprises a polymer selected from polyurethane, polyethylene, polypropylene, polyester, polyamide, polyimide, epoxy resin or combinations thereof; a protective layer, wherein the protective layer is provided as an exterior layer to the alternating graphene and aerogel layers and comprises one or more of aromatic polyamide fibres, boron fibres, ultra-high molecular weight polyethylene, and poly (p-phenylene-2,6-benzobisoxazole) (PBO), including combinations thereof; wherein a fastening element is provided to secure the graphene layers and aerogel layers together when the composite structure is positioned in the protective armor article; and wherein the graphene is provided in each of the graphene layers in an amount of from 0.1 wt % to 5 wt % graphene and wherein the polymer is provided in each of the graphene layers in an amount of from 95 wt % to 99.9 wt %.

Google Patents

https://patents.google.com/patent/US12391022

USPTO PDF

https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/12391022