Polyurea for Blast and Impact Protection: A Review

A Bioinspired Design of Protective Al2O3/Polyurethane Hierarchical Composite Film Through Layer-By-Layer Deposition

Structural materials such as ceramics, metals, and carbon fiber-reinforced plastics (CFRP) are frequently threatened by large compressive and impact forces. Energy absorption layers, i.e., polyurethane and silicone foams with excellent damping properties, are applied on the surfaces of different substrates to absorb energy. However, the amount of energy dissipation and penetration resistance are limited in commercial polyurethane foams. Herein, a distinctive nacre-like architecture design strategy is proposed by integrating hard porous ceramic frameworks and flexible polyurethane buffers to improve energy absorption and impact resistance. Experimental investigations reveal the bioinspired designs exhibit optimized hardness, strength, and modulus compared to that of polyurethane. Due to the multiscale energy dissipation mechanisms, the resulting normalized absorbed energy (≈8.557 MJ m-3) is ≈20 times higher than polyurethane foams under 50% quasi-static compression. The bioinspired composites provide superior protection for structural materials (CFRP, glass, and steel), surpassing polyurethane films under impact loadings. It is shown CFRP coated with the designed materials can withstand more than ten impact loadings (in energy of 10 J) without obvious damage, which otherwise delaminates after a single impact. This biomimetic design strategy holds the potential to offer valuable insights for the development of lightweight, energy-absorbent, and impact-resistant materials.

Polyurea/Aminopropyl Isobutyl Polyhedral Oligomeric Silsesquioxane-Functionalized Graphene Nanoplatelet Nanocomposites for Force Protection Applications

Herein, the development of new nanocomposite systems is reported based on one-part polyurea (PU) and aminopropyl isobutyl polyhedral oligomeric silsesquioxane (POSS)-functionalized graphene nanoplatelets (GNP-POSS) as compatible nanoreinforcements with the PU resin. GNP-POSS was effectively synthesized via a two-step synthesis protocol, including ultrasonication-assisted reaction and precipitation, and carefully characterized with respect to its chemical and crystalline structure, morphology, and thermal stability. FTIR and XPS spectroscopy analyses revealed that POSS interacts with the residual oxygen moieties of the GNPs through both covalent and noncovalent bonding. The X-ray diffraction pattern of GNP-POSS further revealed that the crystallinity of the GNPs was not altered after their functionalization with POSS. GNP-POSS was successfully incorporated in PU at contents of 1, 3, 5, and 10 wt % to yield PU/GNP-POSS nanocomposite films. An ATR-FTIR analysis of these films confirmed the presence of strong interfacial interactions between the urea groups of PU and the GNP-POSS functionalities. Moreover, the PU/GNP-POSS nanocomposite films exhibited enhanced thermal stability and mechanical properties compared to those of the neat PU film. The quasi-static tensile testing of the PU/GNP-POSS samples revealed remarkable enhancements in the tensile strength (from 7.9 for the neat PU to 25.1 MPa for PU/GNP-POSS) and Young's modulus (238-617 MPa), while elongation at break and toughness also showed 14 and 125% improvements, respectively. Finally, the effects of GNP-POSS content on the morphological, quasistatic tensile, and high-strain-rate dynamic behavior of the PU/GNP-POSS nanocomposite films were also investigated. Overall, the tests performed using a split-Hopkinson pressure bar setup revealed a large increase in the film strength (from 147.6 for the neat PU film to 199 MPa for the PU/GNP-POSS film) and a marginal increase in the energy density of the film (38.1-40.8 kJ/m3). These findings support the suitability of the PU/GNP-POSS nanocomposite films for force protection applications.

Synthesis, Structure and Properties of Polyester Polyureas via a Non-Isocyanate Route with Good Combined Properties

Polyureas have been widely applied in many fields, such as coatings, fibers, foams and dielectric materials. Traditionally, polyureas are prepared from isocyanates, which are highly toxic and harmful to humans and the environment. Synthesis of polyureas via non-isocyanate routes is green, environmentally friendly and sustainable. However, the application of non-isocyanate polyureas is quite restrained due to their brittleness as the result of the lack of a soft segment in their molecular blocks. To address this issue, we have prepared polyester polyureas via an isocyanate-free route and introduced polyester-based soft segments to improve their toughness and endow high impact resistance to the polyureas. In this paper, the soft segments of polyureas were synthesized by the esterification and polycondensation of dodecanedioic acid and 1,4-butanediol. Hard segments of polyureas were synthesized by melt polycondensation of urea and 1,10-diaminodecane without a catalyst or high pressure. A series of polyester polyureas were synthesized by the polycondensation of the soft and hard segments. These synthesized polyester-type polyureas exhibit excellent mechanical and thermal properties. Therefore, they have high potential to substitute traditional polyureas.

State-of-the-Art Polyurea Coatings: Synthesis Aspects, Structure-Properties Relationship, and Nanocomposites for Ballistic Protection Applications

This review presents polyurea (PU) synthesis, the structure-properties relationship, and characterization aspects for ballistic protection applications. The synthesis of polyurea entails step-growth polymerization through the reaction of an isocyanate monomer/prepolymer and a polyamine, each component possessing a functionality of at least two. A wide range of excellent properties such as durability and high resistance against atmospheric, chemical, and biological factors has made this polymer an outstanding option for ballistic applications. Polyureas are an extraordinary case because they contain both rigid segments, which are due to the diisocyanates used and the hydrogen points formed, and a flexible zone, which is due to the chemical structure of the polyamines. These characteristics motivate their application in ballistic protection systems. Polyurea-based coatings have also demonstrated their abilities as candidates for impulsive loading applications, affording a better response of the nanocomposite-coated metal sheet at the action of a shock wave or at the impact of a projectile, by suffering lower deformations than neat metallic plates.

Recent Developments in Polyurea Research for Enhanced Impact Penetration Resistance and Blast Mitigation

Polyurea has gained significant attention in recent years as a functional polymer material, specifically regarding blast and impact protection. The molecular structure of polyurea is characterized by the rapid reaction between isocyanate and the terminal amine component, and forms an elastomeric copolymer that enhances substrate protection against blast impact and fragmentation penetration. At the nanoscale, a phase-separated microstructure emerges, with dispersed hard segment microregions within a continuous matrix of soft segments. This unique microstructure contributes to the remarkable mechanical properties of polyurea. To maximize these properties, it is crucial to analyze the molecular structure and explore methods like formulation optimization and the incorporation of reinforcing materials or fibers. Current research efforts in polyurea applications for protective purposes primarily concentrate on construction, infrastructure, military, transportation and industrial products and facilities. Future research directions should encompass deliberate formulation design and modification, systematic exploration of factors influencing protective performance across various applications and the integration of numerical simulations and experiments to reveal the protective mechanisms of polyurea. This paper provides an extensive literature review that specifically examines the utilization of polyurea for blast and impact protection. It encompasses discussions on material optimization, protective mechanisms and its applications in blast and impact protection.

Investigating the Hydrogen Bond-Induced Self-Assembly of Polysulfamides Using Molecular Simulations and Experiments

In this paper, we present a synergistic, experimental, and computational study of the self-assembly of N,N'-disubstituted polysulfamides driven by hydrogen bonds (H-bonds) between the H-bonding donor and acceptor groups present in repeating sulfamides as a function of the structural design of the polysulfamide backbone. We developed a coarse-grained (CG) polysulfamide model that captures the directionality of H-bonds between the sulfamide groups and used this model in molecular dynamics (MD) simulations to study the self-assembly of these polymers in implicit solvent. The CGMD approach was validated by reproducing experimentally observed trends in the extent of crystallinity for three polysulfamides synthesized with aliphatic and/or aromatic repeating units. After validation of our CGMD approach, we computationally predicted the effect of repeat unit bulkiness, length, and uniformity of segment lengths in the polymers on the extent of orientational and positional order among the self-assembled polysulfamide chains, providing key design principles for tuning the extent of crystallinity in polysulfamides in experiments. Those computational predictions were then experimentally tested through the synthesis and characterization of polysulfamide architectures.

Manganese catalysed dehydrogenative synthesis of polyureas from diformamide and diamines

We report here the synthesis of polyureas from the dehydrogenative coupling of diamines and diformamides. The reaction is catalysed by a manganese pincer complex and releases H₂ gas as the only by-product making the process atom-economic and sustainable. The reported method is greener in comparison to the current state-of-the-art production routes that involve diisocyanate and phosgene feedstock. We also report here the physical, morphological, and mechanical properties of synthesized polyureas. Based on our mechanistic studies, we suggest that the reaction proceeds via isocyanate intermediates formed by the manganese catalysed dehydrogenation of formamides.

Effect of Aromatic Chain Extenders on Polyurea and Polyurethane Coatings Designed for Defense Applications

The present work describes the synthesis of new versatile polyurea (PU) and polyurethane (PUR) matrices, including different chain extenders, which facilitate the design of distinct, tunable properties, and high-performance derivatives. These polymers can be used for various defense and security applications, such as coatings for ballistic protection, CBRN protection, binders for energetic formulations, etc. Combining aliphatic and aromatic molecules in PU or PUR structures enables the synthesis of polymers with improved and controllable thermo-mechanical properties. Thus, for polyurea synthesis, we utilized two types of polymeric aliphatic diamines and three types of aromatic chain extenders (1,1'-biphenyl-4,4'-diamine, benzene-1,2-diamine, and 1,2-diphenylhydrazine). An analogous method was used to synthesize polyurethane films by employing one polymeric aliphatic polyol and three types of aromatic chain extenders (benzene-1,3-diol, benzene-1,4-diol, and benzene-1,2,3-triol). Subsequently, various analytic techniques (Fourier transform infrared spectroscopy-attenuated total reflectance (FTIR-ATR), single cantilever dynamic mechanical analysis (DMA), thermogravimetric analysis (TGA), frequency-dependent shear modulus survey, tensile tests, water contact angle measurements, and scanning electron microscopy (SEM) with energy-dispersive X-ray analysis (EDX)) have been utilized to characterize the synthesized materials and to evaluate the influence of each chain extender on their final properties.

Tensile Properties and Fracture Mechanism of Thermal Spraying Polyurea

In this study, polyurea was experimentally tested under various spraying temperatures and pressures. The number of holes and the pore size produced after the tensile fracture of the polyurea were counted to illustrate the effect of the various spraying temperatures and pressures on the performance of the polyurea. The tensile characteristics of polyurea were greatly influenced by the spraying temperatures and pressures, according to the experimental findings and statistical analysis. The polyurea tensile performance was best when the spraying pressure was 17.25 MPa with a spraying temperature of 70 °C. The fracture mechanism was illustrated by the silver streaking phenomenon generated during the tensile stretching process. The fracture energy was absorbed by the fracture holes and pores during silver streaking, thus creating the huge gap in tensile properties.

Comparison of Dynamic Vibration Control Techniques by the GFRPU and/or LTMD System

Reinforced concrete (RC) structures with non-seismic reinforcement details are vulnerable to earthquakes. This experimental study evaluates the efficiency of three techniques to alleviate the dynamic responses of existing structures: glass fiber-reinforced polyurea (GFRPU) reinforcement, a lever-typed tuned mass damper (LTMD) system, and a hybrid system of GFRPU and LTMD reinforcements. The lateral-resisting capacity and ductility of the GFRPU reinforcement specimen were enhanced by the material characteristics, and the dynamic responses were alleviated. The LTMD control specimen controlled the dynamic responses by the passive control system of the tuned mass damper (TMD), and the control forces to sustain its geometric motion were exerted on the specimen. The hybrid system was designed to control the dynamic responses by the GFRPU reinforcement and the LTMD control system. Four specimens, including an unreinforced specimen, were tested under external excitations, including the El Centro earthquake. The vibrations were more controlled in the order of the GFRPU reinforcement specimen, the LTMD control specimen, and the hybrid control specimen. The hybrid system was evaluated as excellent for seismic reinforcement, such as preventing abrupt failure with the lateral-resisting capacity and ductility of GFRPU and improving the dynamic control capacity by LTMD.

Study of Blast Mitigation Performance and Fracture Mechanism of Polyurea under Contact Explosion

In order to further study the blast mitigation performance of polyurea and to investigate the protection mechanism and damage characteristics of polyurea-protected structures under contact explosion loads, based on earlier work, this paper investigated the response and energy absorption performance of polyurea under various frequency loads. Qtech T26 blast mitigation polyurea (T26 polyurea) was adopted to protect the reinforced concrete (RC) slab and damage analysis of the post-explosion specimens was carried out at micro and macro levels. The response and energy absorption capacity of the material towards different frequency loads were investigated by dynamic mechanical analysis (DMA). Protective performance of T26 polyurea on RC slab was examined with a 10 kg TNT contact explosion test. Scanning electron microscopy (SEM) was employed to analyze the microscopic fracture morphology of the typical areas of the coating after the explosion. The chemical structure changes of the blast-face coating before and after the explosion were compared by Fourier transform infrared spectroscopy (FTIR). The results show that the glass transition region of T26 polyurea is −40 °C to 10 °C, which is a large temperature range, and the microphase separation of T26 polyurea is low. It is significantly influenced by the ambient temperature and loading frequency. The energy absorption of T26 polyurea is realized through the interaction between the hard and soft segments. When the frequency is between 10² Hz and 10⁶ Hz, the loss factor of T26 polyurea is between 0.20 and 0.31, which exhibits a good energy dissipation performance. In the contact explosion of 10 kg TNT, the fragmentation rate of the coated specimen decreased significantly compared with that of the unprotected specimen, realizing the zero fragmentation protection effect on the back-blast face. The maximum deformation area and the main energy absorption area of T26 polyurea under contact explosion is the ring area outside the longitudinal deformation area. The chemical structure of T26 polyurea changed significantly after the explosion; typically the N-H bonds, etc., were broken and the percentage of hydrogen bonding was reduced. T26 polyurea has realized the protection effect of zero fragmentation of large-equivalent contact explosion, which has a high application value for blast mitigation and blast-fragmentation prevention in actual engineering.

Effects of Fiber Volume Fraction and Length on the Mechanical Properties of Milled Glass Fiber/Polyurea Composites

Composites of polyurea (PU) reinforced with milled glass fiber (MG_f) were fabricated. The volume fraction and length of the milled glass fiber were varied to study their effects on the morphological and mechanical properties of the MG_f/PU composites. The morphological attributes were characterized with scanning electron microscopy (SEM) and Fourier transform infrared (FTIR) spectroscopy. The SEM investigations revealed a uniform distribution and arbitrary orientation of milled glass fiber in the polyurea matrix. Moreover, it seems that the composites with longer fiber exhibit better interfacial bonding. It was found from the FTIR studies that the incorporation of milled glass fiber into polyurea leads to more phase mixing and decreases the hydrogen bonding of the polyurea matrix, while having a negligible effect on the H-bond strength. The compression tests at different strain rates (0.001, 0.01, 0.1, 1, 2000 and 3000 s⁻¹) and dynamic mechanical properties over the temperature range from −30 to 100 °C at 1 Hz were performed. Experimental results show that the compressive behavior of MG_f/PU composites is nonlinear and strain-rate-dependent. Both elastic modulus and flow stress at any given strain increased with strain rate. The composites with higher fiber volume fraction and longer fiber length are more sensitive to strain rate. Furthermore, the elastic modulus, stress at 65% strain and energy absorption capability were studied, taking into account both the effect of fiber volume fraction and mean fiber length. It is noted that an increase in fiber volume fraction and fiber length leads to an increase in elastic modulus, stress at 65% strain and absorbed energy up to ~103%, 83.0% and 137.5%, respectively. The storage and loss moduli of the composites also increase with fiber volume fraction and fiber length. It can be concluded that the addition of milled glass fiber into polyurea not only improves the stiffness of the composites but also increases their energy dissipative capability.