Lightweight impact absorbing armor panel

1. A multi-layer energy absorbing panel attached to an outer surface of a vehicle hull for protection against explosive blasts, comprising:

a first penetration resistant layer made of a multi-layer stack of anti-ballistic fabric on a side of the panel distal from the vehicle hull and configured to be exposed to a potential explosive blast;

a first core made of a crushable structural material disposed between the first penetration resistant layer and the vehicle hull; and

exclusive of any adhesive layers, a shock dissipation layer made of a porous elastomeric urethane between the first penetration resistant layer and the first core, the shock dissipation layer having sufficient thickness to mitigate the effect of a localized explosive impulse on the first core by spreading the impulse over a substantially larger area.

2. The multi-layer energy absorbing panel of claim 1 , wherein the shock dissipation layer has a compression set of less than about 2% when tested in accordance with ASTM 1667.

3. The multi-layer energy absorbing panel of claim 1 , wherein the shock dissipation layer is an air-frothed polyurethane gel.

4. The multi-layer energy absorbing panel of claim 1 , wherein the first core is selected from the group comprising metal foam and structural honeycomb.

5. The multi-layer energy absorbing panel of claim 4 , wherein the first core is a closed-cell aluminum foam.

6. The multi-layer energy absorbing panel of claim 5 , wherein the first core is a sandwich structure comprising an aluminum foam core and sheet aluminum cladding.

7. The multi-layer energy absorbing panel of claim 1 , further comprising a backing layer attached to the side of the first core opposite the shock dissipation layer.

8. The multi-layer energy absorbing panel of claim 7 , wherein the backing layer is a ductile material.

9. The multi-layer energy absorbing panel of claim 7 , wherein the backing layer is a ballistic composite material.

10. The multi-layer energy absorbing panel of claim 1 , wherein the fabric layers comprise unidirectional high performance fibers.

11. A multi-layer blast panel attached to the underside of a vehicle hull for mitigating the transmission of an under-vehicle explosive impulse to the vehicle hull, comprising:

a first penetration resistant layer on a side of the panel distal from the vehicle hull and configured to be exposed to a potential explosive impulse;

a first core made of a crushable structural material between the first penetration resistant layer and the vehicle hull; and

exclusive of any adhesive layers, a shock dissipation layer made of an elastomeric air-frothed polyurethane disposed between the first penetration resistant layer and the first core, the shock dissipation layer having sufficient thickness to mitigate the effect of a localized explosive impulse on the first core by spreading the impulse over a substantially larger area.

12. The multi-layer blast panel of claim 11 , wherein the shock dissipation layer returns rapidly to approximately its original dimensions and shape after substantial deformation.

13. The multi layer blast panel of claim 11 , wherein the shock dissipation layer has an energy return of between about 35 to 40% in a drop weight impact test.

14. The multi layer blast panel of claim 13 , wherein the shock dissipation layer further has a compression set of less than about 2% when tested in accordance with ASTM 1667.

15. The multi-layer blast panel of claim 11 , wherein the first core is a closed-cell aluminum foam.

16. The multi-layer blast panel of claim 11 , further comprising a backing layer between the core and the vehicle hull.

17. The multi-layer blast panel of claim 16 , wherein the first core is a sandwich structure comprising an aluminum foam core with aluminum cladding, and the backing layer is the cladding on the side closest to the vehicle hull.

18. The multi-layer blast panel of claim 11 , wherein the penetration resistant layer comprises a multi-layer stack of anti-ballistic fabric.

19. The multi-layer blast panel of claim 18 , wherein the fabric layers comprise unidirectional high performance fibers.

20. A multi-layer energy absorbing panel attached to an outer surface of a vehicle hull for protection against explosive blasts, comprising:

a first penetration resistant layer on a side of the panel distal from the vehicle hull and configured to be exposed to a potential explosive blast;

a first core made of a crushable structural material disposed between the first penetration resistant layer and the vehicle hull; and

exclusive of any adhesive layers, a shock dissipation layer between the first penetration resistant layer and the first core, the shock dissipation layer made of an air-frothed polyurethane gel with an energy return of between about 35 to 40% in a drop weight impact test, and a compression set of less than about 2% when tested in accordance with ASTM 1667, the shock dissipation layer having sufficient thickness to mitigate the effect of a localized explosive impulse on the first core by spreading the impulse over a substantially larger area.

21. The multi-layer energy absorbing panel of claim 20 , wherein the shock dissipation layer further has an elongation of about 80% when tested in accordance with ASTM 3574.

22. The multi-layer energy absorbing panel of claim 21 , wherein the shock absorbing layer further has a tear strength of about 10 pounds per inch-minute when tested in accordance with ASTM D-624.

23. The multi-layer energy absorbing panel of claim 22 , wherein the shock absorbing layer further has a tensile strength of about 55 psi when tested in accordance with ASTM 3574.