Mechanical behaviours of a hybrid composite with orthogonal spiral wire mesh and polyurethane elastomer

The application of a new flexible lattice structure, inspired by biological tissues, aims to significantly improve the deformation capacity of conventional rigid lattice structures and has gained widespread usage. Although the developed flexible lattice exhibits unique mechanical properties such as biomimetic J-type stress-strain behaviour and anisotropy, its limited load-bearing capacity, inadequate sealing performance, and complex preparation processes have hindered its application in engineering. To address these issues, a novel hybrid material is proposed based on the concept of interpenetrating composite materials. The material utilizes a woven TC4 orthogonal spiral wire mesh as the skeleton and PU elastomer (OSWM-PU) as the matrix. The uniaxial tensile tests demonstrate that OSWM-PU possesses the excellent load-bearing capacity, allowing for large deformations (≥ 60%) while maintaining partial integrity even after matrix fracture. Optical measurements and simulation analysis reveal that Poisson’s ratio can be adjusted within a certain range by manipulating the microscopic parameters ( p , d ) of the longitudinal helical filaments. Cyclic tensile experiments further demonstrate that OSWM-PU exhibits exceptional energy absorption performance, multiple energy dissipation modes, and a more pronounced Mullins effect. The stress relaxation experiment reveals the significant influence of the volume fraction of the skeleton on long-term loading conditions. The orthogonal spiral wire skeleton exhibits a superior hooking effect without dividing the matrix, enabling OSWM-PU to possess enhanced collaborative deformation capability and inherent designability in the orthogonal direction. These characteristics make it highly promising for applications in various robot joints and as flexible aircraft skin, offering excellent prospects for utilization.