U.S. patent application number 16/639948 was filed with the patent office on 2020-08-06 for impact resistant composite material.
The applicant listed for this patent is HONEYWELL INTERNATIONAL INC.. Invention is credited to Winnie DING, Lori LUO, Shiqing ZHOU.
Application Number | 20200245710 16/639948 |
Document ID | 20200245710 / US20200245710 |
Family ID | 1000004797297 |
Filed Date | 2020-08-06 |
Patent Application | download [pdf] |
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United States Patent
Application |
20200245710 |
Kind Code |
A1 |
ZHOU; Shiqing ; et
al. |
August 6, 2020 |
IMPACT RESISTANT COMPOSITE MATERIAL
Abstract
Apparatus and associated methods relate to an enhanced auxetic
composite material (EACM) of a base thermoplastic elastomer (TPE)
and/or a thermoset material combined with an auxetic material, the
composite formed with a molding process, where the base material is
injected or dripped into or injected, dripped or formed around the
auxetic material, the composite material providing higher impact
performance than the individual materials. In an illustrative
example, combining various energy absorbing materials with auxetic
materials may further enhance impact performance. In some examples,
TPE material injected into auxetic structures may fill internal
voids. In some examples, the auxetic material may be suspended
within the TPE material and be encapsulated around the auxetic
material form. Auxetic materials may take various forms, for
example, sheets, 3-D structures, and particles, each providing
unique benefits. Various embodiments included within various
personal protection articles may advantageously provide long life
and enhance impact resistance.
Inventors: |
ZHOU; Shiqing; (Morris
Plains, NJ) ; DING; Winnie; (Morris Plains, NJ)
; LUO; Lori; (Morris Plains, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HONEYWELL INTERNATIONAL INC. |
Morris Plains |
NJ |
US |
|
|
Family ID: |
1000004797297 |
Appl. No.: |
16/639948 |
Filed: |
August 25, 2017 |
PCT Filed: |
August 25, 2017 |
PCT NO: |
PCT/CN2017/098996 |
371 Date: |
February 18, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/125 20130101;
B29L 2031/4864 20130101; B29C 45/1676 20130101; B29K 2021/003
20130101; A41D 19/01517 20130101 |
International
Class: |
A42B 3/12 20060101
A42B003/12; A41D 19/015 20060101 A41D019/015; B29C 45/16 20060101
B29C045/16 |
Claims
1. An enhanced auxetic composite material (EACM) prepared by a
process comprising the steps of: providing a quantity of auxetic
material; providing a quantity of thermoplastic elastomer (TPE)
material in a molten phase; combining the quantity of auxetic
material and the quantity of TPE material in a molten phase
together in a mold; and, transitioning the TPE material to a solid
phase to form the EACM.
2. The EACM of claim 1, wherein a predetermined shape of the mold
is a rectangular prism.
3. The EACM of claim 1, wherein a predetermined shape of the mold
is sized to the dimensions and shape of a knuckle section of a
glove.
4. The EACM of claim 1, wherein a predetermined shape of the mold
is sized to the dimensions and shape of a cushion section of a
helmet.
5. The EACM of claim 1, wherein the quantity of auxetic material
comprises a continuous unitary sheet of auxetic material.
6. The EACM of claim 1, wherein the quantity of auxetic material
comprises a plurality of auxetic particles.
7. The EACM of claim 1, wherein the quantity of auxetic material
comprises an auxetic 3-D structure material.
8. The EACM of claim 1, wherein the auxetic material further
comprises a porous surface, wherein the TPE material in the molten
phase ingresses into the porous surface when the auxetic material
and TPE material are combined, such that the TPE material permeates
the auxetic material to saturate the auxetic material with the TPE
material.
9. The EACM of claim 1, wherein the mold comprises a mold of a
compression molding machine.
10. The EACM of claim 1, wherein the step of combining the quantity
of auxetic material and the quantity of TPE material further
comprises: placing the TPE material in a molten state into a first
inject cell of a liquid injection molding machine; placing the
auxetic material in a molten or semi-molten state into a second
inject cell of the liquid injection molding machine; and, injecting
the TPE material in the first inject cell and the auxetic material
in the second inject cell into the mold.
11. A method for preparing an auxetic composite material (EACM)
comprising the steps of: providing a quantity of auxetic material;
providing a quantity of thermoplastic elastomer (TPE) material in a
molten phase; mixing the quantity of auxetic material and the
quantity of TPE material together in a mold having a predetermined
shape; and, transitioning the TPE material to a solid phase to form
the EACM.
12. The method of claim 11, wherein a predetermined shape of the
mold is a rectangular prism.
13. The method of claim 11, wherein a predetermined shape of the
mold is sized to the dimensions and shape of a knuckle section of a
glove.
14. The method of claim 11, wherein a predetermined shape of the
mold is sized to the dimensions and shape of a cushion section of a
helmet.
15. The method of claim 11, wherein the quantity of auxetic
material comprises a continuous unitary sheet of auxetic
material.
16. The method of claim 11, wherein the quantity of auxetic
material comprises a plurality of auxetic particles.
17. The method of claim 11, wherein the quantity of auxetic
material comprises an auxetic 3-D structure material.
18. The method of claim 11, wherein the auxetic material further
comprises a porous surface, wherein the TPE material in the molten
phase ingresses into the porous surface when the auxetic material
and TPE material are combined, such that the TPE material permeates
the auxetic material to saturate the auxetic material with the TPE
material.
19. The method of claim 11, wherein the mold comprises a mold of a
compression molding machine.
20. The method of claim 11, wherein the step of combining the
quantity of auxetic material and the quantity of TPE material
further comprises: placing the TPE material in a molten state into
a first inject cell of a liquid injection molding machine; placing
the auxetic material in a molten or semi-molten state into a second
inject cell of the liquid injection molding machine; and, injecting
the TPE material in the first inject cell and the auxetic material
in the second inject cell into the mold.
Description
TECHNICAL FIELD
[0001] Various embodiments relate generally to impact resistant
materials used in personal safety equipment.
BACKGROUND
[0002] Fabrics are employed throughout the world for various
purposes. For example, many fabrics are used to manufacture a wide
variety of clothing. In some instances, fabrics are used to
manufacture various bags, sacks, bed sheets, towels. Fabrics may
even be used in the making of currency. Basic fabrics may include
natural or synthetic fibers. For instance, natural fibers may
include cotton, linen, wool and silk. Synthetic fibers may include
polyester, acrylic and nylon.
[0003] Auxetic structures may be employed to produce auxetic
material. Auxetic material may exhibit unusual behavior when
stretched. Most materials when stretched become thinner. However,
auxetic materials, with their negative Poisson's ratio, become
thicker in response to applied stretching forces. This thickening
phenomenon is due to the way the auxetic structure deforms in
response to lateral stretching. Auxetic material has been employed
in various products to provide various advantages. For example,
auxetic material may be used in bandages with impregnated medicine.
The medicine may be released as the bandage is stretched around the
wound. As the wound swelling subsides, the material may be under
less tension, and may hold the medicine within the bandage.
SUMMARY
[0004] Apparatus and associated methods relate to an enhanced
auxetic composite material (EACM) of a base thermoplastic elastomer
(TPE) and/or a thermoset material combined with an auxetic
material, the composite formed with a molding process, where the
base material is injected or dripped into or injected, dripped or
formed around the auxetic material, the composite material
providing higher impact performance than the individual materials.
In an illustrative example, combining various energy absorbing
materials with auxetic materials may further enhance impact
performance. In some examples, TPE material injected into auxetic
structures may fill internal voids. In some examples, the auxetic
material may be suspended within the TPE material and be
encapsulated around the auxetic material form. Auxetic materials
may take various forms, for example, sheets, 3-D structures, and
particles, each providing unique benefits. Various embodiments
included within various personal protection articles may
advantageously provide long life and enhance impact resistance.
[0005] Various embodiments may achieve one or more advantages. For
example, various instances of personal protection equipment (e.g.,
gloves, shoes, helmets, knee and elbow-pads) may include integrated
EACMs. Wearers of such personal protection equipment (PPEs) may be
provided substantial protection from various impacts. Persons
working with high vibrational equipment or vehicles, with EACM
gloves, may be provided attenuated transfer of vibrational energy
due to the energy absorption of the various EACM materials, thereby
reducing fatigue and increasing comfort.
[0006] The details of various embodiments are set forth in the
accompanying drawings and the description below. Other features and
advantages will be apparent from the description and drawings, and
from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1A depicts a perspective view of an exemplary enhanced
auxetic composite material (EACM) implemented within a glove.
[0008] FIG. 1B depicts a perspective view of various exemplary
EACMs illustrating encapsulation relationships between a base
material and an auxetic material.
[0009] FIG. 2 depicts perspective views of an exemplary EACM
illustrating its impact resistance.
[0010] FIG. 3 depicts a perspective view of various exemplary
auxetic filler materials within an EACM.
[0011] FIG. 4 depicts an exemplary glove, illustrating various
implementation locations of EACM.
[0012] FIG. 5 depicts an exemplary helmet, illustrating various
implementation locations of EACM.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0013] To aid understanding, this document is organized as follows.
First, the fabrication of an exemplary enhanced auxetic composite
material (EACM) and the composition and structure are briefly
introduced with reference to FIG. 1A. Second, with reference to 1B,
various composite embodiments are illustrated. Next, with reference
to FIG. 2, the impact resistance of an exemplary EACM is depicted
in an illustrative use case. Next, with reference to FIG. 3,
various exemplary auxetic filler-material embodiments in various
formats are presented. Finally, in FIGS. 4 and 5, the discussion
turns to exemplary embodiments that illustrate locations of EACM
employment within various personal safety articles.
[0014] FIG. 1A depicts a perspective view of an exemplary enhanced
auxetic composite material (EACM) implemented within a glove. A
fabrication and implementation illustration 100 includes a sheet of
auxetic material 105A. The auxetic material 105A is placed into a
mold 110. The mold 110 is filled with a thermoplastic elastomer
(TPE) 115A, for example, thermoplastic rubber (TPR), in a molten or
semi-molten state. The auxetic material 105A in a solid state is
immersed in the thermoplastic elastomer 115A in a molten or
semi-molten state, within the mold 110. Once the thermoplastic
elastomer 115A is allowed to cure, an EACM 120 results. The EACM
120 is a thermoplastic elastomer 115B with an included auxetic
sheet 105B. The EACM 120 is then cut to fit various pouch sections
125 within a work glove 130. In some instances, the EACM 120 may be
die-cut to fit the various padded pouch sections 125.
[0015] In various examples, the EACM 120 includes the thermoplastic
elastomer 115B and the auxetic sheet 105B, where the thermoplastic
elastomer 115B in a semi-molten or molten state is injected into
the auxetic sheet 105B, substantially filling the gaps within a
structure making up the auxetic sheet 105. In some examples, the
thermoplastic elastomer 115B in a semi-molten or molten state is
injected around the auxetic sheet 105B. In some embodiments, the
thermoplastic elastomer 115B in a semi-molten or molten state is
injected into and around the auxetic sheet 105B. The combination of
the thermoplastic elastomer 115B and the auxetic sheet 105B may
substantially enhance impact performance of the individual
materials, the auxetic sheet 105B and the thermoplastic elastomer
115B.
[0016] An exemplary process for a molded EACM:
[0017] 1) Place a selected auxetic material in a solid state into a
mold.
[0018] 2) Place a pre-determined portion of TPR into the mold.
[0019] 3) Apply pre-determined temperature/time profile.
[0020] 4) Extract the final product(s) out of the mold.
[0021] An exemplary process for a molded EACM:
[0022] 1) Place a selected auxetic material in a solid state into a
mold.
[0023] 2) Dispense a pre-determined portion of TPR into the
mold.
[0024] 3) Apply pre-determined temperature/time profile.
[0025] 4) Extract the final product(s) out of the mold.
[0026] An exemplary process for a molded EACM:
[0027] 1) Place a selected auxetic material in a solid state into a
mold.
[0028] 2) Substantially saturate the auxetic material with molten
or semi-molten TPR.
[0029] 3) Place a pre-determined portion of molten or semi-molten
TPR into the mold.
[0030] 4) Apply pre-determined temperature/time profile.
[0031] 5) Extract the final product(s) out of the mold.
[0032] An exemplary process for a molded EACM:
[0033] 1) Place a selected auxetic material in a solid state into a
mold.
[0034] 2) Substantially saturate the auxetic material with molten
or semi-molten TPR.
[0035] 3) Dispense a pre-determined portion of molten or
semi-molten TPR into the mold.
[0036] 4) Apply pre-determined temperature/time profile.
[0037] 5) Extract the final product(s) out of the mold.
[0038] An exemplary process for a liquid injection molding
EACM:
[0039] 1) Place the selected molten or semi-molten base material
into a first inject cell of a liquid injection molding machine.
[0040] 2) Place a molten or semi-molten auxetic material into a
second inject cell of the liquid injection molding machine.
[0041] 3) Inject the solution from the first and second cells into
a main cell, according to molding structure design
requirements.
[0042] 4) Heat the molding at pre-determined temperature for a
pre-determined time.
[0043] 5) Extract the final product(s) out of the injection molding
machine.
[0044] An exemplary process for a compression molded EACM:
[0045] 1) Place a bottom TPR sheet into a compression tool.
[0046] 2) Place auxetic particles into the compression tool.
[0047] 3) Place a top TPR sheet into a compression tool.
[0048] 4) Place the compression tool into the compression molding
machine.
[0049] 5) Operate the compression molding machine. Pre-determined
variables may include: material thickness, temperature, compression
force and/or compression time.
[0050] 6) Extract the tool from the compression molding
machine.
[0051] 7) Extract the final product(s) out of the tool.
[0052] An exemplary process for a compression molded EACM:
[0053] 1) Place a bottom TPR sheet into a compression tool.
[0054] 2) Place an auxetic sheet into the compression tool.
[0055] 3) Place a top TPR sheet into the compression tool.
[0056] 4) Place the compression tool into the compression molding
machine.
[0057] 5) Operate the compression molding machine. Pre-determined
variables may include: material thickness, temperature, compression
force and/or compression time.
[0058] 6) Extract the tool from the compression molding
machine.
[0059] 7) Extract the final product(s) out of the tool.
[0060] An exemplary process for a resin transfer molded (RTM)
EACM:
[0061] 1) Place a bottom TPR sheet into an RTM tool.
[0062] 2) Place an auxetic sheet into the RTM tool.
[0063] 3) Place a top TPR sheet into the RTM tool.
[0064] 4) Place the compression tool into the compression molding
machine.
[0065] 5) Operate the RTM machine, which may force resin (and/or
glue) into the mold, between the sheets. Pre-determined variables
may include: material thickness, temperature, resin injection force
and/or compression time.
[0066] 6) Extract the tool from the RTM machine.
[0067] 7) Extract the final product(s) out of the tool.
[0068] FIG. 1B depicts a perspective view of various exemplary
EACMs illustrating encapsulation relationships between a base
material and an auxetic material. An EACM 135A includes an auxetic
sheet material 140, and a base material 145 (e.g., thermoplastic
rubber (TPR)). In this example, the base material 145 may be
initially molten or semi-molten, and the auxetic sheet material 140
may be solid, having the consistency of foam rubber. As such, as
the base material 145 is molded around the auxetic sheet material
140, the base material 145 may not substantially ingress into the
auxetic sheet material 140. The result may be the base material 145
surrounding the auxetic sheet material 140.
[0069] An EACM 135B includes an auxetic particle material 150, and
a base material 155 (e.g., Ethylene-Butylene-Styrene (SEBS)). In
this example, the base material 155 may be initially molten or
semi-molten, and the auxetic particle material 150 may have the
consistency of foam rubber. As such, as the base material 155 is
molded around the auxetic particle material 150, the base material
155 may not substantially ingress into the auxetic particle
material 150, but may fill the gaps between the individual
particles within the particle material 150. The result may be the
base material 155 surrounding the auxetic particle material 150 in
a substantially uniform dispersion.
[0070] An EACM 135C includes an auxetic 3-D structure material 160,
and a base material 165 (e.g., thermoplastic urethane (TPU)). In
this example, the base material 165 may be initially molten or
semi-molten. In this example, as the base material 165 is molded
around the auxetic 3-D structure material 160, the base material
165 may not substantially ingress into the 3-D structure material
160. The result may be the base material 165 surrounding the 3-D
structure material 160.
[0071] An EACM 135D includes an auxetic 3-D structure material 170,
and a base material 175 (e.g., silicon rubber, polyvinyl chloride
(PVC)). In this example, the base material 175 may be initially
molten or semi-molten. In this example, as the base material 175 is
molded over the auxetic 3-D structure material 170, the base
material 175 may substantially ingress into the auxetic 3-D
structure material 170, substantially filling the gaps within the
3-D structure material 170. The result may be the base material 175
surrounding and impregnating the auxetic 3-D structure material
170.
[0072] In some embodiments, the EACMs 135A, 135B, 135C and 135D may
include a foamed TPR. The foamed TPR base material 145, 155, 165
and 175 may provide additional energy absorption, providing an even
higher degree of impact protection to the user. In various
examples, other base materials described may be foamed to produce
the higher degree of impact protection.
[0073] In some examples, the molding process may include injection
molding or vacuum injection molding, which may advantageously fill
voids reliably. In some examples, a pressure molding process may be
employed. Employment of pressure molding may allow sheets of base
material and sheets of auxetic material to be pressure molded
together producing a sandwich-style EACM result.
[0074] Various examples of the EACM (e.g., 135A, 135B, 135C and
135D) may substantially enhance impact performance of the
individual materials (e.g., 140, 145, 150, 155, 160, 165, 170,
175).
[0075] FIG. 2 depicts perspective views of an exemplary EACM
illustrating its impact resistance. A protection use case 200
includes a glove 205. A pouch section 210 is fixedly coupled to the
glove 205. The pouch section 210 includes a sheet of EACM 215. The
glove 205, shown in cross-section, is proximate to a user finger
220 also shown in cross-section. In some examples, the sheet of
EACM 215 may be referred to as a filler material.
[0076] In operation, when an object 225 strikes the glove 205,
specifically on the pouch sections 210 containing the sheet of EACM
215, the EACM 215 shortens in height in response to the impact. Due
to its auxetic nature, the internal structure of the EACM 215
consolidates, reflecting some of the impact back to the object 225.
During this consolidation and reflection, the energy of the energy
from the impact is also dispersed over a wider surface 230,
reducing the impact concentration. In addition, due to the
inclusion of a thermoplastic elastomer (e.g., FIG. 1A, item 115)
within the EACM 215, substantial energy absorbing characteristics,
may take place. The EACM 215 composed of a base material (e.g.,
TPR) with auxetic material may advantageously enhance an impact
performance of the composite EACM 215 material.
[0077] FIG. 3 depicts a perspective view of various exemplary
auxetic filler materials within an EACM. FIG. 3 includes an auxetic
sheet 305. Next, FIG. 3 includes auxetic particles 310. The auxetic
particles may be small chunks of the auxetic sheet 305. Finally,
FIG. 3 illustrates an auxetic material in the form of a 3-D
structure 315. The 3-D structure 315 may include substantial open
space (voids) within the structure. The voids within the 3-D
structure 315 may be suitable for liquid injection molding of a
base material. Various examples of EACMs composed of a base
material with various forms of auxetic material, for example,
sheets 305, particles 310, and 3-D structures 315 may
advantageously enhance an impact performance of a resulting
composite EACM material.
[0078] FIG. 4 depicts an exemplary glove, illustrating various
implementation locations of EACMs. An exemplary glove 400 includes
a little knuckle pad 405A, a ring knuckle pad 405B, a middle
knuckle pad 405C and an index knuckle pad 405D. The exemplary glove
400 includes a little proximal pad 410A, a ring proximal pad 410B,
a middle proximal pad 410C and an index proximal pad 410D. The
exemplary glove 400 includes a little intermediate pad 415A, a ring
intermediate pad 415B, a middle intermediate pad 415C and an index
intermediate pad 415D. The exemplary glove 400 includes a little
distal pad 420A, a ring distal pad 420B, a middle distal pad 420C
and an index distal pad 420D.
[0079] The exemplary glove 400 includes a thumb proximal pad 425A
and a thumb distal pad 425B. The exemplary glove 400 includes a
thumb-index metacarpal pad 430. The exemplary glove 400 includes a
middle-little metacarpal pad 435. The exemplary glove 400 includes
a ring metacarpal pad 440. The exemplary glove 400 includes a first
dorsal interosseous pad 445. The exemplary glove 400 includes a
first dorsal interosseous reinforcement 450. Finally, the exemplary
glove 400 includes a wrist sleeve 455.
[0080] The glove 400 may include various embodiments of the EACMs
(e.g., FIG. 1B, items 135A, 135B, 135C and 135D) within the
identified pads (e.g., 405A, 405B, 405C, 405D, 410A, 410B, 410C,
410D, 415A, 415B, 415C, 415D, 420A, 420B, 420C, 420D, 425A, 425B,
430, 435, 440, 445). These EACM inclusions may substantially
enhance impact performance of the individual materials. In various
examples, personal safety articles (e.g., jackets, knee-pads,
elbow-pads) with integrated EACMs may protect the wearer (user)
from cuts, impacts, and vibrations.
[0081] FIG. 5 depicts an exemplary helmet, illustrating various
implementation locations of EACM. A helmet 500, includes a
cushioning material 505. The cushioning material 505 is included
within the interior of the helmet 500. When the helmet 500 is worn
on the head of a user, the cushioning material 505 is located
between the helmet 500 and the user's head. The cushioning material
505 may include one or more of the various embodiments of the EACMs
(e.g., FIG. 1B, items 135A, 135B, 135C and 135D). These inclusions
may substantially enhance impact performance of the individual
materials. In various examples, the EACM may provide substantial
comfort due to the energy dissipation nature of the EACM composite
material.
[0082] Although various embodiments have been described with
reference to the figures, other embodiments are possible. For
example, the EACM may be composed of two materials, a first
material and a second material. In some examples, the first
material may be thermoplastic rubber (TPR), which may
advantageously provide flexibility and energy absorption from
various impacts. In some embodiments, the first material may be
Styrene-ethylene-butylene-styrene (SEBS), which may advantageously
provide substantial weather resistance and heat resistance. In
various examples, the first material may be thermoplastic urethane
(TPU), which may advantageously provide exceptional performance in
cold temperatures, and resistance to water and various petroleum
products. In some examples, the first material may be polyvinyl
chloride (PVC), which may advantageously mix well with other
substances, and may retard microbial growth, as well as provide
impact resistance. In various embodiments, the first material may
be silicon rubber, which may advantageously provide heat
resistance, resistance to cold temperatures and electrical
insulation. In various embodiments, the first material may be
thermoset, which may advantageously provide high strength and
durability.
[0083] In various embodiments, the first material may be a mixture
which includes a shear thickening material. In some examples of the
shear thickening material may be liquid. In some embodiments, the
shear thickening material may be solid.
[0084] In various embodiments, the auxetic material may be composed
of crystalline cellulose. In some examples, the auxetic material
may be composed of molecular-level polymers.
[0085] In some examples, the auxetic material may be composed of
microporous polymer and/or fibers. Such examples may include
cylinders and plaques. Various processes may be employed for
fabrication, for example, powder compaction sintering and
extrusion.
[0086] In various examples, the auxetic material may be composed of
a liquid crystalline polymer, which may advantageously resist
melting at high temperatures.
[0087] Various examples of the auxetic material may be implemented
in a sandwich structure, for example, an angle-ply laminate, an
auxetic textile reinforcement and/or sandwich panels. Various
processes may be employed to fabricate the sandwich structures, for
example, pre-preg, hand layup and vacuum bagging.
[0088] In some examples, the auxetic material may be in the form of
auxetic monofilaments and/or films. Processes employed may include
continuous melt extrusion, for example.
[0089] In various embodiments, the auxetic material may be provided
in the form of auxetic honeycombs, which may be, for example, flat
and curved panels. Various processes may be employed to fabricate
auxetic honeycomb forms, for example, rapid prototyping, laser
cutting and snap fitting.
[0090] In some examples, the auxetic material may be auxetic foams
in various shapes and/or form factors, for example, cylinders and
cuboids or flat and curved thin sheets. Various processes may be
employed, for example, compression and heat treatment.
[0091] In various examples, the EACM may have multiple layers or
pieces of auxetic material. For example, there may be multiple
strips of auxetic material that are overlapping or crisscrossing.
In some examples, the pieces of auxetic material may be parallel,
orthogonal, acute, and/or obtuse with respect to one another. In
some embodiments, the layers of auxetic material may be oriented in
an interstitial pattern. In some examples, the layers of auxetic
material may form interwoven strands. In some embodiments, the
auxetic material may be arbitrarily shaped chucks of auxetic
material (e.g., diced auxetic material).
[0092] The auxetic materials may take various exemplary forms, for
example, sheets, 3-D structures, and particles, each providing
unique benefits. For example, auxetic sheets may be pressure molded
together with various base material. Auxetic 3-D structures may be
impregnated more readily. Auxetic particles may provide
manufacturers with substantial control over performance of the
overall composite material, by allowing flexibility of portion
control.
[0093] In an exemplary aspect, an enhanced auxetic composite
material (EACM) may be prepared by a process comprising the steps
of (1) providing a quantity of auxetic material, (2) providing a
quantity of thermoplastic elastomer (TPE) material in a molten
phase, (3) combining the quantity of auxetic material and the
quantity of TPE material in a molten phase together in a mold, and
(4) transitioning the TPE material to a solid phase to form the
EACM.
[0094] The EACM preparation process may further include a
predetermined mold shape, for example, a rectangular prism. The
EACM preparation process may further include a predetermined mold
shape sized to the dimensions and shape of a knuckle section of a
glove, for example, as depicted in FIG. 4 items 405A, 405B, 405C,
and 405D. The EACM preparation process may further include a
predetermined mold shape sized to the dimensions and shape of a
cushion section of a helmet. The EACM preparation process may
further include a continuous unitary sheet of auxetic material. The
EACM preparation process may further include a plurality of auxetic
particles. The EACM preparation process may further include an
auxetic 3-D structure material. The EACM preparation process may
further include an auxetic material with a porous surface, wherein
the TPE material in the molten phase ingresses into the porous
surface when the auxetic material and TPE material are combined,
such that the TPE material permeates the auxetic material to
saturate the auxetic material with the TPE material. The EACM
preparation process may include a mold of a compression molding
machine.
[0095] The EACM preparation process may further include (1) placing
the TPE material in a molten state into a first inject cell of a
liquid injection molding machine, (2) placing the auxetic material
in a molten or semi-molten state into a second inject cell of the
liquid injection molding machine, and (3) injecting the TPE
material in the first inject cell and the auxetic material in the
second inject cell into the mold.
[0096] In an exemplary aspect, an enhanced auxetic composite
material (EACM) may be prepared by a process comprising the steps
of (1) providing a quantity of auxetic material, (2) providing a
quantity of thermoplastic elastomer (TPE) material in a molten
phase, (3) mixing the quantity of auxetic material and the quantity
of TPE material together in a mold having a predetermined shape,
and (4) transitioning the TPE material to a solid phase to form the
EACM.
[0097] In some examples, the EACM may not be limited to auxetic
materials. In such examples, various non-auxetic materials may be
combined with the base material. For example, foam rubber sheets
may advantageously provide high impact dampening performance. In
some examples, polyethylene closed cell particles may be employed
to provide high cushioning performance. Further, in some examples,
polyurethane open cell 3D structures may be used to reduce
vibration.
[0098] A number of implementations have been described.
Nevertheless, it will be understood that various modification may
be made. For example, advantageous results may be achieved if the
steps of the disclosed techniques were performed in a different
sequence, or if components of the disclosed systems were combined
in a different manner, or if the components were supplemented with
other components. Accordingly, other implementations are
contemplated within the scope of the following claims.
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