MULTI-THREAT PROTECTIVE ARTICLE WITH A MULTI-LAYERED FABRIC COMPOSITE
Traditional protective suits often struggle to balance puncture resistance with flexibility and comfort. Existing materials may provide protection but can be cumbersome or less effective under different threat conditions. This invention addresses these issues by employing a composite structure that leverages 2D fillers, 3D fabric configurations with auxetic performance, and a brick-and-mortar polymer compound to enhance both puncture resistance and energy absorption.
1 . A multi-threat protective article with a multi-layered assembly, wherein the multi-layered assembly comprises:
an external hard coating layer for external protection;
a negative Poisson's ratio fabric layer, the negative Poisson's ratio fabric layer has raised strips or a sandwich structure with two faces partially unconnected, thereby forming a negative Poisson's ratio structure;
a dense unidirectional fabric layer; and
an inner foam layer positioned closest to a user's body for impact absorption,
wherein the negative Poisson's ratio fabric layer and the dense unidirectional fabric layer are deposited between the external hard coating layer and the inner layer,
wherein each layer of the multi-threat protective article has a stiffness ranging from 0.9N in the inner foam layer to 50N in the dense unidirectional fabric layer according to ASTM D4032-08.
2 . The multi-threat protective article of claim 1 , wherein the multi-layered assembly is made from a fabric composite produced using a masterbatch comprising:
an exfoliated two-dimensional filler being exfoliated and surface modified by a compatibilizer; and
a polymeric material, wherein the polymeric material is strengthened by the exfoliated two-dimensional filler to form a microstructure with each layer staggered relative to the adjacent layer,
wherein the exfoliated two-dimensional filler has a width of less than 10 μm and an aspect ratio of at least 50.
3 . The multi-threat protective article of claim 2 , wherein the exfoliated two-dimensional filler is exfoliated and surface modified by the compatibilizer prior to blending with the polymeric material.
4 . The multi-threat protective article of claim 2 , wherein the compatibilizer comprises polypropylene grafted maleic anhydride (PP-g-Ma), polyethylene grafted maleic anhydride (PE-g-Ma), ethylene-butyl acrylate grafted Methacrylate (EBA-g-Ma), poly(oligo(ethylene glycol) grafted methacrylate (POE-g-Ma), amino silane, or a combination thereof.
5 . The multi-threat protective article of claim 2 , wherein the polymeric material comprises polypropylene (PP), high density polyethylene (HDPE), ultrahigh molecular weight polyethylene (UHMWPE), polyamides (PA), polyurethane (PU), silicone rubber, or a combination thereof.
6 . The multi-threat protective article of claim 1 , wherein the exfoliated two-dimensional filler comprises clay, graphene, MXene, zirconium phosphate (ZrP), boron nitride (BN), molybdenum disulfide (MoS), layered double hydroxides (LDH), or a combination thereof.
7 . The multi-threat protective article of claim 1 , wherein the negative Poisson's ratio fabric layer has a negative Poisson's ratio.
8 . The multi-threat protective article of claim 1 , wherein the multi-layered fabric composite further comprises a one-dimensional filler co-mixed with the exfoliated two-dimensional filler, promoting a parallel alignment of the exfoliated two-dimensional filler.
9 . The multi-threat protective article of claim 8 , wherein the one-dimensional filler comprises carbon nanotubes and carbon nanowires.
10 . The multi-threat protective article of claim 9 , wherein the one-dimensional filler has a length greater than 20 μm.
11 . The multi-threat protective article of claim 9 , wherein the carbon nanotubes comprise single-walled carbon nanotubes, multi-walled carbon nanotubes, functionalized carbon nanotubes, or doped carbon nanotubes.
12 . The multi-threat protective article of claim 9 , wherein the carbon nanowires comprise graphene nanoribbons, carbon nanofibers.
13 . The multi-threat protective article of claim 2 , wherein the fabric composite further comprises a thixotropic agent comprising Thixatrol Plus, Thixatrol Max, Thixatrol ST, Thixatrol R, PE-WAX, PP-WAX, or a combination thereof.
14 . The multi-threat protective article of claim 1 , wherein the multi-threat comprises puncture-resistant, knife, and ballistic projectile penetration.
15 . A method for manufacturing a multi-threat protective article, comprising:
preparing a masterbatch, wherein the masterbatch comprises an exfoliated two-dimensional filler that is exfoliated and surface modified by a compatibilizer, and a polymeric material;
forming a multi-layered fabric composite from the masterbatch, wherein the multi-layered fabric composite is sequentially deposited from the inside out to include: an inner foam layer, a dense unidirectional fabric layer, and an external hard coating layer,
wherein the exfoliated two-dimensional filler has a width of less than 10 μm and an aspect ratio of at least 50.
16 . The method of claim 15 , wherein the exfoliated two-dimensional filler is blended with the polymeric material to form a microstructure with each layer staggered relative to the adjacent layer.
17 . The method of claim 15 , wherein the method further comprising co-mixing a one-dimensional filler with the exfoliated two-dimensional filler.
18 . The method of claim 15 , wherein the method further comprising incorporating a thixotropic agent into the masterbatch.