Composite material

Abstract

Systems and methods for composite materials, including coatings and stand-alone structures are provided. An apparatus may include a first layer structure that includes a first plurality of densely packed sub-macroscale particles having a first mean diameter; and at least a second layer structure that includes a second plurality of densely packed sub-macroscale particles having a second mean diameter that is different from the first mean diameter. The first layer structure and the second layer structure may be applied to a substrate, where the substrate may be an article of sports equipment, medical device or other article.

What is claimed is: 
     
         1 . A sports equipment apparatus comprising:
 a first layer structure comprising a first plurality of densely packed sub-macroscale particles having a first mean diameter; and   at least a second layer structure comprising a second plurality of densely packed sub-macroscale particles having a second mean diameter that is different from the first mean diameter,   wherein the first layer structure and the second layer structure are applied to a substrate, and wherein the substrate is an article of sports equipment.   
     
     
         2 . The apparatus of  claim 1 , wherein the first mean diameter is greater than the second mean diameter. 
     
     
         3 . The apparatus of  claim 1 , wherein the first mean diameter is less than the second mean diameter. 
     
     
         4 . The apparatus of  claim 1 , wherein the sub-macroscale particles are selected from a group consisting of: microscale particles, nanoscale particles, and combinations thereof. 
     
     
         5 . The apparatus of  claim 1 , wherein a selected one of the first layer structure and the second layer structure comprises solid particles. 
     
     
         6 . The apparatus of  claim 1 , wherein a selected one of the first layer structure and the second layer structure comprises hollow core shell particles that are configured to deform upon being subjected to the compression wave. 
     
     
         7 . The apparatus of  claim 1 , wherein a selected one of the first layer structure and the second layer structure comprises hollow core shell particles that are configured to rupture upon being subjected to the compression wave. 
     
     
         8 . The apparatus of  claim 1 , wherein a selected one of the first layer structure and the second layer structure comprises liquid filled particles that are configured to release a liquid upon being subjected to the compression wave. 
     
     
         9 . The apparatus of  claim 1 , wherein the sub-macroscale particles comprise particles selected from a group consisting of: polystyrene, silica and carbon. 
     
     
         10 . The apparatus of  claim 1 , further comprising a plurality of adjacent layer structures, each of the plurality of adjacent layer structures including a plurality of densely packed sub-macroscale particles having a corresponding mean diameter, the plurality of adjacent layer structures disposed so that a mean diameter gradient is formed across the plurality of adjacent layer structures. 
     
     
         11 . The apparatus of  claim 1 , wherein the particles are functionalized prior to deposition. 
     
     
         12 . The apparatus of  claim 11 , wherein the particles include carboxylic acid functionality. 
     
     
         13 . The apparatus of  claim 11 , wherein the particles are polarized. 
     
     
         14 . The apparatus of  claim 1 , further comprising an intermediary layer comprising a composite of polymer and carbon allotrope. 
     
     
         15 . The apparatus of  claim 14 , further comprising an outer layer of the same composite. 
     
     
         16 . A method of making an article of sporting equipment, the method comprising:
 depositing a first plurality of sub-macroscale particles having a first mean diameter and suspended in a first liquid medium onto a substrate;   subjecting the first plurality and the substrate to a first environment for a first preselected amount of time sufficient to cause the first liquid medium to evaporate leaving a first layer structure of the plurality of sub-macroscale particles on the substrate;   depositing a second plurality of sub-macroscale particles having a second mean diameter, different from the first mean diameter, and suspended in a second liquid medium onto first layer structure; and   subjecting the second plurality, the first plurality and the substrate to a second environment for a second preselected amount of time sufficient to cause the second liquid medium to evaporate leaving a second layer structure of the plurality of sub-macroscale particles on the first layer structure, and   wherein the substrate is an article of sporting equipment.   
     
     
         17 . The method of  claim 16 , further comprising the action of irradiating the substrate so as to create an organic acid functionality on a surface of the substrate, thereby increasing adhesion of the sub-macroscale particles thereto. 
     
     
         18 . The method of  claim 16 , wherein the sub-macroscale particles comprise particles selected from a group consisting of: polystyrene, silica and carbon. 
     
     
         19 . The method of  claim 16 , wherein the sub-macroscale particles comprise particles selected from a group consisting of: solid, hollow and core shell, filled, unfilled, and filled in part. 
     
     
         20 . The method of  claim 16 , further comprising the action of functionalizing the sub-macroscale particles prior to deposition. 
     
     
         21 . The method of  claim 20 , wherein the functionalizing action comprises providing the sub-macroscale particles so at to include carboxylic acid functionality. 
     
     
         22 . The method of  claim 20 , wherein the functionalizing action comprises polarizing the sub-macroscale particles. 
     
     
         23 . The method of  claim 20 , wherein the sub-macroscale particles comprise particles selected from a group consisting of: nanoscale particles, microscale particles and combinations thereof. 
     
     
         24 . A medical device apparatus comprising:
 a first layer structure comprising a first plurality of densely packed sub-macroscale particles having a first mean diameter; and   at least a second layer structure comprising a second plurality of densely packed sub-macroscale particles having a second mean diameter that is different from the first mean diameter,   wherein the first layer structure and the second layer structure are applied to a substrate, and wherein the substrate is an article of medical equipment.   
     
     
         25 . A sports equipment apparatus comprising:
 a layer structure that includes a plurality of densely packed sub-macroscale particles having a first mean diameter,   wherein the first mean diameter is approximately 150 nm,   wherein the layer structure comprises at least approximately 30 layers of the particles,   wherein the layer structure is applied to a substrate, and   wherein the substrate is an article of sports equipment.