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.

What is claimed is: 
     
         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.