Abstract:
A protective clothing fabric is described which combines hard polymers with flexible polymers. The scales or miniplate components are hard and provide protection from both bullets and knives. The polymer matrix is pliable and gives the composite material sufficient flexibility so that the material is suitable for clothing. With additional design layouts, the composite substances can be formed into gloves, goggles, boots and other accessories and with still additional layouts results in lightweight but protective headgear. With still additional design layouts, the composite substances can be formed into linings for gloves, boots and other accessories or injection molded for goggles and helmets.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 61/693,292, filed Aug. 26, 2012, the contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The life of military personnel on the modern battlefield is becoming increasingly difficult. Because of increasing technological requirements, they are asked to carry more and more equipment into battle. They face improved weapons with greater potential to harm. As a result, the modern military faces a choice of insisting on equipping personnel with heavier and heavier protective clothing or settling for exposing them to greater danger. 
         [0003]    For example, U.S. marines had used 30 pound “interceptor vests” in Iraq and Afghanistan at $1500 per vest. More recently they use “modular tactical vests” which uses the similar plate inserts to protect the vital organs and weigh 3 more pounds than the vests. The heavier body armor and has required further modification to take stress and weight off the shoulders of the marines. 
         [0004]    The Kevlar Personal Armor System for Ground Troops “PASGT” helmet consists of 19 layers of Kevlar. Kevlar is an aramid fiber treated with a phenolic resin system and is rated at a Threat II level to protect against shrapnel and ballistic threats. It weighs between 3.1 and 4.2 pounds depending on size. 
         [0005]    The marines have switched to a lightweight combat helmet manufactured by Gentex Corp of Pa. It offers a 5 oz reduction in head-borne weight. It has more fragmentation protection than the PASGT helmet. 
         [0006]    The helmet of choice for the other services now is the Advanced Combat Helmet, which allows for maximum sensory and situational awareness. Included is an unobstructed field of view. It offers less side and rear protection than the old PASGT. 
         [0007]    In addition to military needs, protective equipment such as helmets, chest protectors, elbow and knee pads and the like are needed for sporting events. 
         [0008]    In view of the above, a need has arisen for substantially lighter, more protective material. Disclosed herein is a protective clothing design significantly different from the prior art. There are, generally speaking, two components, a hard, scale-like component (a “mini-plate” or “nano particles cluster”) combined with a polymer matrix. The polymer matrix can be a polyether-based thermoplastic polyurethane (TPU) containing a plasticizer such as a molten TPU-with-PlasticizerA10W poured onto the sheet of scale components. 
         [0009]    The scale components are hard and provide protection from both bullets and knives. The polymer matrix is pliable and gives the composite material sufficient flexibility so that the material is suitable for clothing. With additional design layouts, the composite substances can be formed into gloves, goggles, boots and other accessories and with still additional layouts results in lightweight but protective headgear. With still additional design layouts, the composite substances can be formed into linings for gloves, boots and other accessories or injection molded for goggles and helmets. 
       BRIEF DESCRIPTION 
       [0010]    A special combination of light weight materials are used to achieve stab puncture, bullet and impact force injury protection. 
         [0011]    In one embodiment several types of materials are combined: thermoplastic urethane (TPU) elastomers, thermoplastic polyurethane (Polyester) elastomers, and glass fiber reinforced thermoplastic polyester-polyurethane (having high impact resistance, high modulus with elasticity, low coefficient of thermal expansion, comparable with steel and aluminum, with low mold shrinkage and other exceptional properties). Preferred embodiments materials such as R 6000, C 60 D 53, C64 D53, making up the plates themselves. Also plates can have a layer of the R6000 and a layer of C60D53 or C64D53 under the R6000. Generally speaking each plate or nano particles&#39; cluster would have been molded or pressed together into one layer. 
         [0012]    These materials can be processed through injection molding for different uses. The particular combination of materials depends on how the end product will be used, as materials can be modified according to the needs of a particular application. 
         [0013]    In addition, these materials can be reinforced at the edges with Glass Reinforced Aramid or better Yarns of at least 1 mm. 
         [0014]    Another embodiment comprises certain urethane foams, used in layers, some perforated to render more cushioning and others with a higher degree of firmness, which provide protection from impact force injury caused by the energy of a bullet or attempted puncture, when striking a soldier or law enforcement officer, as happens with other materials such as Kevlar, which cannot protect against impact injury (broken ribs, etc.) even though it can stop bullets. 
         [0015]    Materials can be combined into different thicknesses, densities and surface textures to accommodate almost any application and activity, from everyday use to the rigorous demands of high-impact military use as well as high impact sports. If the precise material doesn&#39;t already exist for a military or civilian application, one can be custom formulated by combining the properties of the different existing foams to fill the needs of a specific user, military or civilian and their manufacturer&#39;s physical and aesthetic requirements. 
         [0016]    As used herein the term “polymer” is defined broadly to include not only materials made from a single polymers but blends of two or more polymers. The polymers can be combined in any fashion, for example by blending melted precursors together, coating a solid or semi-solid polymer with a liquid polymer, weaving polymers together as well as other methods. 
         [0017]    The foam materials chosen, as combined, with some layers specifically perforated as required for specific “cushioning” applications went through 12-13 years of impact force testing by the manufacturer and another five years of independent wear testing and were shown to provide the following characteristics. 
         [0018]    Maximum retention of comfort and flexibility is provided. Urethanes are made without plasticizers, which means the material will not shrink or become brittle and crack with age. The foam Urethanes were tested and retain “like-new” softness and flexibility. 
         [0019]    This combination of materials results in a high degree of impact, or shock, absorption. This is a desirable quality because it results in less impact to head, body, feet and joints. In side-by-side drop weight tests, the instant combination of materials outperformed vinyl sponge, neoprene sponge, sponge rubber, latex foam and solid visco-elastic materials. 
         [0020]    The specific combination of Urethane foams are assembled to create a breathable layer to help dissipate moisture and allow the soldier to stay dry and cool. Urethane materials form permeable layers that draw water vapor and perspiration away. 
         [0021]    The Urethane foams are also anti-bacterial and anti-allergenic, so it will give maximum comfort to the soldier whether the soldier is in theater or when performing ordinary non-combat duties. 
         [0022]    The instant combination of outer layers of Thermoplastic Urethane Elastomers, Thermoplastic Polyurethane (Polyester) Elastomers and Glass fiber reinforced Thermoplastic Polyester-Polyurethane are used with inner layers of the above described foam materials (for cushioning) and offer puncture and bullet proof protection as well as protection from impact force injury beyond the strike layer of solid (hard) material. Therefore, it can be used as significant protection for the head and the entire body in Helmets, Goggles, Uniforms, Vests, Gloves, Boots and Other Body Armor for use by the Military and/or Law Enforcement. 
         [0023]    Further, since the Urethane Foams are compressible to almost zero, resilient and extremely flexible, they can yield room for certain special uses. For example, a soldier using a helmet lined with urethane foam will find that the foam will compress to provide enough room for ear phones and revert back to previous form when the soldier is not using ear phones. In the case of high impact sports, the foam can be used to protect the head, sensitive body parts and/or joints, neck, spine, etc. Outer solid layers of the TPU&#39;s can be colored as required, as the Military would require. 
     
    
     
       THE DRAWINGS 
         [0024]      FIG. 1  is a schematic view of the protective clothing fabric on the left with individual layers detailed on the right. 
           [0025]      FIG. 2A-C  illustrate a preferred method of connecting the plates together in an array. 
       
    
    
     DETAILED DESCRIPTION 
     Cross Section of Uniform Material Combination 
       [0026]    As shown schematically in  FIG. 1 , in one preferred embodiment, the protective clothing fabric  100  comprises at least some of the following layers (listed here from outer layers to inner layers):
       Uniform Outer Material;   A flexible polymer such as Elastollan® TPU-with-Plasticizer   Combined glass fiber reinforced TPU with other TPU&#39;s and/or PUU or TPU-polyester materials shaped into sheets of mini plates reinforced on the sides with glass reinforced yarn and then imbedded in TPU-with-plasticizer, then layered;   Elastollan® TPU-with-Plasticizer;
           Combined glass fiber reinforced TPU with other TPU&#39;s and/or PUU or TPU-polyester materials (imbedded in TPU-with-Plasticizer) Mini Plates with Snake Skin Design;   
           Imbedded Layered Mini Plates;   TPU-with-Plasticizer;   Perforated High Performance Perforated Micro Cellular Urethane Foam Cushion Materials;   Non Perforated High Performance Perforated Micro Cellular Urethane Foam Cushion Materials;   Perforated High Performance Perforated Micro Cellular Urethane Foam Cushion Materials;   Non Perforated High Performance Perforated Micro Cellular Urethane Foam Cushion Materials; and   Gauze Lining       
 
         [0039]    As shown schematically in  FIG. 1 , these layers  100 , described in more detail below, provide Total Body Protection from Stab Puncture, Bullet and Impact Force Injury limited at impacts such as those of a 50 caliber round and similar, which are capable of destroying a tank. 
         [0040]    The glass fiber reinforced TPU and other TPU&#39;s and/or PUU or TPU-polyester materials typically come in granules which then go through an injection molding process to take a preselected shapes. Illustrated is a pentagonal “miniplate”  106  which can be combined to form an array of rows and columns. In one embodiment the bottoms of the plates in an upper row will overlap with the tops of the plates in the row directly below. 
         [0041]    Any small shape will function to one degree or another such as square circular or the irregular scale-like shapes  112  that combine to form a snake skin pattern  110 . 
         [0042]    Depending on the application and type of protection needed, the granules can be mixed with other super puncture resistant materials such as TPU-polyester materials and also depending on the use and application intended for the preselected shape(s), which are different for a uniform, gloves, helmet, goggles and boots. The combination of glass fiber reinforced TPU and other TPU&#39;S and/or PUU or TPU-polyester materials will be put in plates, secured by Glass Reinforced Yarn and imbedded into the super flexible and puncture resistant TPU-with plasticizer (although less than the TPU-Polyester Materials). 
         [0043]    Imbedding into this super flexible material (TPU with Plasticizer) is only for the purpose of providing utmost body parts flexibility while maintaining the mini-plates&#39; position within the specially designed sheet for protection of the person wearing a uniform with the layered material. 
         [0044]    The glass fiber reinforced TPU with other TPU&#39;s and/or PUU or TPU-polyester materials can be combined during injection molding process, with TPU-polyester materials and be colored or transparent, depending on the particular application intended. For instance, when higher stab puncture protection is needed as in gloves or goggles. While combined glass fiber reinforced TPU with other TPU&#39;S and/or PUU or TPU-polyester materials is as strong as steel if not stronger, TPU-Polyester Material has proven to have particularly high stab puncture resistance, which may be useful in certain combat situations. 
         [0045]    Then, in order to make the sheet material of layered mini plates even more secure, the plates may be outlined with Aramid Fiber, such as Technora® or Teijin®, as reinforcement for the mini-plates not to move from their position when imbedded on the TPU-with-Plasticizer and making said reinforcement no less than a 1 mm width and able to reinforce prevention of bullets of most battleground or law enforcement use calibers from penetrating the uniform anywhere. Seams of the uniforms will be required to overlap as well in order to provide maximum protection from any angle. 
         [0046]    When required for greater protection, Aramid Yarn, such as Technora® or Teijin® or other, even stronger Aramid Yarn, such as Vectran®, depending on the application and degree of protection wanted, and where or how it will be used, such as Carbon PAN based. 
         [0047]    The above layer can be composed of Mini Plates made of combined glass fiber reinforced TPU with other TPU&#39;S and/or PUU or TPU-polyester materials is specially shaped into Mini Plates, which are then specially layered. The mini-plates can be outlined with aramid fiber if desired and then imbedding the sheet of the miniplates material described above in a bed of TPU-with-Plasticizer material. 
         [0048]    As described above, another preferred embodiment includes the same properties of the previous layer regarding the combination of materials to provide maximum protection. For example, another sheet of layered mini plates, for example in the shape of snake skin. Snake skin is the most flexible skin of any living creature. Thus, this design is used in order to provide the greatest flexibility throughout the entire body of the person wearing a uniform or clothing while maintaining utmost bullet and puncture protection. These mini-plates&#39; layered material may also have each mini-plate outlined with Aramid Fiber, such as Technora® or Teijin®, as reinforcement for the mini-plates not to move from their position when imbedded on the TPU-with-Plasticizer (making said reinforcement no less than a 1 mm width) and at the same time reinforce prevention of bullet calibers from penetrating the uniform anywhere, which calibers may be encountered in most battleground or law enforcement situations. 
         [0049]    In another embodiment, and in order to make the sheet material of layered mini plates even more secure, the plates may be outlined with Aramid Fiber, such as Technora® or Teijin®, or a Glass Reinforced Fiber Yarn, as reinforcement for the mini-plates not to move from their position when imbedded on the TPU-with-Plasticizer and making said reinforcement no less than a 1 mm width. This feature provides sufficient reinforcement to resist penetration anywhere on the uniform of bullets of the caliber found on most battlegrounds or in law enforcement environments. Seams of the uniforms will be required to overlap as well in order to provide maximum protection from any angle. 
         [0050]    When required for greater protection, Aramid Yarn, such as Technora® or Teijin® (or for plastic covers for pallets or items in the back of trucks an even stronger Aramid Yarn, such as Vectran®), will be used, depending on the application and degree of protection wanted and where the material will be used. Another preferred embodiment is Carbon PAN. Mini-Plates can be made smaller, even on a nanometer scale, but the individual components of the Aramid lining matrix should be no spaced longer than ½ mm apart for optimal levels of protection. 
         [0051]    Also contemplated for use are Vectran Aramid Fibers, believed to be, in the context of the disclosed combinations, stronger than Kevlar and many more times stronger than steel. Also suitable is AGY S2 Glass Reinforced Fiber Yarn. 
         [0052]    Illustrated in  FIGS. 2A-C  are various methods of assembling the array of miniplates  210  using the yarn  220 . 
         [0053]    The mini plate design made of combined glass fiber reinforced TPU with other TPU&#39;S and/or PUU or TPU-polyester materials material, can be specially shaped into Mini Plates which are then specially layered. The mini-plates can be outlined with aramid fiber if desired and then imbedding the mini plates in a bed of TPU-with-Plasticizer Material. 
         [0054]    Note, in all cases maximum protection from bullets fired any angle is provided by overlapping uniform seams. 
         [0055]    Another layer of material  120 ,  140  is composed of High Performance Perforated Micro Cellular Urethane Foam Cushion Materials. These materials are preferably at least 4 mm but can be 7 mm to 8 mm in thickness for each layer. Both the High Performance Microcellular Urethane Perforated Foam and the high performance microcellular urethane Non Perforated Foams  130 ,  150  are commonly manufacture in thicknesses from 1.58 mm to 12.7 mm. The perforations must be spaced substantially equidistant and substantially equal in diameter in order to work properly as evidenced by two years of wear testing. 
         [0056]    Another layer is composed of Supporting Non Perforated Micro Cellular Urethane Foam Cushion Materials  130 ,  150 . These materials must be about 1.5 mm in thickness if the High Performance Microcellular Urethane Perforated Foam is about 4 mm in thickness. The same ratio should be kept as the High Performance Microcellular Urethane Perforated Foam increases in thickness. 
         [0057]    In another embodiment the supporting non perforated cellular urethane foam cushion materials must be exactly 1.5 mm if Perforated High Performance Microcellular Urethane Perforated Foam is 4 mm in thickness and the same ratio should be kept as Perforated High Performance Microcellular Urethane Perforated Foam increases in thickness. 
         [0058]    The two Urethane Layers above are repeated. The thickness of materials as specified for a particular use or application. 
         [0059]    A clothing lining can be added such as a gauze material. 
         [0060]    The protective uniform lining at the edges of the uniform can remain uncovered, so that the moisture and/or perspiration can dissipate faster and so that the foam materials can also help protect the uniform wearer from either cold, heat, allergens and/or bacteria in the atmosphere, while at the same time giving extra protection from puncture, ballistic or impact force with the miniplates matrix. The foam capabilities would act at the edges and then travel through in between stitches of the outer seams of the uniform. 
       Helmet 
       [0061]    In one embodiment the protective helmet material comprises the following layers: 
         [0062]    A combined glass fiber reinforced TPU with other TPU&#39;S and/or PUU or TPU-polyester materials bullet and puncture proof, 7 mm-12.7 mm thick 
         [0063]    A High Performance Microcellular Urethane Perforated Foamperforated 
         [0064]    A foam layer sufficient for trama/impact force injury protection; 
         [0065]    A High Performance Microcellular Urethane Non Perforated Foam NP (non perforated); 
         [0066]    A 2 nd  foam layer similar to the above. 
         [0067]    And, a breathability/moisture gathering and dissipation layer, e.g. from cotton gauze or other suitable material lining. 
       Other Accessories 
       [0068]    The same materials as in above applications can be assembled in different combinations, as required by user or buyer, can be used as impact force, stab puncture and bullet protection in gloves, goggles, hats or boots.