Impact Resistant Structures for Protective Garments

Abstract

A multi-layer composite structure is conformable to the contours of the body parts for which protection is required. The composition structure contains a rigid shock-deflecting outer layer, two semi-rigid shock-damping and shock-dissipating middle layers, and a pliable shock-absorbing lower layer. In one embodiment, the structure is designed for impacts associated with contact sports, such as football, hockey and lacrosse. In another embodiment, the structure is designed for military/police applications, in which impacts can be blunt forces, from weapons such as clubs, or penetrative forces, from knives, bullets or shrapnel.

What is claimed: 
     
         1 . A protective garment comprising:
 multiple interconnected impact resistant structures, wherein each impact resistant structure comprises four interconnected layers, consisting of a rigid outer shock-deflecting layer, overlaying a semi-rigid, deformable, polymer-based, microlattice shock-damping layer, overlaying a semi-rigid, polyurethane, honeycomb lattice dissipative layer, overlaying a shock-absorbing lower fabric layer.   
     
     
         2 . The protective garment according to  claim 1 , wherein the microlattice shock-damping layer comprises a three-dimensional network of multiple hollow polymer nanotubes, having tube diameters less than 1 mm, and wherein the polymer nanotubes are interconnected at multiple nanotube nodes which undergo resilient deformation under an applied stress, thereby effecting a damping of the applied stress. 
     
     
         3 . The protective garment according to  claim 2 , wherein the honeycomb lattice dissipative layer comprises multiple thermoplastic polyurethane open polygonal cells, less than 0.5 inches in diameter, having cell walls that are fused together without interstitial voids, and wherein the transmission of the applied stress through the open polygonal cells dissipates the applied stress, and wherein the honeycomb lattice dissipative layer constrains the microlattice shock-damping layer, thereby increasing the resilient deformation of the nanotube nodes and increasing the damping of the applied stress. 
     
     
         4 . The protective garment according to  claim 3 , wherein the shock-absorbing lower fabric layer comprises a base woven layer, consisting of multiple woven fibers with interstices, and multiple carbon nanotubes, less than 1 mm in diameter, which are interwoven between the woven fibers and the interstices. 
     
     
         5 . The protective garment according to  claim 4 , wherein the woven fibers of the base woven layer are breathable natural or artificial fibers that wick moisture. 
     
     
         6 . The protective garment according to  claim 4 , wherein the woven fibers of the base woven layer are ballistic and puncture resistant. 
     
     
         7 . The protective garment according to  claim 5 , wherein the outer shock-deflecting layer comprises a rigid, light-weight, impact-resistant plastic, polymer, polymer blend, or ceramic material. 
     
     
         8 . The protective garment according the  claim 6 , wherein the outer shock-deflecting layer comprises a rigid plastic or metal material which is ballistic and puncture resistant. 
     
     
         9 . The protective garment according to  claim 7 , wherein the outer shock-deflecting layer comprises one or more panels or shells, each of which is sized and contoured to conform to a size and a shape of a covered body part over which the panel or shell is to be worn. 
     
     
         10 . The protective garment according to  claim 8 , wherein the outer shock-deflecting layer comprises one or more panels or shells, each of which is sized and contoured to conform to a size and a shape of a covered body part over which the panel or shell is to be worn. 
     
     
         11 . The protective garment according to  claim 9 , wherein each of the panels or shells are sized and contoured by 3D printing in conjunction with 3D optical scanning of the covered body part. 
     
     
         12 . The protective garment according to  claim 10 , wherein each of the panels or shells are sized and contoured by 3D printing in conjunction with 3D optical scanning of the covered body part. 
     
     
         13 . The protective garment according to  claim 9 , wherein the covered body part is a body joint, and wherein the outer shock-deflecting layer comprises multiple overlapping, articulated concave panels, which are elastically interconnected so as to move translationally and rotationally with respect to one another. 
     
     
         14 . The protective garment according to  claim 10 , wherein the covered body part is a body joint, and wherein the outer shock-deflecting layer comprises multiple overlapping, articulated concave panels, which are elastically interconnected so as to move translationally and rotationally with respect to one another. 
     
     
         15 . The protective garment according to  claim 11 , wherein the covered body part is a body joint, and wherein the outer shock-deflecting layer comprises multiple overlapping, articulated concave panels, which are elastically interconnected so as to move translationally and rotationally with respect to one another. 
     
     
         16 . The protective garment according to  claim 12 , wherein the covered body part is a body joint, and wherein the outer shock-deflecting layer comprises multiple overlapping, articulated concave panels, which are elastically interconnected so as to move translationally and rotationally with respect to one another.