Composite article and method of manufacture

Patent metadata

Field	Value
Publication number	US-2018304598-A1
Application number	US-201615569989-A
Country	US
Kind code	A1
Filing date	Apr 29, 2016
Priority date	Apr 30, 2015
Publication date	Oct 25, 2018
Grant date	—

Abstract

A multilayer composite includes adjacent filler layers having a filler material dispersed within a first polymeric matrix and an intervening-layer disposed between the adjacent filler layers. The intervening-layer comprises nanoplatelets embedded within a second polymeric matrix and are aligned substantially parallel to the adjacent filler layers. The intervening-layer is configured to fail upon application of a force to the multilayer composite that is greater than or equal to a predetermined force threshold.

First claim

What is claimed is:

1 . A multilayer composite comprising:
adjacent filler layers comprising a filler material dispersed within a first polymeric matrix; and an intervening-layer disposed between the adjacent filler layers, said intervening-layer comprising nanoplatelets embedded within a second polymeric matrix; wherein said nanoplatelets are aligned substantially parallel to the adjacent filler layers, and wherein the intervening-layer is configured to fail upon application of a force to the multilayer composite that is greater than or equal to a predetermined force threshold, said failure inducing at least partial delamination of the multilayer composite.

2 . The multilayer composite as set forth in claim 1 , further comprising a plurality of adjacent filler layers and a plurality of intervening-layers, wherein at least one of the plurality of intervening-layers is disposed between each of the adjacent filler layers.

3 . The multilayer composite as set forth in claim 2 wherein at least one of the plurality of intervening-layers is configured to fail at a different predetermined force threshold than the other of the plurality of intervening-layers.

4 . The multilayer composite as set forth in claim 2 wherein at least one of an amount of nanoplatelets, an average thickness of the nanoplatelets, an average aspect ratio of the nanoplatelets, and a thickness of at least one of the plurality of intervening-layers is different than the other of the plurality of intervening-layers.

5 . The multilayer composite as set forth in claim 2 wherein all of said plurality of adjacent filler layers are free of said nanoplatelets.

6 . The multilayer composite as set forth in claim 1 wherein said nanoplatelets have an average thickness of less than 10 nanometers and an average aspect ratio of at least 100.

7 . (canceled)

8 . The multilayer composite as set forth in claim 1 wherein said nanoplatelets are present in the intervening-layer within a range of 0.1 to 10 parts by weight.

9 . The multilayer composite as set forth in claim 1 wherein the intervening-layer has a thickness within a range of 0.025 to 2.5 millimeters.

10 . The multilayer composite as set forth in claim 1 wherein the filler material comprises at least one of carbon fibers, boron fibers, glass fibers, silicon carbide fibers, ceramic fibers, aramid fibers, talc, calcium carbonate, powdered minerals, mica, cellulose fibers, or glass spheres.

11 . The multilayer composite as set forth in claim 1 wherein the first polymeric matrix and the second polymeric matrix comprise a thermoplastic or thermoset resin.

12 . The multilayer composite as set forth in claim 11 wherein the first polymeric matrix is different than the second polymeric matrix.

13 . The multilayer composite as set forth in claim 1 wherein the nanoplatelets are selected from the group comprising graphine nanoplatelets, graphite nanoplatelets, few-layer graphite nanoplatelets, few-layer graphine nanoplatelets, layered aluminosilicates, and nanoclays.

14 . (canceled)

15 . A method of deflecting force translated to an article through an impact, comprising the steps of:
providing a carrier layer of material including nanoplatelets suspended therein, with the nanoplatelets including a central portion and a periphery; orienting the nanoplatelets in a first layer of nanoplatelets and a second layer of nanoplatelets disposed in a generally parallel relationship with the nanoplatelets disposed in the first layer being oriented in an overlapping relationship with the nanoplatelets disposed in the second layer such that the periphery of the nanoplatelets disposed in the first layer overlap the central portion of the nanoplatelets disposed in the second layer; and deflecting a force impacting the central portion of the nanoplatelets disposed in the first layer to the central portion of the nanoplatelets in the second layer, thereby creating a tortuous path for the force translating through the article generated by the impact.

16 . The method set forth in claim 15 , further including the step of providing a plurality of carrier layers of material.

17 . The method set forth in claim 15 , wherein the step of providing a plurality of carrier layers of material is further defined by the carrier layers of material including decreasing amounts of nanoplatelets disposed therein in a direction extending away from the force generated by the impact.

18 . The method set forth in claim 15 , further including the step of at least partial delamination within the carrier layer of material upon the deflecting of a force impacting the article.

19 . The method set forth in claim 15 , wherein the step of orienting the nanoplatelets is further defined by orienting the nanoplatelets with rheological force.

20 . The method set forth in claim 15 , further including the step of the carrier layer of material absorbing force translated to the article from the impact.

21 . The method set forth in claim 15 , wherein the step of providing a carrier layer of material including nanoplatelets is further defined by providing nanoplatelets having an average aspect ratio of at least 100.

22 . (canceled)

23 . The method as set forth in claim 15 , wherein the nanoplatelets are selected from the group comprising graphine nanoplatelets, graphite nanoplatelets, few-layer graphite nanoplatelets, few-layer graphine nanoplatelets, layered aluminosilicates, and nanoclays.

Assignees

• Univ Michigan State

Inventors

• Drzal Lawrence T
• Haq Mahmoodul

Classifications

• B32B2250/42

  Alternating layers, e.g. ABAB(C), AABBAABB(C) · CPC title

• A42B3/20

  Face guards, e.g. for ice hockey (A42B3/22 takes precedence) · CPC title

• B32B27/08

  of synthetic resin · CPC title

• B32B2571/02

  defensive, e.g. armour plates or anti-ballistic clothing · CPC title

• B32B27/20 Primary

  using fillers, pigments, thixotroping agents · CPC title