CN118024687B - 一种柔性的运动防护护甲、护具及其成型方法 - Google Patents

一种柔性的运动防护护甲、护具及其成型方法 Download PDF

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CN118024687B
CN118024687B CN202410162169.0A CN202410162169A CN118024687B CN 118024687 B CN118024687 B CN 118024687B CN 202410162169 A CN202410162169 A CN 202410162169A CN 118024687 B CN118024687 B CN 118024687B
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layer
armor
protective
flexible composite
flexible
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CN118024687A (zh
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史先锋
张磊
张彬
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Changzhou Carbon Front Composite Material Technology Co ltd
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Changzhou Carbon Front Composite Material Technology Co ltd
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Abstract

本发明涉及一种柔性的运动防护护甲、护具及其成型方法，由防护护甲构成与人体部位相适配的整体式的护甲片，护甲片内嵌于服饰获得全防护结构的防护护具，实现对人体全方位保护；护甲片中核心的防护层由泄力减震层、柔性复合层、缓冲层经界面热贴合构成一体，柔性复合层由间隔层设的纤维织物层、树脂层热压构成，纤维织物层层内孔隙被树脂层的树脂浸润形成纤维树脂共存；护具受击打时，力经纤维织物层缓冲而法向扩散，达到泄力效果，结合泄力减震层和缓冲层的共同防护，被击打时能明显感觉力的扩散；并且本发明的护甲作为运动护具重量轻盈，穿戴舒适，尤其适用于武术兵器击打类的运动护甲，特别是在高频长效类击打运动中的防护。

Description

一种柔性的运动防护护甲、护具及其成型方法
技术领域
本发明涉及运动防护服饰技术领域，尤其是一种柔性的运动防护护甲、护具及其成型方法。
背景技术
护具，是指在击打运动中对人体进行防护，免受伤害的一种工具，现有的护具通常采用尼龙或是冷轧钢钢条作为防护主要材质。
由于尼龙或钢板材料所固有的刚性特性，即常规情况下材质不会、不易发生明显形变弯曲，若将护具制作成整体甲，虽能起到全方位的防护，但活动性或灵活性很差，比如，将胸甲制作成整体，人在弯腰下蹲时将会有明显的阻力；中世纪的骑士板甲，其重防护而轻运动性，虽有马匹增加灵活性，但整体板甲基本没有活动性。
现有技术中，为了在防护和运动性上进行平衡，通常将护具制作成碎甲拼接式结构，以古代步兵为例，其大多穿的是札甲和鳞甲，由无数个细小的碎甲组合而成。碎甲拼接式的护具，需要将各个碎甲按照预设逐个进行拼接，制作工序繁杂；另一方面，其虽采用碎甲，但护具整体重量仍较重，通常达到10-25公斤；并且，碎甲拼接式是牺牲整体甲的全方位防护，以局部防护换取了穿戴者的部分动作灵活性。
另外，现有的尼龙注塑护具，在受击打超过承受力时，护具会裂开、断裂、掉渣，运动中破碎的碎片极易引起人员二次受伤，使用安全性低，且尼龙护具属于低频防护用具，在受力破损后即失去防护作用，不能高频长效地对运动进行防护。
现有市场上还存在一种软质泡棉类的运动护具，其虽然价格低廉，但这类护具仅仅依靠软质的厚泡棉来进行运动防护，抗冲击、抗击打能力很差，防护效果一般，更多是起到缓冲力的作用，穿戴后显得体态臃肿，活动性一般，只能应用在简单的运动场景中。
发明内容
为解决上述问题，本发明提供一种结构合理的柔性的运动防护护甲、护具及其成型方法，从而实现对人体的全方位保护，并且护具整体重量轻盈，穿戴舒适，尤其适用于武术兵器击打类的运动护甲，极大地保证了穿戴人的整体防护和动作灵活性。
本发明所采用的技术方案如下：
一种柔性的运动防护护甲，包括柔性复合层，柔性复合层包括多层布设的树脂层，树脂层之间层设纤维织物层，多层树脂层和纤维织物层热压成型柔性复合层，纤维织物层的层内孔隙被树脂层的树脂浸润形成纤维树脂共存；所述柔性复合层一侧敷设泄力减震层，柔性复合层另一侧敷设缓冲层，泄力减震层、柔性复合层、缓冲层相接的界面表面热喷热熔胶粉，热熔胶粉均匀覆盖在界面上，经热真空贴合促使界面粘结，由界面热贴合构成整体结构的防护层。
作为上述技术方案的进一步改进：
所述柔性复合层上规则开设有多个贯穿的小孔，小孔的直径为1-2mm，小孔之间的孔间距为3-5cm。
所述柔性复合层中包括有三层树脂层，相邻树脂层之间共层设两层纤维织物层；所述柔性复合层纤维含量占比50-80％，密度为0.9-1.0g/cm3，柔性复合层厚度为0.5-5mm。
所述纤维织物层为涤纶、丙纶、锦纶、腈纶、氯纶、维纶、氨纶中的一种或两种以上，纤维织物层的编织纹理为平纹、斜纹、缎纹中的一种或两种以上；所述树脂层选用热塑性树脂材料，为PP、PE、POE、TPE、PVC中的一种或两种以上。
所述泄力减震层为由PE/EVA共混后采用超临界CO2微发泡技术制成的柔性弹性层，厚度为1-4mm；所述缓冲层为由天然乳胶和PU料共混后，在高温下超高倍率发泡制成的海绵体，经辐照交联后定型，泡孔密集且孔径大，表面存在开口的泡孔，厚度为1-3mm。
所述防护层两侧分别贴合设置外层、透气层，防护层中的缓冲层紧贴透气层，泄力减震层紧贴外层；所述透气层和外层边缘均外凸于防护层构成供缝纫走针的空间。
所述外层包括由尼龙丝束经纬编织成的尼龙布料层，尼龙丝束表面上均涂敷耐磨的特氟龙涂层；所述尼龙布料层的厚度为0.2-0.5mm，尼龙布料层内侧设置有优质皮革作为支撑层，支撑层的厚度为0.2-0.5mm；所述透气层为由棉麻纤维和涤纶纤维混纺、机织形成的网眼布，网眼布具有三层网孔结构，厚度可以是0.5-1mm。
一种柔性的运动防护护具，包括与人体的前胸、后背、手、腿分别形状相配的独立、完整的各个护甲片，单个护甲片均由上述中任一项所述的防护护甲制作构成，单个护甲片各自独立内嵌于服饰中，护甲片边缘隐藏，构成整体内嵌式全防护结构的防护护具。
作为上述技术方案的进一步改进：
所述前胸处的护甲覆盖率90％以上，后背处的护甲覆盖率93％以上，手、腿处的护甲覆盖率85％以上。
一种柔性的运动防护护具的成型方法，包括如下步骤：
挤出纺丝制得纤维丝束，由纤维丝束按规格编织成纤维织物层，纤维织物层与树脂层间隔层叠，经热压复合制得柔性复合层；
在柔性复合层上规则开设多个贯穿的小孔；
将柔性复合层放置于模具中，经热成型方式定型出与人体前胸、后背、手、腿相匹配的曲面，定型后裁切；
裁切获得的各个柔性复合层，经界面热贴合在两侧分别粘结泄力减震层和缓冲层，获得防护层；
裁切边缘尺寸外凸大于防护层的外层、透气层，将防护层内置于外层、透气层之间，将外层、透气层相贴合的四周边缘进行缝纫走针，缝合获得与人体前胸、后背、手、腿相匹配的各个护甲片；
将各个护甲片边缘隐藏、内嵌于服饰的相应位置，制得整体内嵌式全防护结构的防护护具。
与现有技术相比，本发明具有以下有益效果：
本发明结构紧凑、合理，使用方便，由间隔层设的树脂层、纤维织物层热压构成柔性复合层，由泄力减震层、柔性复合层、缓冲层经界面热贴合构成护甲的一体式的防护层，护具受击打时，力经纤维织物层的缓冲而法向扩散，达到泄力效果，结合泄力减震层和缓冲层的共同防护，被击打时能明显感觉力的扩散，虽击打的声音很响，但痛觉却很微弱；防护护甲构成与人体部位相适配的整体式的护甲片，护甲片内嵌于服饰获得全防护结构的防护护具，实现对人体的全方位保护；并且，护甲作为运动护具重量轻盈，穿戴舒适，尤其适用于武术兵器击打类的运动护甲，特别是在高频长效类击打运动中的防护，极大地保证了穿戴人的整体防护和动作灵活性；
本发明还包括如下优点：
护具内部核心的防护层是柔性的纤维编织物与树脂的结合，使得护具具有极高的抗冲击能力，有效保证防护特性，结合护具整体式内嵌护甲的特点，有效保证了对于穿戴者身体的全方位保护；
本发明中的防护护甲，重量是常规尼龙护具的0.7-0.8倍，是常规冷轧钢板甲的0.3-0.5倍，由于轻盈，穿戴后极大地提高了舒适度，结合护具材质所呈现的柔性特性，可以很轻易的弯曲，使运动不受影响，有效保障了穿戴者的动作灵活性；
在防护层的柔性复合层上做冲孔处理提高透气性，结合缓冲层的吸汗、透气特性，能够有效将体表的汗液排出，对人体进行降温，极大地提高运动舒适性；
护具核心的防护层中，柔性复合层采用纤维织物层与树脂层热压浸润，构成独特的纤维编织布结构，在受击打时，不会出现破裂掉渣情况，且护具做内嵌式处理，不会存在人员二次伤害问题；
本发明的防护护具在成型过程中不涉及胶水、丙烯酸类双面胶等有害物质、放射性元素和刺激性气味的化学品，对人体无毒无害，绿色健康。
附图说明
图1为本发明护甲的构成示意图。
图2为本发明柔性复合层的构成示意图。
图3为本发明护甲片边缘处的构成示意图。
图4为本发明防护护具的结构示意图。
其中：1、外层；2、防护层；3、透气层；10、护甲片；21、泄力减震层；22、柔性复合层；23、缓冲层；220、小孔；221、纤维织物层；222、树脂层。
具体实施方式
下面结合附图，说明本发明的具体实施方式。
如图1和图2所示，本实施例的一种柔性的运动防护护甲，包括柔性复合层22，柔性复合层22包括多层布设的树脂层222，相邻树脂层222之间层设纤维织物层221，多层树脂层222和纤维织物层221热压成型柔性复合层22，纤维织物层221的层内孔隙被树脂层222的树脂浸润形成纤维树脂共存；柔性复合层22一侧敷设泄力减震层21，柔性复合层22另一侧敷设缓冲层23，泄力减震层21、柔性复合层22、缓冲层23相接的界面表面热喷热熔胶粉，热熔胶粉均匀覆盖在界面上，经热真空贴合促使界面粘结，由界面热贴合构成整体结构的防护层2。
本实施例中，由间隔层设的纤维织物层221、树脂层222热压构成柔性复合层22，由泄力减震层21、柔性复合层22、缓冲层23经界面热贴合构成护甲的一体式的防护层2，护具受击打时，力经纤维织物层221的缓冲而法向扩散，达到泄力效果，结合泄力减震层21和缓冲层23的共同防护，被击打时能明显感觉力的扩散，虽击打的声音很响，但痛觉却很微弱。
本实施例中，构成防护层2的泄力减震层21、柔性复合层22、缓冲层23，三层性能互补，共同构成适用于运动防护的核心的防护层2；其中，泄力减震层21能够把击打导致的共振消除，并发挥吸能作用；柔性复合层22能够把击打的力从点受力延伸为面受力，实现力的分解，降低力值和受力压强；缓冲层23贴近人体，能够提供柔软的舒适感，并将从柔性复合层22逃逸的力值过滤。
柔性复合层22上规则开设有多个贯穿的小孔220，小孔220的直径为1-2mm，小孔220之间的孔间距为3-5cm。
在防护层2的柔性复合层22上做冲孔处理提高透气性，结合缓冲层23的吸汗、透气特性，能够有效将体表的汗液排出，对人体进行降温，极大地提高运动舒适性。
本实施例中，小孔220可以采用激光切割设备进行加工，有效保证小孔220开设的均匀性和一致性。
在图2所示的实施例中，柔性复合层22中包括有三层树脂层222，相邻树脂层222之间共层设两层纤维织物层221，构成树脂层222-纤维织物层221-树脂层222-纤维织物层221-树脂层222的间隔层设结构；柔性复合层22纤维含量占比50-80％，密度为0.9-1.0g/cm3，柔性复合层22厚度为0.5-5mm，优选1.5mm；在同防护级别下，本实施例的护具非常轻盈，穿戴舒适度极高。
本实施例中，将纤维织物层221与树脂层222间隔设置，能够使得树脂层222更好地浸润到纤维织物层221中，使得柔性复合层22材质高度整体化，内层结构高度规整，在树脂层222和纤维织物层221之间存在较为明显的层界面；其具体的层数可以根据实际使用需求进行设定。
纤维织物层221为涤纶、丙纶、锦纶、腈纶、氯纶、维纶、氨纶中的本实施例的或两种以上，纤维织物层221的编织纹理为平纹、斜纹、缎纹中的本实施例的或两种以上；树脂层222选用热塑性树脂材料，为PP、PE、POE、TPE、PVC中的本实施例的或两种以上。
本实施例中，纤维织物层221作为护甲防护性能的主体，体现了抗冲击性、柔性和高强度等优异性能，在制造过程中，通过树脂层222的间隔铺设来保障纤维织物层221保持其结构形态；树脂层222则起到结构保护和粘结的作用。
在实际操作中，纤维织物层221优选丙纶和涤纶，树脂层222优选PE和PP，其均为现有常规物料，价格低，来源广泛，便于获取。
泄力减震层21为由PE/EVA共混后采用超临界CO2微发泡技术制成的柔性弹性层，在超临界温度和压力下，使PE/EVA内部产生均匀细小的闭合气囊，且表皮不发泡，表皮平整光滑无孔洞，厚度为1-4mm。
本实施例中，可以设置超临界参数为，温度＞31℃，压力＞7.4Mpa；超临界发泡跟常规的自由发泡不同，它在产品模腔内发泡，表皮不发泡是因为表皮接触模腔内壁，受模腔内壁的空间阻碍，发泡受限，导致表皮不发泡。
本实施例中，泄力减震层21采用微发泡的发泡技术，能够有效保证其吸能作用，并避免受力坍塌，有效保证结构稳定性。
缓冲层23为由天然乳胶和PU料共混后，在高温下超高倍率发泡制成的海绵体，经辐照交联后定型，泡孔密集且孔径大，表面存在开口的泡孔，厚度为1-3mm。
本实施例中，缓冲层23进行超高倍率的发泡，有效保证柔软的舒适感，并辅助透气层3进行透气和吸汗，还能够有效将从柔性复合层22逃逸的力值过滤。
本实施例中天然乳胶和PU料可以采用现有的物理共混操作来实现，液态的天然乳胶和粒子态的PU料在搅拌机中按4：1或者5：1的比例混合均匀，发泡时加入0.5-2％的发泡剂和1％作用的交联剂。
防护层2两侧分别贴合设置外层1、透气层3，防护层2中的缓冲层23紧贴透气层3，泄力减震层21紧贴外层1，构成护甲；透气层3和外层1边缘均外凸于防护层2构成供缝纫走针的空间，如图3所示。
在实际操作中，可以将透气层3和外层1边缘对齐，并将一条边缝合，再将防护层2放进去，而后把透气层3与外层1四周缝合，完成缝纫。
在实际使用中，还可以做包边将缝纫线隐藏遮挡起来；当然，也可以使用模板机，进行自动缝纫。
外层1包括由尼龙丝束经纬编织成的尼龙布料层，尼龙丝束表面上均涂敷耐磨的特氟龙涂层；尼龙布料层的厚度为0.2-0.5mm，尼龙布料层内侧设置有优质皮革作为支撑层，支撑层的厚度为0.2-0.5mm。
本实施例中，采用高强度耐磨改性尼龙进行挤出牵引成丝束后，将尼龙丝束经过特氟龙涂层做表面处理，使每根丝束表面都涂敷上耐磨的特氟龙涂层，再进行经纬编织成尼龙布料，获得外层1中的尼龙布料层。
透气层3为由棉麻纤维和涤纶纤维混纺、机织形成的网眼布，网眼布具有三层网孔结构，厚度可以是0.5-1mm。
本实施例的柔性的运动防护护具，如图4所示，包括与人体的前胸、后背、手、腿分别形状相配的独立、完整的各个护甲片10，单个护甲片10均由上述中任一项的防护护甲制作构成，单个护甲片10各自独立内嵌于服饰中，护甲片10边缘隐藏，构成整体内嵌式全防护结构的防护护具。
本实施例中，防护护甲构成与人体部位相适配的整体式的护甲片10，护甲片10内嵌于服饰获得全防护结构的防护护具，实现对人体的全方位保护。
区别于现有常规护具中外置甲片的结构，本实施例中的护甲片10采用隐藏式结构，将护甲片10边缘缝合在服饰的布料内，有效防止护甲片10的脱落、移位，且有效保证整体的外观美观性。
本实施例中，护具内部核心的防护层2是柔性的纤维编织物与树脂的结合，使得护具具有极高的抗冲击能力，有效保证防护特性，结合护具整体式内嵌护甲的特点，有效保证了对于穿戴者身体的全方位保护。
护具核心的防护层中，柔性复合层采用纤维织物层与树脂层热压浸润，构成独特的纤维编织布结构，在受击打时，不会出现破裂掉渣情况，且护具做内嵌式处理，不会存在人员二次伤害问题
前胸处的护甲覆盖率90％以上，后背处的护甲覆盖率93％以上，手、腿处的护甲覆盖率85％以上，保证护甲的防护面积覆盖区域大，对运动过程中易受击打部位进行有效的防护。
本发明中的防护护甲，重量是常规尼龙护具的0.7-0.8倍，是常规冷轧钢板甲的0.3-0.5倍，由于轻盈，穿戴后极大地提高了舒适度，结合护具材质所呈现的柔性特性，可以很轻易的弯曲，使运动不受影响，有效保障了穿戴者的动作灵活性。
本实施例的柔性的运动防护护具的成型方法，包括如下步骤：
第一步：挤出纺丝制得纤维丝束，由纤维丝束按规格编织成纤维织物层221，纤维织物层221与树脂层222间隔层叠，在纤维织物层221两侧均敷设树脂层222，经热压复合制得柔性复合层22，纤维织物层221的层内孔隙被树脂层222的树脂浸润形成纤维树脂共存；由树脂层222构成柔性复合层22的结构支承，由纤维织物层221构成护甲防护性能的主体。
第二步：在柔性复合层22上规则开设多个贯穿的小孔220；
第三步：将柔性复合层22放置于模具中，经热成型方式定型出与人体前胸、后背、手、腿相匹配的曲面，提升贴合性和穿戴舒适性，定型后裁切；
第四步：裁切获得的各个柔性复合层22，经界面热贴合在两侧分别粘结泄力减震层21和缓冲层23，获得防护层2；
在泄力减震层21、柔性复合层22、缓冲层23的界面表面热喷一层热溶胶粉，均匀覆盖在界面上，经过热真空贴合设备，将不同界面粘结，稳定地组合成一个整体结构的防护层2。
第五步：裁切边缘尺寸外凸大于防护层2的外层1、透气层3，将防护层2内置于外层1、透气层3之间，将外层1、透气层3相贴合的四周边缘进行缝纫走针，缝合获得与人体前胸、后背、手、腿相匹配的各个护甲片10；
第六步：将各个护甲片10边缘隐藏、内嵌于服饰的相应位置，制得整体内嵌式全防护结构的防护护具。
本实施例的防护护具在成型过程中不涉及胶水、丙烯酸类双面胶等有害物质、放射性元素和刺激性气味的化学品，对人体无毒无害，绿色健康。
本发明护甲片内嵌于服饰获得全防护结构的防护护具，实现对人体的全方位保护；并且，护甲作为运动护具重量轻盈，穿戴舒适，尤其适用于武术兵器击打类的运动护甲，极大地保证了穿戴人的整体防护和动作灵活性。
本说明书中各个实施例采用递进的方式描述，每个实施例重点说明的都是与其他实施例的不同之处，各个实施例之间相同相似部分互相参见即可。
以上描述是对本发明的解释，不是对发明的限定，本发明所限定的范围参见权利要求，在本发明的保护范围之内，可以作任何形式的修改。

Claims (7)

1.一种柔性的运动防护护具，其特征在于：包括与人体的前胸、后背、手、腿分别形状相配的独立、完整的各个护甲片（10），单个护甲片（10）均由防护护甲制作构成，单个护甲片（10）各自独立内嵌于服饰中，护甲片（10）边缘隐藏，构成整体内嵌式全防护结构的防护护具；
所述防护护甲的结构为：包括柔性复合层（22），柔性复合层（22）包括多层布设的树脂层（222），相邻树脂层（222）之间层设纤维织物层（221），多层树脂层（222）和纤维织物层（221）热压成型为柔性复合层（22），纤维织物层（221）的层内孔隙被树脂层（222）的树脂浸润形成纤维树脂共存形态；所述柔性复合层（22）一侧敷设泄力减震层（21），柔性复合层（22）另一侧敷设缓冲层（23），泄力减震层（21）、柔性复合层（22）、缓冲层（23）相接的界面表面热喷热熔胶粉，热熔胶粉均匀覆盖在界面上，经热真空贴合促使界面粘结，由界面热贴合构成整体结构的防护层（2）；
所述泄力减震层（21）为由PE/EVA共混后采用超临界CO2微发泡技术制成的柔性弹性层，厚度为1-4mm；所述缓冲层（23）为由天然乳胶和PU料共混后，在高温下超高倍率发泡制成的海绵体，经辐照交联后定型，泡孔密集且孔径大，表面存在开口的泡孔，厚度为1-3mm；
所述防护层（2）两侧分别贴合设置外层（1）、透气层（3），防护层（2）中的缓冲层（23）紧贴透气层（3），泄力减震层（21）紧贴外层（1）；所述透气层（3）和外层（1）边缘均外凸于防护层（2）构成供缝纫走针的空间。
2.如权利要求1所述的一种柔性的运动防护护具，其特征在于：所述柔性复合层（22）上规则开设有多个贯穿的小孔（220），小孔（220）的直径为1-2mm，小孔（220）之间的孔间距为3-5cm。
3.如权利要求1所述的一种柔性的运动防护护具，其特征在于：所述柔性复合层（22）中包括有三层树脂层（222），相邻树脂层（222）之间共层设两层纤维织物层（221）；所述柔性复合层（22）纤维含量占比50-80%，密度为0.9-1.0g/cm3，柔性复合层（22）厚度为0.5-5mm。
4.如权利要求1所述的一种柔性的运动防护护具，其特征在于：所述纤维织物层（221）为涤纶、丙纶、锦纶、腈纶、氯纶、维纶、氨纶中的一种或两种以上，纤维织物层（221）的编织纹理为平纹、斜纹、缎纹中的一种或两种以上；所述树脂层（222）选用热塑性树脂材料，为PP、PE、POE、TPE、PVC中的一种或两种以上。
5.如权利要求1所述的一种柔性的运动防护护具，其特征在于：所述外层（1）包括由尼龙丝束经纬编织成的尼龙布料层，尼龙丝束表面上均涂敷耐磨的特氟龙涂层；所述尼龙布料层的厚度为0.2-0.5mm，尼龙布料层内侧设置有优质皮革作为支撑层，支撑层的厚度为0.2-0.5mm；所述透气层（3）为由棉麻纤维和涤纶纤维混纺、机织形成的网眼布，网眼布具有三层网孔结构，厚度是0.5-1mm。
6.如权利要求1所述的一种柔性的运动防护护具，其特征在于：所述前胸处的护甲覆盖率90%以上，后背处的护甲覆盖率93%以上，手、腿处的护甲覆盖率85%以上。
7.一种权利要求1所述的柔性的运动防护护具的成型方法，其特征在于：包括如下步骤：
挤出纺丝制得纤维丝束，由纤维丝束按规格编织成纤维织物层（221），纤维织物层（221）与树脂层（222）间隔层叠，经热压复合制得柔性复合层（22）；
在柔性复合层（22）上规则开设多个贯穿的小孔；
将柔性复合层（22）放置于模具中，经热成型方式定型出与人体前胸、后背、手、腿相匹配的曲面，定型后裁切；
裁切获得的各个柔性复合层（22），经界面热贴合在两侧分别粘结泄力减震层（21）和缓冲层（23），获得防护层（2）；
裁切边缘尺寸外凸大于防护层（2）的外层（1）、透气层（3），将防护层（2）内置于外层（1）、透气层（3）之间，将外层（1）、透气层（3）相贴合的四周边缘进行缝纫走针，缝合获得与人体前胸、后背、手、腿相匹配的各个护甲片（10）；
将各个护甲片（10）边缘隐藏、内嵌于服饰的相应位置，制得整体内嵌式全防护结构的防护护具。
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