US20140318911A1 - Energy management structure - Google Patents
Energy management structure Download PDFInfo
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- US20140318911A1 US20140318911A1 US14/254,505 US201414254505A US2014318911A1 US 20140318911 A1 US20140318911 A1 US 20140318911A1 US 201414254505 A US201414254505 A US 201414254505A US 2014318911 A1 US2014318911 A1 US 2014318911A1
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- US
- United States
- Prior art keywords
- component
- energy management
- response profile
- compressive response
- management structure
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F7/00—Vibration-dampers; Shock-absorbers
- F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
- F16F7/121—Vibration-dampers; Shock-absorbers using plastic deformation of members the members having a cellular, e.g. honeycomb, structure
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- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/10—Linings
- A42B3/12—Cushioning devices
- A42B3/124—Cushioning devices with at least one corrugated or ribbed layer
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F7/00—Vibration-dampers; Shock-absorbers
- F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H1/00—Personal protection gear
- F41H1/02—Armoured or projectile- or missile-resistant garments; Composite protection fabrics
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H1/00—Personal protection gear
- F41H1/04—Protection helmets
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- G06F17/50—
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/28—Shock absorbing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F2234/00—Shape
- F16F2234/02—Shape cylindrical
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F2234/00—Shape
- F16F2234/06—Shape plane or flat
Definitions
- This disclosure relates to an energy management structure, and particularly to an energy management structure that is adapted to absorb an impact force applied thereto.
- the energy management structure is applicable, but not limited, to body protective gear for military, athletic and recreational activities, for example, including a helmet where a chance of cranial impact is possible, protective pads (e.g., shoulder pads), and other pads such as cushions for hard seats and packing material.
- Helmets and other types of protective gear used in military, athletic and recreational activities are intended to provide protection against a sudden impact.
- a helmet protects the head by preventing direct impact on the head, but also by causing the head to more gradually accelerate to a stop.
- the shell of the helmet and liner components together act as a system.
- the shell is constructed to provide rigidity to the helmet to guard against protruding objects, and is as a platform to support the liner structure.
- the liner is designed to complement the shell's geometry and regional stiffness, so that the liner and shell together provide a more ideal reduction in peak accelerations that would be observed should a head come to violent and sudden stop or accelerated state.
- the shell and liner provide an appropriate efficiency and stiffness response such that the head is more gently accelerated using as much of the available liner thickness as possible.
- acceleration is used to describe both acceleration and deceleration.
- Expanded Polystyrene (EPS), Expanded Polypropylene (EPP), Ethyl Vinyl Acetate (EVA), Vinyl Nitrile (VN), and Polyurethane foams (PU) are conventional materials used for acceleration management inside helmets to protect the head.
- Non-foam materials such as honeycomb, hemisphere and cylindrical crushable structures have been suggested as an alternative for managing impact forces applied to the helmet. All of these materials and structures exhibit crushing efficiencies, typically less than 75% compression until the material is considered bottomed. Crushing efficiency of the materials and structures are affected by their density. Generally, greater density results in increased stiffness. As stiffness is increased, crush efficiency is diminished.
- Crushable structures also have inherent crushing efficiencies, which are ultimately governed by the stacking-up of the structure walls at full compression. Structures such as honeycombs can be very stiff, but typically not very efficient or resilient. In order to reach full compression, wall damage of these structures is often observed.
- the deformation characteristics of the non-foam honeycomb, hemisphere and cylinder crushable structures display erratic buckling modes when subject to an impact force, which are discussed in further detail below. Such awkward or “noisy” deformation characteristics can degrade the crushable structures and result in highly reduced “multi-hit” capacity, for example. It is desirable to produce an improved crushable structure that in certain embodiments can offer increased impact performance compared to the conventional foams and structures.
- the disclosure below discusses configurations that overcome the disadvantages of the conventional materials and structures by providing an energy management structure demonstrating a smoother deformation characteristic in response to an applied impact force.
- the energy management structures disclosed herein can have increased densifying efficiency (Le., usable thickness before bottoming/densifying) and increased resiliency for multi-impact performance.
- the energy management structure is applicable, but not limited, to body protective gear including, for example, helmets and protective pads for military, athletic and recreational activities where a chance of cranial or other body part impact is possible.
- the energy management structures described herein are also applicable to a vest, arm/elbow pads, leg/knee pads and footwear, padding for hard seats and padding for shipping materials, for example.
- an energy management structure is adapted to absorb a force applied thereto.
- the structure comprises a first component possessing a first compressive response profile, a second component possessing a second compressive response profile different from the first compressive response profile, and a third component connecting the first component to the second component.
- the second compressive response profile of the second component is additive to the first compressive response profile of the first component to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile.
- At least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
- the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
- smoothness of the curve is based on the first component of the structure buckling and then bending when the force is applied to the structure, and the second component, surrounding the first component, beginning to bend or buckle when the first component transitions from bending to buckling.
- the first compressive response profile possesses a compression profile characteristic that shows a transition point in compression resistance from a relatively high compression resistance to a relatively low compression resistance of the first component when a force is applied to the energy management structure
- the second compressive response profile possesses a compression profile characteristic that is additive to the compression profile characteristic of the first component at the transition point when the force is applied to the second component
- the first compressive response profile possesses a buckling/bending profile characteristic such that the first component buckles and then bends when the force is applied to the energy management structure
- the second compressive response profile possesses a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component transitions form buckling to bending.
- the second component surrounds the first component.
- the first component surrounds the second component.
- a recess is present between the first component and the second component and is formed by the first, second and third components.
- the third component is provided at one of an upper and lower end of the structure.
- the third component is provided at a location of the structure between an upper and lower end of the structure.
- the first component is a center column extending from one end of the structure to an opposing end of the structure.
- the first component includes at least one reinforcing rib on a side of the first component facing the second component.
- the first component is corrugated, so that the first component has a wavy cross-sectional profile.
- the second component includes at least one reinforcing rib.
- the third component includes at least one aperture.
- the second component surrounds the first component and the first component is hollow, and the aperture opens into the hollow first component.
- the size of the offset of the one end of the second component relative to the one end of the first component is about 10% of the total height of the structure.
- the structure has a frusta-conical shape.
- the structure has a cylindrical shape.
- the structure has a mushroom shape.
- the structure is formed of a polymer material.
- the structure is formed of thermoplastic elastomer.
- the structure is formed of an injection-molded material.
- the structure is configured to elastically deform in an axial direction of the structure when a force is applied to the structure.
- the structure is configured to plastically deform in an axial direction of the structure when a force is applied to the structure.
- the structure is crushable to about 30% of its original size.
- the structure is crushable to about 20% of its original size.
- the structure is crushable to about 10% of its original size.
- the energy management structure further comprises a fourth component between the first and second components and connected to the third component, and the fourth component possesses a third compressive response profile.
- the fourth component comprises two walls, one of the walls surrounding the other of the walls.
- the second component is an outermost component and comprises walls that are separated from each other by gaps between the walls.
- the gaps extend into the third component.
- the energy management structure comprises a plurality of the first components surrounded by the second component, and each of the plurality of first components possesses a respective compressive response profile.
- a height of the second component is the same as the height of each of the plurality of first components.
- a height of the second component is the same as the height of some of the plurality of first components, such that the height of other of the of the plurality of first components is different than that of the second component.
- each of the plurality of first components comprises a substructure having at least one wall surrounded by another wall.
- At least one of the walls of the substructure is concentric to another wall of the substructure.
- each of the plurality of substructures comprises a first subcomponent possessing a first compressive response profile, and a second subcomponent possessing a second compressive response profile different from the first compressive response profile.
- the second compressive response profile of the second subcomponent is additive to the first compressive response profile of the first subcomponent to result in an compressive response profile of the substructure that meets a design compressive response profile.
- a height of the second component is the same as the height of each of the plurality of substructures.
- a height of the second component is different than the height of the plurality of substructures.
- an array of energy management structures there is provided an array of energy management structures.
- the structures in the array are connected to each other with a connector attached to a lower end portion of adjacent structures.
- the structures in the array are identical.
- the structures in the array are stackable on top of each other.
- the array is enveloped in a padding.
- the energy management structure is adapted to be attached to the inside of a helmet.
- the structure is detachably attachable to the helmet, so that the structure is detachable from one location on the helmet and reattachable to another location on the helmet.
- a helmet including at least one energy management structure.
- a method of designing an energy management system for body protective gear comprises at least one energy management structure.
- the method comprises selectively distributing the at least one energy management structure to a desired location on the body protective gear.
- a method of designing an energy management structure adapted to absorb a force applied thereto comprises determining a first compressive response profile of a first component, determining a second compressive response profile of a second component, the second compressive response profile being different from the first compressive response profile, and designing an energy management structure by coupling at least one first component having the first compressive response profile with at least one second component having the second compressive response profile to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile.
- the determining steps are carried out in a specifically programmed computer executing code to carry out the steps.
- At least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
- the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
- FIG. 1 a is a perspective view of an energy management structure according to one embodiment
- FIG. 1 b is another perspective view of the energy management structure according to the embodiment of FIG. 1 a;
- FIG. 1 c is a plan view of the upper end of the energy management structure according to the embodiment of FIG. 1 a;
- FIG. 1 d is a plan view of the opposite lower end of the energy management structure according to the embodiment of FIG. 1 a;
- FIG. 1 e is a cross-sectional view of the energy management structure according to the embodiment of FIG. 1 a;
- FIG. 2 a is a stress/strain curve graphically illustrating the results of a Finite Element Analysis performed on a conventional structure
- FIG. 2 b is a stress/strain curve graphically illustrating the results of a Finite Element Analysis performed on an energy management structure disclosed herein;
- FIG. 2 c illustrates a compression characteristics of an energy management structure disclosed herein
- FIG. 3 a is a perspective view of an array of energy management structures according to one embodiment
- FIG. 3 b is another perspective view of the array of energy management structures according to the embodiment of FIG. 3 a;
- FIG. 3 c is a perspective view showing compression of the array of energy management structures of FIG. 3 a;
- FIG. 3 d is another perspective view showing compression of the array of energy management structures of FIG. 3 a;
- FIG. 3 e is a perspective view showing the array of energy management structures enveloped in a foam of FIG. 3 a;
- FIG. 3 f is another perspective view showing the array of energy management structures enveloped in a foam of FIG. 3 a;
- FIG. 4 a is a perspective view of a helmet including a plurality of energy management structures
- FIG. 4 b is a perspective view of a helmet including a plurality of energy management structures used with a padding;
- FIGS. 5 a - 5 d illustrate different views of another embodiment of the energy management structure
- FIGS. 6 a and 6 b illustrate different views of a modified embodiment of the energy management structure shown in FIGS. 5 a - 5 d;
- FIGS. 7 a - 7 d illustrate different views of a further embodiment of the energy management structure
- FIGS. 8 a - 8 d illustrate different views of another embodiment of the energy management structure
- FIG. 9 illustrates the steps associated with a method of designing an energy management structure
- FIG. 10 shows one embodiment of a computer system for carrying out the process shown in FIG. 9 .
- FIGS. 1 a - 1 e illustrate an energy management structure 100 according to one embodiment.
- the energy management structure 100 includes a first component 102 , a second component 104 and a third component 106 .
- the second component 104 surrounds the first component 102 , so that a recess 108 , formed by the first, second and third components is present between the first component 102 and the second component 104 .
- the “second component” 104 surrounds the “first component” 102
- the second component 104 may behave (as discussed below) like the first component 102 , and vice versa, such that the “first component” may also refer to the component 104 surrounding the “second component” 102 .
- the width of the recess is not particularly limited, and provides space for the first component 102 to buckle/bend before bending or buckling of the second component 104 .
- the second component 104 concentrically surrounds the first component 102 .
- the second component 104 and the first component 102 do not share the same axis.
- the first component 102 may be disposed off-center relative to the second component 104 .
- the shape of the first component 102 is not particularly limited, although some shapes have greater advantages than others.
- the shape may be comprised of a column in the form of a circular tube.
- the profile of the first component 102 may have a polygonal shape, such as a triangular, rectangular, pentagonal, hexagonal or other multi-sided shape.
- the first component 102 is arranged to extend from the upper end 120 of the structure 100 to an opposing lower end 122 of the structure 100 .
- the first component 102 is hollow.
- a solid, un-hollow first component 102 gives additional stiffness to the first component 102 .
- the shape of the second component 104 is not particularly limited, and may be circular, triangular, rectangular, pentagonal, hexagonal or have another multi-sided shape.
- a third component 106 connects the first component 102 to the second component 104 , and is generally shaped to match the profile of the second component 104 . For instance, if the second component 104 possesses a generally circular shape, the third component 106 also possesses a circular shape. However, the shape of the third component 106 may be different from the shape of the second component 104 .
- the third component 106 can help to spread the point load of an impact force applied to the structure 100 , but primarily is in place to assure the first and second components work in concert, for example, and provides a spatial relationship that the second component engages at a certain point in the crushing of the first component.
- the third component 106 may be provided at an upper end 120 or lower end 122 of the structure 100 .
- the third component 106 may be provided at a location of the structure 100 between the upper end 120 and the lower end 122 of the structure 100 , such as at the midpoint between the upper end 120 and the lower end 122 .
- the third component 106 is provided at the upper end 120 of the structure 100 .
- the third component 106 in this embodiment is substantially planar and orthogonal to the center axis of the structure 100 .
- the third component 106 may be convex, or may have an overall concave shape.
- the third component 106 be substantially planar and orthogonal to the center axis of the structure 100 to better distribute the load of the force applied to the structure 100 and/or avoid the creation of pressure points or spikes, and may also act to provide greater area for affixing (e.g., gluing) the energy management structure to another structure, such as the inside of padding or a helmet, for example.
- affixing e.g., gluing
- the third component 106 includes apertures 114 . Apertures 114 open into the recess 108 between the first component 102 and the second component 104 . In addition, in embodiments where the first component 102 is hollow as discussed above, the third component 106 may include an aperture 116 opening into the hollow first component 102 .
- the apertures 114 , 116 may assist with the evacuation of air within the recess 108 and hollow first component 102 when the structure 100 is rapidly compressed upon application of an impact force. The evacuation of air from within the structure 100 may contribute to enhanced compressibility of the structure 100 by providing a channeled escape route of rapidly compressed air, if the design parameters suggest the appropriateness of this feature. In some embodiments, the compression force of trapped air or other gasses might be desirable. Compressibility of the structure 100 is discussed in further detail below.
- the first component 102 includes one or more reinforcing ribs 110 on a side of the first component 102 in the recess 108 facing the second component 104 .
- the reinforcing ribs 110 provide added stiffness to the first component 102 .
- the first component 102 includes three ribs 110 .
- the number of ribs 110 may be more or less.
- the reinforcing ribs 110 extend longitudinally from the upper end 120 of the structure 100 to the lower end 122 of the structure 100 .
- the reinforcing ribs 110 extend along the first component 102 for only a portion of the extension from the upper end 120 to the lower end 122 of the structure.
- the first component may have at least one spiral rib 110 extending spirally between the upper end 120 of the structure 100 and the lower end 122 of the structure 100 .
- the first component 102 may corrugated, so that the first component 102 has a wavy profile.
- the second component 104 may include reinforcing ribs 112 on a side of the second component 104 in the recess 108 facing the first component 102 . Similar to the first component reinforcing ribs 110 , the second component reinforcing ribs 112 may extend longitudinally from the upper end 120 of the structure 100 to the lower end 122 of the structure 100 . In the illustrated embodiment, the second component 104 includes three ribs 112 . However, the number of ribs 112 may be more or less. In other embodiments, the second component reinforcing ribs 112 extend along the second component 104 for only a portion of the extension from the upper end 120 to the lower end 122 of the structure 100 .
- the second component 104 may have at least one spiral rib 112 extending spirally inside the structure 100 between the upper end 120 of the structure 100 and the lower end 122 of the structure.
- the structure 100 includes the ribs 110 on the first component 102 and the ribs 112 on the second component 104 .
- the first component ribs 110 and the second component ribs 112 may be radially offset from each other as shown in FIG. 1 b.
- one end 102 a of the first component 102 may extend all the way to the lower end 122 of the structure 100
- one end 104 a of the second component 104 may extend to a lesser extent toward the lower end 122 end of the structure 100 as shown in FIG. 1 e.
- the second component 104 does not extend as far toward the end 122 of the structure 100 as the first component 102 . That is, as principally shown in FIG. 1 e, an offset 118 is provided at the at the outer circumference of the structure 100 at the lower end 122 .
- the size of the offset 118 of the end 104 a of the second component 104 relative to the end 102 a of the first component 102 may range from about 5% to 20% of the total height of the structure 100 .
- the size of the offset 118 is about 10% of the total height of the structure 100 in this particular embodiment, but the offset may be determined by the additive compression profiles.
- the offset 118 adds significant stiffness to the overall structure 100 during compression after the first component 102 has buckled and can be dimensioned to substantively engage when the first component 102 is transitioning from buckling to bending modes, as explained below.
- the second component 104 substantively engages during an impact event when it measurably adds to the crush resistance.
- the second component 104 had a thin skirt that extended as far as the first component 102 for aesthetics, sealing, or a second part of a third component (so that the third component 106 appears on each end of the first and second components 102 and 104 etc.), but the thin skirt did not add differentially to the crush resistance, it could be part of the offset 118 .
- FIG. 2 a shows the compression response characteristic in terms of stress versus strain of the conventional structure due to an applied constant velocity compression force.
- the compression response characteristic here is defined by a line which increases and decreases rapidly with sharp peaks and valleys.
- Such an awkward or “noisy” deformation characteristic degrades the structure's performance and results in a highly reduced ability of the conventional structure to sustain repeatable and predictable impact performance. That is, the “noisy” deformation characteristic yields a less predictable and poor repeatable impact performance.
- the first component 102 provides an initial stiffness, especially when anchored to the third component 106 at the upper end 120 of the structure 100 .
- the first component 102 initially yields to an applied impact force
- the first component 102 begins to buckle.
- the first component 102 bends as the applied impact force increases.
- the second component 104 does not initially bend or buckle when the first component 102 begins to buckle. This is, in part, due to the offset 118 , in the illustrated embodiment. That is, when the impact force is first applied to the structure 100 , only the first component 102 is affected initially, by buckling.
- the second component 104 begins bend or buckle under the applied impact force when the first component 102 transitions from buckling to bending.
- the second component 104 does not have to engage exactly when the transition of buckling to bending of the first component 102 , but within a range that the second component 104 has a measurable effect on smoothing the crush profile of the first component 102 .
- the offset 118 may affect the timing of the bending/buckling of the second component 104 relative to the first component 102 . It is also possible, however, to manipulate the timing of the bending/buckling of the second component 104 relative to the first component 102 by (i) increasing/decreasing the wall thickness of the second component 104 relative to the wall thickness of the first component 102 and vice versa, (ii) enlarging/reducing the recess 108 between the first component 102 and the second component 104 so that the first component 102 is farther/closer to the second component 104 , and/or (iii) eliminating the offset 118 , or changing the height of the offset 118 (including changing the height of one offset 118 relative to the height of another offset 118 ).
- the first component 102 possesses a compressive response profile having a buckling/bending profile characteristic such that the first component 102 buckles and then bends when an impact force is applied to the structure 100 .
- the second component 104 possesses compressive response profile different from that of the first component 102 and having a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component transitions from buckling to bending.
- FIG. 2 b illustrating the results of a Finite Element Analysis performed on the energy management structure 100 according to the embodiments discussed herein, with the graph in FIG. 2 a illustrating the results of the analysis performed on the conventional structure.
- the graph in FIG. 2 b shows the compression response characteristic in terms of stress versus strain of the structure 100 due to a compression force applied thereto.
- the compression response characteristic is defined by a smooth curve that increases relatively rapidly at first before tapering, and then increases again.
- smooth as used herein means that the curve extends without steep and/or pointed peeks and valleys, or sudden/abrupt changes in direction.
- 2 b is based on the first component 102 of the structure 100 first buckling and then bending when the impact force is applied to the structure 100 , and the second component 104 , due at least in part to the offset 118 , beginning to bend or buckle when the first component 102 transitions from buckling to bending.
- the second compressive response profile of the second component 104 is additive to the first compressive response profile of the first component 102 to result in an overall compressive response profile of the energy management structure 100 that meets a desired design compressive response profile. That is, the first compressive response profile possesses a compression profile characteristic that shows a transition point in compression resistance from a relatively high compression resistance to a relatively low compression resistance of the first component 102 when a force is applied to the energy management structure, and the second compressive response profile possesses a compression profile characteristic that is additive to the compression profile characteristic of the first component 102 at the transition point when the force is applied to the second component 104 .
- FIG. 2 c shows the compression response characteristic of the energy management structure by adding together the compressive response profiles of the first and second components 102 , 104 , respectively.
- the compressive response profile of the first component 102 is somewhat erratic, while the and the compressive response profile of the second component 104 is smoother.
- the combined curve in the graph (representing the overall compressive response profile of the energy management structure 100 ) shown with the broken line represents the sum of the first and second compressive response profiles and is a smooth curve that increases relatively rapidly at first before tapering, and then increases.
- the smoothness of the curve is based on the first component 102 of the structure 100 buckling and then bending when the force is applied to the structure 100 , and the second component 104 beginning to bend or buckle when the first component 102 transitions from bending to buckling.
- the smoothness of the curve in FIGS. 2 b and 2 c may also result, without an offset 118 , by adjusting the angle of the second component 104 relative to the first component 102 , increasing/decreasing the wall thickness of the second component 104 relative to the wall thickness of the first component 102 , and/or enlarging/reducing the recess 108 between the first component 102 and the second component 104 so that the first component 102 is farther/closer to the second component 104 .
- the smooth curve compressive response profile results in the structure 100 providing a more ideal impact response as compared to the conventional structures.
- the usable thickness of the structure 100 before bottoming/densifying in response to an impact force (Le., densifying efficiency), is increased. Further, the structure 100 exhibits a relatively high stiffness per unit density. As used herein, stiffness generally describes a stress/strain measurement obtained by compressing the structure 100 to around the plateau magnitude, which occurs at about 10%-20% compression of the structure 100 . It is noted that in the above embodiments, each of the first component 102 and the second component 104 both bend and buckle. However, in other embodiments, the first component 102 and/or the second component 104 simply buckle. In alternative embodiments, the first component 102 and/or the second component 104 simply bend.
- the structure 100 is crushable to about 30% of its original size when an impact or compression force is applied to the structure 100 . In other embodiments, the structure 100 is crushable to about 20% of its original size when an impact force is applied. Preferably, for a military helmet of a particular design, the illustrated structure 100 is crushable to about 10% of its original size. Stiffness, cost, and weight requirements may govern (Le., increase/reduce the crushability (e.g., less than the 10-30% range) of the structure 100 .
- the structure 100 is formed of a material which permits the structure 100 to elastically deform in an axial direction of the structure 100 when an impact force is applied to the structure 100 , thus allowing the structure to sustain multiple successive impact forces if particular material used is not stretched passed its plastic yield point.
- the structure 100 may be formed of a polymer material, a thermoplastic elastomer or an injection-molded material. Additional processes used to form the structure include compression molding, rim molding and casting.
- the structure 100 may be configured to plastically deform in an axial direction of the structure 100 upon an application of an impact force.
- the structure 100 exhibits a tangential compression when a force is applied tangentially to the structure 100 rather than axially.
- the tangential compression of the structure is greater than the axial compression of the structure 100 . That is, the structure 100 compresses tangentially easier than the structure 100 compresses axially in this embodiment.
- the tangential compression of the structure 100 enables the structure 100 to absorb a force that grazes the structure 100 in a direction tangential to the structure 100 . This ability to absorb glancing blows, for instance, can result in reduced trauma to the wearer.
- an outer part of the helmet might be permitted to rapidly rotate relative to the head of the wearer so that the wearer's head does not have to, thus reducing the chances of trauma to the brain or neck of the wearer.
- the energy management structure absorbs the tangential energy so that the wearer's head and neck do not have to.
- this is not limited to helmets, and extends to other body protective gear.
- the structure 100 may be formed of a stiff thermoplastic elastomer (TPE) or plastic urethane.
- TPE thermoplastic elastomer
- Other materials include Expanded Polystyrene (EPS) and Expanded Polypropylene (EPP).
- EPS Expanded Polystyrene
- EPP Expanded Polypropylene
- a softer material with much higher strain until plastic yield, such as Estane 58138 and Thermoplastic Urethane (TPU) may also be used.
- TPU which may reach about 500% strain before breaking, possesses a flexural modulus of 0.731 MPa, an elongation prior to break of greater than 400%, and a plastic yield of about 4% material strain.
- a structure formed of this material may have regions that will plastically deform at about 20% compression.
- the structure 100 is rotationally symmetric. In alternative embodiments, however, the structure 100 may not be rotationally symmetric.
- the structure 100 has a frusta-conical shape as shown in FIGS. 1 a - 1 c. That is, the lower end 122 open end of the structure 100 has a larger circumference than the upper end 120 of the structure 100 .
- the structure 100 may be cylindrically shaped.
- the structure 100 may have a mushroom shape in profile.
- the height of the structure 100 is about 0.5 inches
- the outer diameter of the structure 100 at the lower end 122 is about 0.75 inches.
- the structure is not limited to these dimensions.
- the dimensions may be scaled up or down depending on the application in which the structure 100 is used. Further, thickness of the walls of the first component 102 , the second component 104 and the third component 106 may be varied depending on the application in which the structure 100 used. The thickness of the walls of the components may be varied or tapered depending on the applications in which the structure 100 is used and tooling requirements for manufacturing the structure 100 .
- FIGS. 3 a and 3 b show one embodiment of an array 250 of energy management structures 200 adapted to absorb a force applied thereto.
- Each structure 200 of the array 250 includes a first component 202 possessing a compressive response profile having a buckling/bending profile characteristic such that the first component 202 buckles and then bends when the force is applied to the energy management structure 200 , and a second component 204 surrounding the first component 202 (or vice versa) and possessing a compressive response profile having a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component 202 transitions from buckling to bending.
- a third component 206 connects the first component 202 to the second 17 component 204 .
- Each structure 200 in the array 250 may be configured according to any of the embodiments discussed above with respect to the energy management structure 100 .
- the structures 200 in the array 250 are connected to each other with a connector 224 attached to a lower end portion 222 of adjacent structures 200 .
- the connector 224 may be attached to an upper end portion 220 of adjacent structures 200 or to a location between the upper end portion 220 and the lower end portion 222 .
- the connector 224 is about 0.2 inches wide. However, the size of the connector 224 may be more or less depending on the application in which the array 250 is used.
- the array 250 is rectangular in plan view.
- the array 250 may be formed in any shape suitable for the particular application in which the array is used.
- the array 250 may be circular, triangular, pentagonal, hexagonal, star shaped, or any other desired polygonal shape.
- the total number of structures 200 in the array 250 is not particularly limited, and may include any desired number of structures 200 .
- FIGS. 3 c and 3 d show compression of the array 250 of energy management structures 200 in response to an impact force applied to the entire array 250 . In some instances, only one or some of the structures 200 in the array may compress in response to the impact force.
- the structures 200 in the array 250 are identical. In other embodiments, some of the structures 200 in the array 250 may be different from the other structures 200 in the array 250 . For instance, some of the structures 200 in the array 250 may be formed according to one or more embodiments of the structure 100 discussed above, while other of the structures 200 in the array 250 may be formed according to other embodiments of the structure 100 discussed above. In different embodiments, some of the structures 200 in the array 250 may inverted, such that the upper end 220 of some structures 200 are adjacent the lower end 222 of adjacent structures 200 .
- additional structures 200 may be stackable on top of the structures 200 in the array 250 .
- the upper end 220 of the additional structures 200 may be in contact with the upper end of the structures 200 in the array 250 .
- the number of layers of additional structures 200 on top of the array 250 is not particularly limited, may include any desired number of layers of additional structures 200 depending on the application in which the additional structures 200 and the array 250 are used.
- the additional structures 200 may be insertable or nestable with respect to the structures 200 in the array 250 , meaning that the upper end 220 of one structure 200 is in the array 250 is insertable into the lower end 220 of one of the additional structures 200 .
- the structures 200 may be joined or attached to each other. For example they may be welded to each other, for example, via Rf welding, depending on the material from which they are made.
- the array 200 may be used as an independent liner material or utilized in a liner assembly.
- the array 250 is enveloped in a padding 260 .
- the padding 260 may be of the types disclosed in U.S. Pat. No. 7,341,776 or U.S. Patent Application Publication No. 2007/0281125 A1, for example, the disclosures of which are incorporated herein by reference.
- a portion of the structures 200 in the array 250 may (or may not) be exposed through the padding 260 a shown in FIG. 3 e .
- the array 250 is completely enveloped in the padding 260 .
- the array 250 may be enveloped in a foam, adjacent to a soft comfort layer, encapsulated by PU film, wicking fabric, and hook or loop fabric so as to be incorporated into a helmet pad assembly.
- the array 250 of energy management structures 200 reinforces the padding 260 or alternative materials while allowing the pad assembly to easily conform to the curvature of the helmet shell.
- the padding 260 may include attachment devices, such as a hook and loop fastening system or reusable adhesive, to detachably attach the padding 260 to portions of body protective gear subject to impact forces.
- the energy management structure 300 is adapted to be attached to the inside of a helmet 360 as shown in FIG. 4 a .
- the structure 300 comprises a first component 102 possessing a compressive response profile having a buckling/bending profile characteristic such that the first component 102 buckles and then bends when the force is applied to the energy management structure 300 , and a second component 104 surrounding the first component 102 (or vice versa) and possessing a compressive response profile having a bending/buckling profile characteristic such that the second component 104 begins to bend or buckle when the first component 102 transitions from buckling to bending.
- the structure 300 also includes a third component 106 connecting the first 102 component to the second component 104 .
- the structure 300 may be configured according to any of the embodiments discussed above with respect to the energy management structure 100 and the array 250 of the energy management structures 200 .
- the lower end 122 of the structure 300 is adapted to be facing the shell of the helmet 360
- the upper end 120 of the structure is adapted to be facing the head of the helmet wearer.
- the part of the structure 200 facing the helmet 360 includes a low-friction boundary with the helmet 360 so as to permit rotation of the helmet 360 on the head of the wearer when an impact force is applied to the helmet 360 .
- the structure 300 or array of structures 300 is detachably attachable to the helmet 360 , so that the structure 300 is detachable from one location on the helmet 360 and re-attachable to another location on the helmet 360 .
- the manner in which the structure 300 is detachably attached to the helmet 360 is not particularly limited.
- the structure 300 is detachably attached to the helmet 360 via a hook and loop fastening system or a reusable or re-appliable adhesive.
- the structures 300 may accompanied in the helmet 360 with a padding of the type disclosed in U.S. Pat. No. 7,341,776 or U.S. Patent Application Publication No. 2007/0281125 A1, the disclosures of which are incorporated herein by reference.
- the structures 300 are detachably attachable to the helmet 360 , a user or supplier can selectively distribute the structures 300 to a desired location on the helmet 360 .
- the structures 300 may be strategically placed on the helmet 360 to yield an ideal stiffness per shell location.
- a helmet 360 with a relatively stiff shell may need a substantially “softer” array of structures 300 for large flat regions such as on the side above the ear.
- a comparably stiffer array of structures 300 is more suitable for regions on the shell in front of the forehead, which may utilize a much smaller area of energy management structures 300 .
- the reattachability of the structures 300 on the helmet 360 offers convenient regional tuning of the structure configuration by spacing the structures 300 as desired without the need for complex molds as conventionally required for typical multi-density foam helmet liners.
- the spacing of the structures 300 may also contribute to the smoothness of the compression response characteristic stress/strain curve discussed above for the overall structure and for particular impact events.
- Such a method includes selectively distributing at least one energy management structure 300 to a desired location on the helmet 360 .
- FIGS. 5 a - 5 d illustrate different views of another embodiment of the energy management structure 100 .
- the energy management structure 100 in this embodiment may be configured according to any of the embodiments discussed above with respect to the energy management structure 100 , and further includes a fourth component 524 between the first component 102 and the second component 104 , and is also connected to the third component 106 .
- the fourth component 524 comprises two walls 526 , 528 , one of the walls surrounding the other wall.
- the fourth component 524 possesses a third compressive response profile that may be additive to the first and second compressive response profiles in the same manner as discussed above to result in an overall compressive response profile of the energy management structure 100 that meets a desired design compressive response profile.
- the energy management structure 100 may include additional components similar to fourth component 524 depending on the application in which the structure 100 is to be used.
- FIGS. 6 a and 6 b illustrate a modified embodiment of the energy management structure 100 shown in FIGS. 5 a - 5 d.
- the energy management structure 100 in this modified embodiment may be configured according to any of the embodiments discussed above with respect to the energy management structure 100 .
- the second component 104 here comprises walls 630 that are separated from each other by gaps 632 between the walls 630 . These gaps 632 may extend into the third component 106 as shown in FIGS. 6 a and 6 b .
- the gaps 632 between the walls 630 of the second component 104 may be used to affect (e.g., decrease) the stiffness of the second component 104 , thus manipulating the compressive response profile of the second component 104 as desired.
- FIGS. 7 a - 7 d illustrate a further embodiment of the energy management structure, designated with reference numeral 700 .
- the energy management structure 700 in this modified embodiment may include the features discussed above with respect to the energy management structure 100 .
- the energy management structure 700 comprises a plurality of first components 702 surrounded by a second component 704 .
- Each of the plurality of first components 702 possesses a respective compressive response profile as discussed above. That is, each first component 702 possesses a compressive response profile having a buckling/bending profile characteristic such that the first component 702 buckles and then bends when the force is applied to the energy management structure 700 .
- the second component 704 surrounding the plurality of first components 702 possesses a compressive response profile having a bending/buckling profile characteristic such that the second component 704 begins to bend or buckle when one or more of the first components 702 transitions from buckling to bending.
- the energy management structure 700 be configured such that the second component 704 possesses a compressive response profile having a buckling/bending profile characteristic such that the second component 704 buckles and then bends when the force is applied to the energy management structure 700 , and one or more of the first components 702 possesses a compressive response profile having a bending/buckling profile characteristic such that one or more of the first components 702 begins to bend or buckle when the second component 704 transitions from buckling to bending.
- the energy management structure 700 may possess an overall compression response characteristic that is defined by a smooth curve as discussed above with respect to the other embodiments.
- the height of the second component 704 may be the same as the height of each of the plurality of first components 702 .
- the height of the second component 704 may be the same as the height of some of the plurality of first components 702 , such that the height of other of the of the plurality of first components 702 is different than that of the second component 704 .
- the difference in height, or lack thereof may affect the overall compression response characteristic of the energy management structure 700 to suite the overall compressive response profile to desired applications.
- FIGS. 8 a - 8 d illustrate different views of another embodiment of the energy management structure, designated with reference numeral 800 .
- the energy management structure 800 in this modified embodiment is somewhat similar to the energy management structure 700 in that the energy management structure 800 comprises a plurality of first components 802 surrounded by a second component 804 , and may include the features discussed above with respect to the energy management structure 100 .
- each of the plurality of first components 802 comprises a substructure 840 having at least one wall 842 surrounded by another wall 844 .
- the wall 844 is concentric to the wall 842 .
- the substructure 840 may include one or more additional concentric walls, such as wall 843 shown in FIGS. 8 a and 8 b.
- the wall 842 comprises a first subcomponent possessing a first compressive response profile
- the wall 844 comprises a second subcomponent possessing a second compressive response profile different from the first compressive response profile.
- the first and second compressive response profiles are similar to those discussed above. That is, when a force is applied to the energy management structure 800 and/or the substructure 840 , the second compressive response profile of the second subcomponent 844 is additive to the first compressive response profile of the first subcomponent 842 to result in an compressive response profile of the substructure 840 that meets a design compressive response profile of the substructure 840 .
- each substructure 840 of the energy management structure 800 provides the respective first component 802 with a compressive response profile different from the compressive response profile of the second component 804 .
- ach first component 802 (substructure 840 ) possesses a compressive response profile having a buckling/bending profile characteristic such that the first component 802 (substructure 840 ) buckles and then bends when the force is applied to the energy management structure 800 .
- the second component 804 surrounding the plurality of first components 802 (substructures 840 ) possesses a compressive response profile having a bending/buckling profile characteristic such that the second component 804 begins to bend or buckle when one or more of the first components 802 (substructures 840 ) transitions from buckling to bending.
- the energy management structure 800 be configured such that the second component 804 possesses a compressive response profile having a buckling/bending profile characteristic such that the second component 804 buckles and then bends when the force is applied to the energy management structure 800 , and one or more of the first components 802 (substructures 840 ) possesses a compressive response profile having a bending/buckling profile characteristic such that one or more of the first components 802 (substructures 840 ) begins to bend or buckle when the second component 804 transitions from buckling to bending.
- the energy management structure 800 may possess an overall compression response characteristic that is defined by a smooth curve as discussed above with respect to the other embodiments.
- the height of the second component 804 may be shorter than the height of the plurality of first components 802 .
- the height of the second component 804 may be the same as the height of one or more of the plurality of first components 802 .
- the difference in height, or lack thereof may affect the overall compression response characteristic of the energy management structure 800 to suite the overall compressive response profile to desired applications.
- FIG. 9 illustrates a method of designing an energy management structure in connection with the above embodiments.
- the method comprises a first step 8901 of determining a first compressive response profile of the first component 102 , and a second step 8902 of determining a second compressive response profile of the second component 104 .
- the second compressive response profile is different from the first compressive response profile.
- the energy management structure 100 is designed by coupling at least one first component 102 having the first compressive response profile with at least one second component 104 having the second compressive response profile to result in an overall compressive response profile of the energy management structure 100 that meets a design compressive response profile.
- the computer may be a conventional computer having all of the components necessary, as would be understood by one skilled in the art, to execute the above steps.
- at least one of the first compressive response profile and the second compressive response profile may be erratic, while the overall design compressive response profile of the energy management structure 100 is smooth. That is, the overall design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
- FIG. 10 shows an exemplary computer system 1000 for carrying out the process shown in FIG. 9 , for example.
- the system 1000 has a computer 1014 , which may be a dedicated, specific purpose computer, or a specifically programmed general purpose computer.
- the computer 1014 can have a database of various materials and structures collated with their compression response profiles.
- the computer 1014 via a network 1016 , can access other databases 1010 or servers 1012 operatively connected to databases 1012 a that have this form of data.
- the data can be empirically derived through testing, or by computer modeling and/or simulation.
- the computer 1014 has input devices (e.g., keyboard and mouse) for inputting an energy management system/structure design compression profile.
- the user can then select materials and structures whose compression profiles add up to the overall design compression profile, or the computer can propose combinations based on known computer modeling and simulation techniques (e.g., finite element analysis), or simple algebraically additive graphing techniques that use best-fit graphic techniques to select additive compression profiles for two, three or more components that suggest the additive result will be the design compression profile, and output a suggested design or design according to predetermined criteria.
- known computer modeling and simulation techniques e.g., finite element analysis
- simple algebraically additive graphing techniques that use best-fit graphic techniques to select additive compression profiles for two, three or more components that suggest the additive result will be the design compression profile, and output a suggested design or design according to predetermined criteria.
- the energy management structures have been described herein primarily in connection with a helmet for military, athletic and recreational activities where a chance of cranial impact is possible. However, the described energy management structures are also applicable to body protective gear including a vest, arm/elbow pads, leg/knee pads and footwear. Additionally, the energy management structures may be configured for larger scale applications, such as padding for packages, floors and floor mats, boat decking, and walls and foundations of buildings, in which sheets of the arrays of the energy management structures that are designed for particular environments can be provided for installation by the buyer or installer.
Abstract
An energy management structure is adapted to absorb a force applied thereto. The structure includes a first component possessing a first compressive response profile, a second component possessing a second compressive response profile different from the first compressive response profile, and a third component connecting the first component to the second component. Upon application of a force, the second compressive response profile of the second component is additive to the first compressive response profile of the first component to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile.
Description
- This application is a continuation application of U.S. patent application Ser. No. 12/792,858, with a filing date of Jun. 3, 2010, the entire disclosure of which is fully incorporated herein by reference.
- This disclosure relates to an energy management structure, and particularly to an energy management structure that is adapted to absorb an impact force applied thereto. The energy management structure is applicable, but not limited, to body protective gear for military, athletic and recreational activities, for example, including a helmet where a chance of cranial impact is possible, protective pads (e.g., shoulder pads), and other pads such as cushions for hard seats and packing material.
- Helmets and other types of protective gear used in military, athletic and recreational activities are intended to provide protection against a sudden impact. Generally, a helmet protects the head by preventing direct impact on the head, but also by causing the head to more gradually accelerate to a stop. The shell of the helmet and liner components together act as a system. The shell is constructed to provide rigidity to the helmet to guard against protruding objects, and is as a platform to support the liner structure. The liner is designed to complement the shell's geometry and regional stiffness, so that the liner and shell together provide a more ideal reduction in peak accelerations that would be observed should a head come to violent and sudden stop or accelerated state. In an impact scenario, the shell and liner provide an appropriate efficiency and stiffness response such that the head is more gently accelerated using as much of the available liner thickness as possible. Herein, “acceleration” is used to describe both acceleration and deceleration.
- Expanded Polystyrene (EPS), Expanded Polypropylene (EPP), Ethyl Vinyl Acetate (EVA), Vinyl Nitrile (VN), and Polyurethane foams (PU) are conventional materials used for acceleration management inside helmets to protect the head. Non-foam materials, such as honeycomb, hemisphere and cylindrical crushable structures have been suggested as an alternative for managing impact forces applied to the helmet. All of these materials and structures exhibit crushing efficiencies, typically less than 75% compression until the material is considered bottomed. Crushing efficiency of the materials and structures are affected by their density. Generally, greater density results in increased stiffness. As stiffness is increased, crush efficiency is diminished. Crushable structures also have inherent crushing efficiencies, which are ultimately governed by the stacking-up of the structure walls at full compression. Structures such as honeycombs can be very stiff, but typically not very efficient or resilient. In order to reach full compression, wall damage of these structures is often observed.
- The deformation characteristics of the non-foam honeycomb, hemisphere and cylinder crushable structures display erratic buckling modes when subject to an impact force, which are discussed in further detail below. Such awkward or “noisy” deformation characteristics can degrade the crushable structures and result in highly reduced “multi-hit” capacity, for example. It is desirable to produce an improved crushable structure that in certain embodiments can offer increased impact performance compared to the conventional foams and structures.
- The disclosure below discusses configurations that overcome the disadvantages of the conventional materials and structures by providing an energy management structure demonstrating a smoother deformation characteristic in response to an applied impact force. The energy management structures disclosed herein can have increased densifying efficiency (Le., usable thickness before bottoming/densifying) and increased resiliency for multi-impact performance. The energy management structure is applicable, but not limited, to body protective gear including, for example, helmets and protective pads for military, athletic and recreational activities where a chance of cranial or other body part impact is possible. The energy management structures described herein are also applicable to a vest, arm/elbow pads, leg/knee pads and footwear, padding for hard seats and padding for shipping materials, for example.
- According to one aspect, an energy management structure is adapted to absorb a force applied thereto. The structure comprises a first component possessing a first compressive response profile, a second component possessing a second compressive response profile different from the first compressive response profile, and a third component connecting the first component to the second component. Upon application of a force, the second compressive response profile of the second component is additive to the first compressive response profile of the first component to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile.
- According to some embodiments, at least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
- According to some embodiments, the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
- According to some embodiments, smoothness of the curve is based on the first component of the structure buckling and then bending when the force is applied to the structure, and the second component, surrounding the first component, beginning to bend or buckle when the first component transitions from bending to buckling.
- According to some embodiments, the first compressive response profile possesses a compression profile characteristic that shows a transition point in compression resistance from a relatively high compression resistance to a relatively low compression resistance of the first component when a force is applied to the energy management structure, and the second compressive response profile possesses a compression profile characteristic that is additive to the compression profile characteristic of the first component at the transition point when the force is applied to the second component.
- According to some embodiments, the first compressive response profile possesses a buckling/bending profile characteristic such that the first component buckles and then bends when the force is applied to the energy management structure, and the second compressive response profile possesses a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component transitions form buckling to bending.
- According to some embodiments, the second component surrounds the first component.
- According to some embodiments, the first component surrounds the second component.
- According to some embodiments, wherein a recess is present between the first component and the second component and is formed by the first, second and third components.
- According to some embodiments, the third component is provided at one of an upper and lower end of the structure.
- According to some embodiments, the third component is provided at a location of the structure between an upper and lower end of the structure.
- According to some embodiments, the first component is a center column extending from one end of the structure to an opposing end of the structure.
- According to some embodiments, the first component includes at least one reinforcing rib on a side of the first component facing the second component.
- According to some embodiments, the first component is corrugated, so that the first component has a wavy cross-sectional profile.
- According to some embodiments, the second component includes at least one reinforcing rib.
- According to some embodiments, the third component includes at least one aperture.
- According to some embodiments, the second component surrounds the first component and the first component is hollow, and the aperture opens into the hollow first component.
- According to some embodiments, one end of the first component extends to one end of the structure, and one end of the second component extends toward the one end of the structure and is offset from the one end of the first component, such that the second component does not extend as far as the one end of the first component.
- According to some embodiments, the size of the offset of the one end of the second component relative to the one end of the first component is about 10% of the total height of the structure.
- According to some embodiments, the structure has a frusta-conical shape.
- According to some embodiments, the structure has a cylindrical shape.
- According to some embodiments, the structure has a mushroom shape.
- According to some embodiments, the structure is formed of a polymer material.
- According to some embodiments, the structure is formed of thermoplastic elastomer.
- According to some embodiments, the structure is formed of an injection-molded material.
- According to some embodiments, the structure is configured to elastically deform in an axial direction of the structure when a force is applied to the structure.
- According to some embodiments, the structure is configured to plastically deform in an axial direction of the structure when a force is applied to the structure.
- According to some embodiments, the structure is crushable to about 30% of its original size.
- According to some embodiments, the structure is crushable to about 20% of its original size.
- According to some embodiments, the structure is crushable to about 10% of its original size.
- According to some embodiments, the energy management structure further comprises a fourth component between the first and second components and connected to the third component, and the fourth component possesses a third compressive response profile.
- According to some embodiments, the fourth component comprises two walls, one of the walls surrounding the other of the walls.
- According to some embodiments, the second component is an outermost component and comprises walls that are separated from each other by gaps between the walls.
- According to some embodiments, the gaps extend into the third component.
- According to some embodiments, the energy management structure comprises a plurality of the first components surrounded by the second component, and each of the plurality of first components possesses a respective compressive response profile.
- According to some embodiments, a height of the second component is the same as the height of each of the plurality of first components.
- According to some embodiments, a height of the second component is the same as the height of some of the plurality of first components, such that the height of other of the of the plurality of first components is different than that of the second component.
- According to some embodiments, each of the plurality of first components comprises a substructure having at least one wall surrounded by another wall.
- According to some embodiments, at least one of the walls of the substructure is concentric to another wall of the substructure.
- According to some embodiments, each of the plurality of substructures comprises a first subcomponent possessing a first compressive response profile, and a second subcomponent possessing a second compressive response profile different from the first compressive response profile. Upon application of a force, the second compressive response profile of the second subcomponent is additive to the first compressive response profile of the first subcomponent to result in an compressive response profile of the substructure that meets a design compressive response profile.
- According to some embodiments, a height of the second component is the same as the height of each of the plurality of substructures.
- According to some embodiments, a height of the second component is different than the height of the plurality of substructures.
- According to another aspect, there is provided an array of energy management structures.
- According to some embodiments, the structures in the array are connected to each other with a connector attached to a lower end portion of adjacent structures.
- According to some embodiments, the structures in the array are identical.
- According to some embodiments, the structures in the array are stackable on top of each other.
- According to some embodiments, the array is enveloped in a padding.
- According to another aspect, the energy management structure is adapted to be attached to the inside of a helmet.
- According to some embodiments, the structure is detachably attachable to the helmet, so that the structure is detachable from one location on the helmet and reattachable to another location on the helmet.
- According to a further aspect, there is provided a helmet including at least one energy management structure.
- According to a further aspect, a method of designing an energy management system for body protective gear is provided. The energy management system comprises at least one energy management structure. The method comprises selectively distributing the at least one energy management structure to a desired location on the body protective gear.
- According to another aspect, a method of designing an energy management structure adapted to absorb a force applied thereto, is provided. The method comprises determining a first compressive response profile of a first component, determining a second compressive response profile of a second component, the second compressive response profile being different from the first compressive response profile, and designing an energy management structure by coupling at least one first component having the first compressive response profile with at least one second component having the second compressive response profile to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile. The determining steps are carried out in a specifically programmed computer executing code to carry out the steps.
- According to some embodiments, at least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
- According to some embodiments, the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
-
FIG. 1 a is a perspective view of an energy management structure according to one embodiment; -
FIG. 1 b is another perspective view of the energy management structure according to the embodiment ofFIG. 1 a; -
FIG. 1 c is a plan view of the upper end of the energy management structure according to the embodiment ofFIG. 1 a; -
FIG. 1 d is a plan view of the opposite lower end of the energy management structure according to the embodiment ofFIG. 1 a; -
FIG. 1 e is a cross-sectional view of the energy management structure according to the embodiment ofFIG. 1 a; -
FIG. 2 a is a stress/strain curve graphically illustrating the results of a Finite Element Analysis performed on a conventional structure; -
FIG. 2 b is a stress/strain curve graphically illustrating the results of a Finite Element Analysis performed on an energy management structure disclosed herein; -
FIG. 2 c illustrates a compression characteristics of an energy management structure disclosed herein; -
FIG. 3 a is a perspective view of an array of energy management structures according to one embodiment; -
FIG. 3 b is another perspective view of the array of energy management structures according to the embodiment ofFIG. 3 a; -
FIG. 3 c is a perspective view showing compression of the array of energy management structures ofFIG. 3 a; -
FIG. 3 d is another perspective view showing compression of the array of energy management structures ofFIG. 3 a; -
FIG. 3 e is a perspective view showing the array of energy management structures enveloped in a foam ofFIG. 3 a; -
FIG. 3 f is another perspective view showing the array of energy management structures enveloped in a foam ofFIG. 3 a; -
FIG. 4 a is a perspective view of a helmet including a plurality of energy management structures; -
FIG. 4 b is a perspective view of a helmet including a plurality of energy management structures used with a padding; -
FIGS. 5 a-5 d illustrate different views of another embodiment of the energy management structure; -
FIGS. 6 a and 6 b illustrate different views of a modified embodiment of the energy management structure shown inFIGS. 5 a-5 d; -
FIGS. 7 a-7 d illustrate different views of a further embodiment of the energy management structure; -
FIGS. 8 a-8 d illustrate different views of another embodiment of the energy management structure; -
FIG. 9 illustrates the steps associated with a method of designing an energy management structure; and -
FIG. 10 shows one embodiment of a computer system for carrying out the process shown inFIG. 9 . -
FIGS. 1 a-1 e illustrate anenergy management structure 100 according to one embodiment. As shown in these figures, theenergy management structure 100 includes afirst component 102, asecond component 104 and athird component 106. As shown inFIGS. 1 b and 1 e, thesecond component 104 surrounds thefirst component 102, so that arecess 108, formed by the first, second and third components is present between thefirst component 102 and thesecond component 104. While it is illustrated here that the “second component” 104 surrounds the “first component” 102, it will be recognized that thesecond component 104 may behave (as discussed below) like thefirst component 102, and vice versa, such that the “first component” may also refer to thecomponent 104 surrounding the “second component” 102. The width of the recess is not particularly limited, and provides space for thefirst component 102 to buckle/bend before bending or buckling of thesecond component 104. In the illustrated embodiment, thesecond component 104 concentrically surrounds thefirst component 102. However, in some embodiments, thesecond component 104 and thefirst component 102 do not share the same axis. That is, thefirst component 102 may be disposed off-center relative to thesecond component 104. The shape of thefirst component 102 is not particularly limited, although some shapes have greater advantages than others. The shape may be comprised of a column in the form of a circular tube. Alternatively, the profile of thefirst component 102 may have a polygonal shape, such as a triangular, rectangular, pentagonal, hexagonal or other multi-sided shape. In the embodiment, thefirst component 102 is arranged to extend from theupper end 120 of thestructure 100 to an opposinglower end 122 of thestructure 100. In the embodiment, thefirst component 102 is hollow. However, a solid, un-hollowfirst component 102 gives additional stiffness to thefirst component 102. Further, the shape of thesecond component 104 is not particularly limited, and may be circular, triangular, rectangular, pentagonal, hexagonal or have another multi-sided shape. - A
third component 106 connects thefirst component 102 to thesecond component 104, and is generally shaped to match the profile of thesecond component 104. For instance, if thesecond component 104 possesses a generally circular shape, thethird component 106 also possesses a circular shape. However, the shape of thethird component 106 may be different from the shape of thesecond component 104. Thethird component 106 can help to spread the point load of an impact force applied to thestructure 100, but primarily is in place to assure the first and second components work in concert, for example, and provides a spatial relationship that the second component engages at a certain point in the crushing of the first component. Thethird component 106 may be provided at anupper end 120 orlower end 122 of thestructure 100. Alternatively, thethird component 106 may be provided at a location of thestructure 100 between theupper end 120 and thelower end 122 of thestructure 100, such as at the midpoint between theupper end 120 and thelower end 122. In the illustrated embodiment, thethird component 106 is provided at theupper end 120 of thestructure 100. Thethird component 106 in this embodiment is substantially planar and orthogonal to the center axis of thestructure 100. However, thethird component 106 may be convex, or may have an overall concave shape. It is preferable that thethird component 106 be substantially planar and orthogonal to the center axis of thestructure 100 to better distribute the load of the force applied to thestructure 100 and/or avoid the creation of pressure points or spikes, and may also act to provide greater area for affixing (e.g., gluing) the energy management structure to another structure, such as the inside of padding or a helmet, for example. - In some embodiments, the
third component 106 includesapertures 114.Apertures 114 open into therecess 108 between thefirst component 102 and thesecond component 104. In addition, in embodiments where thefirst component 102 is hollow as discussed above, thethird component 106 may include anaperture 116 opening into the hollowfirst component 102. Theapertures recess 108 and hollowfirst component 102 when thestructure 100 is rapidly compressed upon application of an impact force. The evacuation of air from within thestructure 100 may contribute to enhanced compressibility of thestructure 100 by providing a channeled escape route of rapidly compressed air, if the design parameters suggest the appropriateness of this feature. In some embodiments, the compression force of trapped air or other gasses might be desirable. Compressibility of thestructure 100 is discussed in further detail below. - According to some embodiments, the
first component 102 includes one or more reinforcingribs 110 on a side of thefirst component 102 in therecess 108 facing thesecond component 104. The reinforcingribs 110 provide added stiffness to thefirst component 102. In the illustrated embodiment, thefirst component 102 includes threeribs 110. However, the number ofribs 110 may be more or less. In a preferred embodiment, the reinforcingribs 110 extend longitudinally from theupper end 120 of thestructure 100 to thelower end 122 of thestructure 100. In some embodiments, the reinforcingribs 110 extend along thefirst component 102 for only a portion of the extension from theupper end 120 to thelower end 122 of the structure. - As an alternative to the longitudinally extending reinforcing
ribs 110, the first component may have at least onespiral rib 110 extending spirally between theupper end 120 of thestructure 100 and thelower end 122 of thestructure 100. As a further alternative, thefirst component 102 may corrugated, so that thefirst component 102 has a wavy profile. - Further, the
second component 104 may include reinforcingribs 112 on a side of thesecond component 104 in therecess 108 facing thefirst component 102. Similar to the firstcomponent reinforcing ribs 110, the secondcomponent reinforcing ribs 112 may extend longitudinally from theupper end 120 of thestructure 100 to thelower end 122 of thestructure 100. In the illustrated embodiment, thesecond component 104 includes threeribs 112. However, the number ofribs 112 may be more or less. In other embodiments, the secondcomponent reinforcing ribs 112 extend along thesecond component 104 for only a portion of the extension from theupper end 120 to thelower end 122 of thestructure 100. Alternatively, thesecond component 104 may have at least onespiral rib 112 extending spirally inside thestructure 100 between theupper end 120 of thestructure 100 and thelower end 122 of the structure. In some embodiments, thestructure 100 includes theribs 110 on thefirst component 102 and theribs 112 on thesecond component 104. In these embodiments, thefirst component ribs 110 and thesecond component ribs 112 may be radially offset from each other as shown inFIG. 1 b. - In all of the embodiments discussed above, one
end 102 a of thefirst component 102 may extend all the way to thelower end 122 of thestructure 100, and oneend 104 a of thesecond component 104 may extend to a lesser extent toward thelower end 122 end of thestructure 100 as shown inFIG. 1 e. In this regard, thesecond component 104 does not extend as far toward theend 122 of thestructure 100 as thefirst component 102. That is, as principally shown inFIG. 1 e, an offset 118 is provided at the at the outer circumference of thestructure 100 at thelower end 122. The size of the offset 118 of theend 104 a of thesecond component 104 relative to theend 102 a of thefirst component 102 may range from about 5% to 20% of the total height of thestructure 100. The size of the offset 118 is about 10% of the total height of thestructure 100 in this particular embodiment, but the offset may be determined by the additive compression profiles. The offset 118 adds significant stiffness to theoverall structure 100 during compression after thefirst component 102 has buckled and can be dimensioned to substantively engage when thefirst component 102 is transitioning from buckling to bending modes, as explained below. Thesecond component 104 substantively engages during an impact event when it measurably adds to the crush resistance. For instance, if thesecond component 104 had a thin skirt that extended as far as thefirst component 102 for aesthetics, sealing, or a second part of a third component (so that thethird component 106 appears on each end of the first andsecond components - Conventional structures often possess a deformation characteristic that is erratic when subject to an impact force. This is evidenced by the graph shown in
FIG. 2 a illustrating the results of a Finite Element Analysis performed on a conventional structure. The graph inFIG. 2 a shows the compression response characteristic in terms of stress versus strain of the conventional structure due to an applied constant velocity compression force. The compression response characteristic here is defined by a line which increases and decreases rapidly with sharp peaks and valleys. Such an awkward or “noisy” deformation characteristic degrades the structure's performance and results in a highly reduced ability of the conventional structure to sustain repeatable and predictable impact performance. That is, the “noisy” deformation characteristic yields a less predictable and poor repeatable impact performance. - According to the embodiments discussed above, the
first component 102 provides an initial stiffness, especially when anchored to thethird component 106 at theupper end 120 of thestructure 100. When thefirst component 102 initially yields to an applied impact force, thefirst component 102 begins to buckle. Eventually, thefirst component 102 bends as the applied impact force increases. Thesecond component 104 does not initially bend or buckle when thefirst component 102 begins to buckle. This is, in part, due to the offset 118, in the illustrated embodiment. That is, when the impact force is first applied to thestructure 100, only thefirst component 102 is affected initially, by buckling. Thesecond component 104 begins bend or buckle under the applied impact force when thefirst component 102 transitions from buckling to bending. Thesecond component 104 does not have to engage exactly when the transition of buckling to bending of thefirst component 102, but within a range that thesecond component 104 has a measurable effect on smoothing the crush profile of thefirst component 102. - As discussed above, the offset 118 may affect the timing of the bending/buckling of the
second component 104 relative to thefirst component 102. It is also possible, however, to manipulate the timing of the bending/buckling of thesecond component 104 relative to thefirst component 102 by (i) increasing/decreasing the wall thickness of thesecond component 104 relative to the wall thickness of thefirst component 102 and vice versa, (ii) enlarging/reducing therecess 108 between thefirst component 102 and thesecond component 104 so that thefirst component 102 is farther/closer to thesecond component 104, and/or (iii) eliminating the offset 118, or changing the height of the offset 118 (including changing the height of one offset 118 relative to the height of another offset 118). - According to the above configurations, the
first component 102 possesses a compressive response profile having a buckling/bending profile characteristic such that thefirst component 102 buckles and then bends when an impact force is applied to thestructure 100. Thesecond component 104 possesses compressive response profile different from that of thefirst component 102 and having a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component transitions from buckling to bending. As a result, theenergy management structure 100 as a whole demonstrates a more uniform deformation characteristic in response to an applied impact force than the conventional structure. This is evidenced by comparing the graph inFIG. 2 b illustrating the results of a Finite Element Analysis performed on theenergy management structure 100 according to the embodiments discussed herein, with the graph inFIG. 2 a illustrating the results of the analysis performed on the conventional structure. The graph inFIG. 2 b shows the compression response characteristic in terms of stress versus strain of thestructure 100 due to a compression force applied thereto. As shown inFIG. 2 b, the compression response characteristic is defined by a smooth curve that increases relatively rapidly at first before tapering, and then increases again. The definition of “smooth” as used herein means that the curve extends without steep and/or pointed peeks and valleys, or sudden/abrupt changes in direction. The smoothness of the curve inFIG. 2 b is based on thefirst component 102 of thestructure 100 first buckling and then bending when the impact force is applied to thestructure 100, and thesecond component 104, due at least in part to the offset 118, beginning to bend or buckle when thefirst component 102 transitions from buckling to bending. - Accordingly, upon application of a force, the second compressive response profile of the
second component 104 is additive to the first compressive response profile of thefirst component 102 to result in an overall compressive response profile of theenergy management structure 100 that meets a desired design compressive response profile. That is, the first compressive response profile possesses a compression profile characteristic that shows a transition point in compression resistance from a relatively high compression resistance to a relatively low compression resistance of thefirst component 102 when a force is applied to the energy management structure, and the second compressive response profile possesses a compression profile characteristic that is additive to the compression profile characteristic of thefirst component 102 at the transition point when the force is applied to thesecond component 104. Thus, even if one or both of the first compressive response profile and the second compressive response profile is erratic (by design or otherwise), when added together the first and second compressive response profiles result in an overall design compressive response profile is smooth. This principle is illustrated by the stress/strain graph inFIG. 2 c, which shows the compression response characteristic of the energy management structure by adding together the compressive response profiles of the first andsecond components FIG. 2 c, the compressive response profile of thefirst component 102 is somewhat erratic, while the and the compressive response profile of thesecond component 104 is smoother. The combined curve in the graph (representing the overall compressive response profile of the energy management structure 100) shown with the broken line represents the sum of the first and second compressive response profiles and is a smooth curve that increases relatively rapidly at first before tapering, and then increases. As discussed above, the smoothness of the curve is based on thefirst component 102 of thestructure 100 buckling and then bending when the force is applied to thestructure 100, and thesecond component 104 beginning to bend or buckle when thefirst component 102 transitions from bending to buckling. - The smoothness of the curve in
FIGS. 2 b and 2 c may also result, without an offset 118, by adjusting the angle of thesecond component 104 relative to thefirst component 102, increasing/decreasing the wall thickness of thesecond component 104 relative to the wall thickness of thefirst component 102, and/or enlarging/reducing therecess 108 between thefirst component 102 and thesecond component 104 so that thefirst component 102 is farther/closer to thesecond component 104. The smooth curve compressive response profile results in thestructure 100 providing a more ideal impact response as compared to the conventional structures. - In addition, the usable thickness of the
structure 100, before bottoming/densifying in response to an impact force (Le., densifying efficiency), is increased. Further, thestructure 100 exhibits a relatively high stiffness per unit density. As used herein, stiffness generally describes a stress/strain measurement obtained by compressing thestructure 100 to around the plateau magnitude, which occurs at about 10%-20% compression of thestructure 100. It is noted that in the above embodiments, each of thefirst component 102 and thesecond component 104 both bend and buckle. However, in other embodiments, thefirst component 102 and/or thesecond component 104 simply buckle. In alternative embodiments, thefirst component 102 and/or thesecond component 104 simply bend. - In some embodiments, the
structure 100 is crushable to about 30% of its original size when an impact or compression force is applied to thestructure 100. In other embodiments, thestructure 100 is crushable to about 20% of its original size when an impact force is applied. Preferably, for a military helmet of a particular design, the illustratedstructure 100 is crushable to about 10% of its original size. Stiffness, cost, and weight requirements may govern (Le., increase/reduce the crushability (e.g., less than the 10-30% range) of thestructure 100. Thestructure 100 according to the above embodiments is formed of a material which permits thestructure 100 to elastically deform in an axial direction of thestructure 100 when an impact force is applied to thestructure 100, thus allowing the structure to sustain multiple successive impact forces if particular material used is not stretched passed its plastic yield point. In this regard, thestructure 100 may be formed of a polymer material, a thermoplastic elastomer or an injection-molded material. Additional processes used to form the structure include compression molding, rim molding and casting. - In other embodiments, the
structure 100 may be configured to plastically deform in an axial direction of thestructure 100 upon an application of an impact force. In addition, thestructure 100 exhibits a tangential compression when a force is applied tangentially to thestructure 100 rather than axially. The tangential compression of the structure is greater than the axial compression of thestructure 100. That is, thestructure 100 compresses tangentially easier than thestructure 100 compresses axially in this embodiment. The tangential compression of thestructure 100 enables thestructure 100 to absorb a force that grazes thestructure 100 in a direction tangential to thestructure 100. This ability to absorb glancing blows, for instance, can result in reduced trauma to the wearer. For instance, by controlling the tangential component of a compression profile, an outer part of the helmet, for instance, might be permitted to rapidly rotate relative to the head of the wearer so that the wearer's head does not have to, thus reducing the chances of trauma to the brain or neck of the wearer. In other words, the energy management structure absorbs the tangential energy so that the wearer's head and neck do not have to. Of course, this is not limited to helmets, and extends to other body protective gear. - The
structure 100 may be formed of a stiff thermoplastic elastomer (TPE) or plastic urethane. Other materials include Expanded Polystyrene (EPS) and Expanded Polypropylene (EPP). A softer material with much higher strain until plastic yield, such asEstane 58138 and Thermoplastic Urethane (TPU) may also be used. TPU, which may reach about 500% strain before breaking, possesses a flexural modulus of 0.731 MPa, an elongation prior to break of greater than 400%, and a plastic yield of about 4% material strain. However, a structure formed of this material may have regions that will plastically deform at about 20% compression. - According to the embodiments discussed herein, the
structure 100 is rotationally symmetric. In alternative embodiments, however, thestructure 100 may not be rotationally symmetric. In some embodiments, thestructure 100 has a frusta-conical shape as shown inFIGS. 1 a-1 c. That is, thelower end 122 open end of thestructure 100 has a larger circumference than theupper end 120 of thestructure 100. Alternatively, thestructure 100 may be cylindrically shaped. As a further alternative, thestructure 100 may have a mushroom shape in profile. In exemplary embodiments of a design usable for military helmets, the height of thestructure 100 is about 0.5 inches, and the outer diameter of thestructure 100 at thelower end 122 is about 0.75 inches. However, the structure is not limited to these dimensions. The dimensions may be scaled up or down depending on the application in which thestructure 100 is used. Further, thickness of the walls of thefirst component 102, thesecond component 104 and thethird component 106 may be varied depending on the application in which thestructure 100 used. The thickness of the walls of the components may be varied or tapered depending on the applications in which thestructure 100 is used and tooling requirements for manufacturing thestructure 100. -
FIGS. 3 a and 3 b show one embodiment of anarray 250 ofenergy management structures 200 adapted to absorb a force applied thereto. Eachstructure 200 of thearray 250 includes afirst component 202 possessing a compressive response profile having a buckling/bending profile characteristic such that thefirst component 202 buckles and then bends when the force is applied to theenergy management structure 200, and asecond component 204 surrounding the first component 202 (or vice versa) and possessing a compressive response profile having a bending/buckling profile characteristic such that the second component begins to bend or buckle when thefirst component 202 transitions from buckling to bending. Athird component 206 connects thefirst component 202 to the second 17component 204. Eachstructure 200 in thearray 250 may be configured according to any of the embodiments discussed above with respect to theenergy management structure 100. Thestructures 200 in thearray 250 are connected to each other with aconnector 224 attached to alower end portion 222 ofadjacent structures 200. In some embodiments, theconnector 224 may be attached to an upper end portion 220 ofadjacent structures 200 or to a location between the upper end portion 220 and thelower end portion 222. In the exemplary embodiment, theconnector 224 is about 0.2 inches wide. However, the size of theconnector 224 may be more or less depending on the application in which thearray 250 is used. - As shown in
FIGS. 3 a and 3 b, thearray 250 is rectangular in plan view. However, thearray 250 may be formed in any shape suitable for the particular application in which the array is used. For example, thearray 250 may be circular, triangular, pentagonal, hexagonal, star shaped, or any other desired polygonal shape. In this regard, the total number ofstructures 200 in thearray 250 is not particularly limited, and may include any desired number ofstructures 200.FIGS. 3 c and 3 d show compression of thearray 250 ofenergy management structures 200 in response to an impact force applied to theentire array 250. In some instances, only one or some of thestructures 200 in the array may compress in response to the impact force. - In the illustrated embodiment, the
structures 200 in thearray 250 are identical. In other embodiments, some of thestructures 200 in thearray 250 may be different from theother structures 200 in thearray 250. For instance, some of thestructures 200 in thearray 250 may be formed according to one or more embodiments of thestructure 100 discussed above, while other of thestructures 200 in thearray 250 may be formed according to other embodiments of thestructure 100 discussed above. In different embodiments, some of thestructures 200 in thearray 250 may inverted, such that the upper end 220 of somestructures 200 are adjacent thelower end 222 ofadjacent structures 200. - In addition,
additional structures 200 may be stackable on top of thestructures 200 in thearray 250. For example, the upper end 220 of theadditional structures 200 may be in contact with the upper end of thestructures 200 in thearray 250. The number of layers ofadditional structures 200 on top of thearray 250 is not particularly limited, may include any desired number of layers ofadditional structures 200 depending on the application in which theadditional structures 200 and thearray 250 are used. Further, theadditional structures 200 may be insertable or nestable with respect to thestructures 200 in thearray 250, meaning that the upper end 220 of onestructure 200 is in thearray 250 is insertable into the lower end 220 of one of theadditional structures 200. Moreover, thestructures 200 may be joined or attached to each other. For example they may be welded to each other, for example, via Rf welding, depending on the material from which they are made. - The
array 200 may be used as an independent liner material or utilized in a liner assembly. In the embodiments shown inFIGS. 3 e and 3 f, thearray 250 is enveloped in apadding 260. Thepadding 260 may be of the types disclosed in U.S. Pat. No. 7,341,776 or U.S. Patent Application Publication No. 2007/0281125 A1, for example, the disclosures of which are incorporated herein by reference. A portion of thestructures 200 in thearray 250 may (or may not) be exposed through the padding 260 a shown inFIG. 3 e. In some embodiment's, thearray 250 is completely enveloped in thepadding 260. Alternatively, thearray 250 may be enveloped in a foam, adjacent to a soft comfort layer, encapsulated by PU film, wicking fabric, and hook or loop fabric so as to be incorporated into a helmet pad assembly. In these embodiments, thearray 250 ofenergy management structures 200 reinforces thepadding 260 or alternative materials while allowing the pad assembly to easily conform to the curvature of the helmet shell. Thepadding 260 may include attachment devices, such as a hook and loop fastening system or reusable adhesive, to detachably attach thepadding 260 to portions of body protective gear subject to impact forces. - According to a further embodiments, the
energy management structure 300 is adapted to be attached to the inside of ahelmet 360 as shown inFIG. 4 a. Thestructure 300 comprises afirst component 102 possessing a compressive response profile having a buckling/bending profile characteristic such that thefirst component 102 buckles and then bends when the force is applied to theenergy management structure 300, and asecond component 104 surrounding the first component 102 (or vice versa) and possessing a compressive response profile having a bending/buckling profile characteristic such that thesecond component 104 begins to bend or buckle when thefirst component 102 transitions from buckling to bending. As discussed above, it is also possible, however, to manipulate the timing of the bending/buckling of thesecond component 104 relative to thefirst component 102 by (i) increasing/decreasing the wall thickness of thesecond component 104 relative to the wall thickness of thefirst component 102, (ii) enlarging/reducing therecess 108 between thefirst component 102 and thesecond component 104 so that thefirst component 102 is farther/closer to the second component 304, and/or (iii) eliminating the offset 118, or changing the height of the offset 118 (including changing the height of one offset 118 relative to the height of another offset 118). Thestructure 300 also includes athird component 106 connecting the first 102 component to thesecond component 104. Thestructure 300 may be configured according to any of the embodiments discussed above with respect to theenergy management structure 100 and thearray 250 of theenergy management structures 200. As shown inFIG. 4 a, thelower end 122 of thestructure 300 is adapted to be facing the shell of thehelmet 360, and theupper end 120 of the structure is adapted to be facing the head of the helmet wearer. In the embodiment, the part of thestructure 200 facing thehelmet 360 includes a low-friction boundary with thehelmet 360 so as to permit rotation of thehelmet 360 on the head of the wearer when an impact force is applied to thehelmet 360. - According to some embodiments, the
structure 300 or array ofstructures 300 is detachably attachable to thehelmet 360, so that thestructure 300 is detachable from one location on thehelmet 360 and re-attachable to another location on thehelmet 360. The manner in which thestructure 300 is detachably attached to thehelmet 360 is not particularly limited. For example, thestructure 300 is detachably attached to thehelmet 360 via a hook and loop fastening system or a reusable or re-appliable adhesive. In addition, as shown inFIG. 4 b, thestructures 300 may accompanied in thehelmet 360 with a padding of the type disclosed in U.S. Pat. No. 7,341,776 or U.S. Patent Application Publication No. 2007/0281125 A1, the disclosures of which are incorporated herein by reference. - Because the
structures 300 are detachably attachable to thehelmet 360, a user or supplier can selectively distribute thestructures 300 to a desired location on thehelmet 360. As different regions of the shell of thehelmet 360 require varying ideal stiffness, thestructures 300 may be strategically placed on thehelmet 360 to yield an ideal stiffness per shell location. For instance, ahelmet 360 with a relatively stiff shell may need a substantially “softer” array ofstructures 300 for large flat regions such as on the side above the ear. A comparably stiffer array ofstructures 300 is more suitable for regions on the shell in front of the forehead, which may utilize a much smaller area ofenergy management structures 300. The reattachability of thestructures 300 on thehelmet 360 offers convenient regional tuning of the structure configuration by spacing thestructures 300 as desired without the need for complex molds as conventionally required for typical multi-density foam helmet liners. The spacing of thestructures 300 may also contribute to the smoothness of the compression response characteristic stress/strain curve discussed above for the overall structure and for particular impact events. - The above discussion is applicable to a method of designing an energy management system for a helmet. Such a method includes selectively distributing at least one
energy management structure 300 to a desired location on thehelmet 360. -
FIGS. 5 a-5 d illustrate different views of another embodiment of theenergy management structure 100. Theenergy management structure 100 in this embodiment may be configured according to any of the embodiments discussed above with respect to theenergy management structure 100, and further includes afourth component 524 between thefirst component 102 and thesecond component 104, and is also connected to thethird component 106. In the embodiment, thefourth component 524 comprises twowalls fourth component 524 possesses a third compressive response profile that may be additive to the first and second compressive response profiles in the same manner as discussed above to result in an overall compressive response profile of theenergy management structure 100 that meets a desired design compressive response profile. In further, embodiments, theenergy management structure 100 may include additional components similar tofourth component 524 depending on the application in which thestructure 100 is to be used. -
FIGS. 6 a and 6 b illustrate a modified embodiment of theenergy management structure 100 shown inFIGS. 5 a-5 d. Theenergy management structure 100 in this modified embodiment may be configured according to any of the embodiments discussed above with respect to theenergy management structure 100. In addition, thesecond component 104 here compriseswalls 630 that are separated from each other bygaps 632 between thewalls 630. Thesegaps 632 may extend into thethird component 106 as shown inFIGS. 6 a and 6 b. Thegaps 632 between thewalls 630 of thesecond component 104 may be used to affect (e.g., decrease) the stiffness of thesecond component 104, thus manipulating the compressive response profile of thesecond component 104 as desired. -
FIGS. 7 a-7 d illustrate a further embodiment of the energy management structure, designated withreference numeral 700. Theenergy management structure 700 in this modified embodiment may include the features discussed above with respect to theenergy management structure 100. In this embodiment, theenergy management structure 700 comprises a plurality offirst components 702 surrounded by asecond component 704. Each of the plurality offirst components 702 possesses a respective compressive response profile as discussed above. That is, eachfirst component 702 possesses a compressive response profile having a buckling/bending profile characteristic such that thefirst component 702 buckles and then bends when the force is applied to theenergy management structure 700. Thesecond component 704 surrounding the plurality offirst components 702 possesses a compressive response profile having a bending/buckling profile characteristic such that thesecond component 704 begins to bend or buckle when one or more of thefirst components 702 transitions from buckling to bending. Alternatively, theenergy management structure 700 be configured such that thesecond component 704 possesses a compressive response profile having a buckling/bending profile characteristic such that thesecond component 704 buckles and then bends when the force is applied to theenergy management structure 700, and one or more of thefirst components 702 possesses a compressive response profile having a bending/buckling profile characteristic such that one or more of thefirst components 702 begins to bend or buckle when thesecond component 704 transitions from buckling to bending. Accordingly, theenergy management structure 700 may possess an overall compression response characteristic that is defined by a smooth curve as discussed above with respect to the other embodiments. - As shown in
FIGS. 7 a-7 d, the height of thesecond component 704 may be the same as the height of each of the plurality offirst components 702. Alternatively, however, the height of thesecond component 704 may be the same as the height of some of the plurality offirst components 702, such that the height of other of the of the plurality offirst components 702 is different than that of thesecond component 704. The difference in height, or lack thereof may affect the overall compression response characteristic of theenergy management structure 700 to suite the overall compressive response profile to desired applications. -
FIGS. 8 a-8 d illustrate different views of another embodiment of the energy management structure, designated withreference numeral 800. Theenergy management structure 800 in this modified embodiment is somewhat similar to theenergy management structure 700 in that theenergy management structure 800 comprises a plurality of first components 802 surrounded by a second component 804, and may include the features discussed above with respect to theenergy management structure 100. In theenergy management structure 800, each of the plurality of first components 802 comprises asubstructure 840 having at least onewall 842 surrounded by anotherwall 844. As shown inFIGS. 8 a and 8 b, thewall 844 is concentric to thewall 842. Thesubstructure 840 may include one or more additional concentric walls, such aswall 843 shown inFIGS. 8 a and 8 b. - According to the embodiment, the
wall 842 comprises a first subcomponent possessing a first compressive response profile, and thewall 844 comprises a second subcomponent possessing a second compressive response profile different from the first compressive response profile. The first and second compressive response profiles are similar to those discussed above. That is, when a force is applied to theenergy management structure 800 and/or thesubstructure 840, the second compressive response profile of thesecond subcomponent 844 is additive to the first compressive response profile of thefirst subcomponent 842 to result in an compressive response profile of thesubstructure 840 that meets a design compressive response profile of thesubstructure 840. Moreover, eachsubstructure 840 of theenergy management structure 800 provides the respective first component 802 with a compressive response profile different from the compressive response profile of the second component 804. In this regard, ach first component 802 (substructure 840) possesses a compressive response profile having a buckling/bending profile characteristic such that the first component 802 (substructure 840) buckles and then bends when the force is applied to theenergy management structure 800. The second component 804 surrounding the plurality of first components 802 (substructures 840) possesses a compressive response profile having a bending/buckling profile characteristic such that the second component 804 begins to bend or buckle when one or more of the first components 802 (substructures 840) transitions from buckling to bending. Alternatively, theenergy management structure 800 be configured such that the second component 804 possesses a compressive response profile having a buckling/bending profile characteristic such that the second component 804 buckles and then bends when the force is applied to theenergy management structure 800, and one or more of the first components 802 (substructures 840) possesses a compressive response profile having a bending/buckling profile characteristic such that one or more of the first components 802 (substructures 840) begins to bend or buckle when the second component 804 transitions from buckling to bending. Accordingly, theenergy management structure 800 may possess an overall compression response characteristic that is defined by a smooth curve as discussed above with respect to the other embodiments. - As shown in
FIG. 8 d, the height of the second component 804 may be shorter than the height of the plurality of first components 802. Alternatively, however, the height of the second component 804 may be the same as the height of one or more of the plurality of first components 802. The difference in height, or lack thereof may affect the overall compression response characteristic of theenergy management structure 800 to suite the overall compressive response profile to desired applications. -
FIG. 9 illustrates a method of designing an energy management structure in connection with the above embodiments. The method comprises a first step 8901 of determining a first compressive response profile of thefirst component 102, and a second step 8902 of determining a second compressive response profile of thesecond component 104. The second compressive response profile is different from the first compressive response profile. In step 8903, theenergy management structure 100 is designed by coupling at least onefirst component 102 having the first compressive response profile with at least onesecond component 104 having the second compressive response profile to result in an overall compressive response profile of theenergy management structure 100 that meets a design compressive response profile. These steps may be carried out in a specifically programmed computer executing code to carry out the steps. The computer may be a conventional computer having all of the components necessary, as would be understood by one skilled in the art, to execute the above steps. As discussed above, at least one of the first compressive response profile and the second compressive response profile may be erratic, while the overall design compressive response profile of theenergy management structure 100 is smooth. That is, the overall design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force. -
FIG. 10 shows anexemplary computer system 1000 for carrying out the process shown inFIG. 9 , for example. Thesystem 1000 has acomputer 1014, which may be a dedicated, specific purpose computer, or a specifically programmed general purpose computer. Thecomputer 1014 can have a database of various materials and structures collated with their compression response profiles. Alternatively or additionally, thecomputer 1014, via anetwork 1016, can accessother databases 1010 orservers 1012 operatively connected todatabases 1012 a that have this form of data. The data can be empirically derived through testing, or by computer modeling and/or simulation. Thecomputer 1014 has input devices (e.g., keyboard and mouse) for inputting an energy management system/structure design compression profile. The user can then select materials and structures whose compression profiles add up to the overall design compression profile, or the computer can propose combinations based on known computer modeling and simulation techniques (e.g., finite element analysis), or simple algebraically additive graphing techniques that use best-fit graphic techniques to select additive compression profiles for two, three or more components that suggest the additive result will be the design compression profile, and output a suggested design or design according to predetermined criteria. - The energy management structures have been described herein primarily in connection with a helmet for military, athletic and recreational activities where a chance of cranial impact is possible. However, the described energy management structures are also applicable to body protective gear including a vest, arm/elbow pads, leg/knee pads and footwear. Additionally, the energy management structures may be configured for larger scale applications, such as padding for packages, floors and floor mats, boat decking, and walls and foundations of buildings, in which sheets of the arrays of the energy management structures that are designed for particular environments can be provided for installation by the buyer or installer.
- While the energy management structures have been described with reference to preferred embodiments thereof, it is to be understood that the energy management structures are not limited to the preferred embodiments or constructions. The disclosed energy management structures are intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the preferred embodiments are shown in various combinations and configurations, that are exemplary, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.
Claims (21)
1. An energy management structure adapted to absorb a force applied thereto, the structure comprising:
a first component possessing a first compressive response profile;
a second component possessing a second compressive response profile different from the first compressive response profile; and
a third component connecting the first component to the second component; wherein
upon application of a force, the second compressive response profile of the second component is additive to the first compressive response profile of the first component to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile.
2. The energy management structure according to claim 1 , wherein at least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
3. The energy management structure according to claim 1 , wherein the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
4. The energy management structure according to claim 3 , wherein smoothness of the curve is based on the first component of the structure buckling and then bending when the force is applied to the structure, and the second component, surrounding the first component, beginning to bend or buckle when the first component transitions from bending to buckling.
5. The energy management structure according to claim 1 , wherein
the first compressive response profile possesses a compression profile characteristic that shows a transition point in compression resistance from a relatively high compression resistance to a relatively low compression resistance of the first component when a force is applied to the energy management structure; and
the second compressive response profile possesses a compression profile characteristic that is additive to the compression profile characteristic of the first component at the transition point when the force is applied to the second component.
6. The energy management structure according to claim 1 , wherein
the first compressive response profile possesses a buckling/bending profile characteristic such that the first component buckles and then bends when the force is applied to the energy management structure; and
the second compressive response profile possesses a bending/buckling profile characteristic such that the second component begins to bend or buckle when the first component transitions form buckling to bending.
7. The energy management structure according to claim 1 , wherein the second component surrounds the first component.
8. The energy management structure according to claim 1 , wherein the first component surrounds the second component.
9. The energy management structure according to claim 1 , wherein a recess is present between the first component and the second component and is formed by the first, second and third components.
10. The energy management structure according to claim 1 , wherein the third component is provided at one of an upper and lower end of the structure.
11. The energy management structure according to claim 1 , wherein the third component is provided at a location of the structure between an upper and lower end of the structure.
12. The energy management structure according to claim 7 , wherein the first component is a center column extending from one end of the structure to an opposing end of the structure.
13. The energy management structure according to claim 7 , wherein the first component includes at least one reinforcing rib on a side of the first component facing the second component.
14. The energy management structure according to claim 7 , wherein the first component is corrugated, so that the first component has a wavy cross-sectional profile.
15. The energy management structure according to claim 7 , wherein the second component includes at least one reinforcing rib.
16. The energy management structure according to claim 1 , wherein the third component includes at least one aperture.
17.-50. (canceled)
51. A method of designing an energy management system for body protective gear, the energy management system comprising at least one energy management structure of claim 1 , the method comprising selectively distributing the at least one energy management structure to a desired location on the body protective gear.
52. A method of designing an energy management structure adapted to absorb a force applied thereto, the method comprising:
determining a first compressive response profile of a first component;
determining a second compressive response profile of a second component, the second compressive response profile being different from the first compressive response profile; and
designing an energy management structure by coupling at least one first component having the first compressive response profile with at least one second component having the second compressive response profile to result in an overall compressive response profile of the energy management structure that meets a design compressive response profile,
wherein the determining steps are carried out in a specifically programmed computer executing code to carry out the steps.
53. The method according to claim 52 , wherein at least one of the first compressive response profile and the second compressive response profile is erratic, and the design compressive response profile is smooth.
54. The method according to claim 52 , wherein the design compressive response profile is defined by a smooth curve on a graph showing a stress/strain relationship of the structure in response to an applied force.
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WO2011153309A3 (en) | 2012-01-19 |
WO2011153309A2 (en) | 2011-12-08 |
US8726424B2 (en) | 2014-05-20 |
US20110296594A1 (en) | 2011-12-08 |
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