Air venting, impact-absorbing compressible members

Abstract

An impact-absorbing compressible member includes a thin-walled enclosure defining an inner chamber containing a volume of fluid such as air. The enclosure includes one or more orifices which as sized and positioned to allow air to vent from the inner chamber in response to an impact on the member and to refill the inner chamber in response to an impact on the member and to refill the inner chamber after the impact is released. The enclosure is formed of a blow-molded thermoplastic elastomer (TPE) material which is economical to make and durable in use. The compressible members can be used as building blocks for impact-absorbing shell structures for a wide variety of applications such as helmets, protective pads for body parts, sports arena wall padding, vehicular bumpers, dashboards and the like. The compressible member has impact-absorbing advantages over conventional foams currently used in those applications.

Claims

1. An energy-absorbing shell structure comprising: a plurality of energy-absorbing compressible members arranged side-by-side and interconnected by a thin web of material to form a connecting layer, each compressible member comprising: i) a compressible enclosure having a wall defining a hollow inner chamber; ii) a volume of fluid at least partially filling said inner chamber; and iii) at least one orifice in the enclosure wall configured to vent fluid from the inner chamber to an interior of the shell structure; each orifice being configured to provide a first resistance to compression when the member is subjected to a relatively high energy impact and a second, lower resistance to compression when the member is subjected to a lesser energy impact, wherein each orifice is initially closed and opens when the member is impacted.

2. The shell structure of claim 1, wherein the thin web is made of a thermoplastic elastomer material.

3. The shell structure of claim 1, further comprising an outer shell layer secured to the connecting layer of interconnected energy-absorbing compressible member.

4. The shell structure of claim 1, wherein the connecting layer of interconnected energy-absorbing compressible member is disposed between an outer layer and an inner layer.

5. The shell structure of claim 4, wherein the outer layer is capable of rotating or shearing relative to the inner layer.

6. The shell structure of claim 1, further comprising an inflow opening configured to allow fluid to flow into the inner chamber and configured to prevent air from flowing out of the inner chamber through the inflow opening.

7. The shell structure of claim 6, further comprising a flap valve coupled to the inflow opening.

8. The shell structure of claim 6, wherein the inflow opening is larger than each orifice.

9. The shell structure of claim 8, wherein the compressible enclosure is configured to return to an uncompressed configuration faster than the compressible enclosure compresses.

10. The shell structure of claim 1, wherein the at least one orifice has a first diameter when the shell structure is subject to the relatively high energy impact and a second, smaller diameter when the shell structure is subject to the lesser energy impact.

11. The shell structure of claim 1, wherein the at least one orifice is configured to vent the fluid from the inner chamber at a first rate when the member is subjected to the relatively high energy impact and is configured to vent the fluid from the inner chamber at a second, slower rate when the member is subjected to the lesser energy impact.

12. The shell structure of claim 1, wherein the compressible enclosure is compressible by up to ninety percent of its uncompressed volume.

13. The shell structure of claim 1, wherein the shell structure includes an inner layer configured to be positioned adjacent a user's head with an opening in the inner layer, wherein the at least one orifice is configured to be aligned with the opening in the inner layer such that the fluid is vented from the inner chamber through the opening in the inner layer to the user's head.

14. The shell structure of claim 1, wherein the size of each orifice increases as the energy of the impact increases.

15. The shell structure of claim 1, wherein each orifice comprises a vertical slit.

16. The shell structure of claim 1, wherein the plurality of compressible members comprise a material having a glass transition temperature of less than negative twenty degrees Fahrenheit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and further advantages of this invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale or relative dimension, emphasis instead being placed upon illustrating the principles of the invention.

(2) FIGS. 1A and 1I-1K are diagrams illustrating an embodiment of a compressible member of the invention having an enclosure with a bellows-like wall construction and defining a hollow inner chamber for holding a volume of fluid (e.g., air).

(3) FIGS. 1B and 1I-1K are diagrams of a sequence illustrating simulated effects of a high-energy impact to the compressible member of FIG. 1A.

(4) FIGS. 1C and 1D are diagrams illustrating the stretching and bending (e.g., shearing) capabilities of the compressible member of FIG. 1A.

(5) FIG. 1E is a diagram of the compressible member of FIG. 1A following an impact.

(6) FIGS. 1F-1H are diagrams illustrating the expansion of the compressible member of FIG. 1A to its uncompressed condition after impact force is removed.

(7) FIG. 2 is a diagram of another embodiment of a compressible member of the invention having a generally rectangular shape and configuration.

(8) FIGS. 3A-3D are diagrams of a sequence illustrating simulated effects of an impact on another embodiment of a compressible member of the invention having separate in-flow and outflow orifices for the fluid contained in its inner chamber.

(9) FIG. 4A is a partial, cross-sectional view of an embodiment of a multilayer shell structure, which includes a layer formed of a plurality of compressible members embodied in accordance with the invention, configured to function as a protective helmet for a wearer's head.

(10) FIG. 4B is a diagram illustrating the operation of protective shell of FIG. 4A during a direct impact.

(11) FIG. 4C is a diagram illustrating the operation of protective shell of FIG. 4A during a tangential impact.

(12) FIG. 5 is a partial, cross-sectional view of an embodiment of a multilayered shell structure, similar to that of FIG. 4A, configured for use as a protective body pad, e.g., a shin pad.

(13) FIGS. 6A and 6B are diagrams illustrating an embodiment of a multilayer shell structure, similar to that of FIGS. 4A and 5, configured for use as an energy-absorbing covering for the boards of a hockey rink.

(14) FIG. 7 is a diagram illustrating an embodiment of a multilayered shell structure, similar to those of FIGS. 4A, 5 and 6, configured for use as an impact-absorbing bumper on a motor vehicle.

(15) FIG. 8 is a diagram illustrating an embodiment of a multilayered shell structure, similar to those of FIGS. 4A through 7, configured for use as an energy-absorbing dashboard in a vehicle.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

(16) FIG. 1A illustrates a compressible member 50 embodied in accordance with the present invention. The member 50 has a top surface 120, a bottom surface 124, and a sidewall 128 that together define a hollow inner chamber 132. The bottom surface 124 has a small orifice 136 formed therein. When the member 50 compresses in the general direction indicated by arrow 140, airflow 144, for example, exits the small orifice 136. The member 50 is formed of TPE material which, as discussed in more detail below, because of its unique properties, optimizes the impact-absorbing properties of the compressible member 50.

(17) Thermoplastic elastomers or TPEs are polymer blends or compounds, which exhibit thermoplastic characteristics that enable shaping into a fabricated article when heated above their melting temperature, and which possess elastomeric properties when cooled to their designed temperature range. Accordingly, TPEs combine the beneficial properties of plastic and rubber, that is, TPEs are moldable and shapeable into a desired shape when heated and are compressible and stretchable when cooled. In contrast, neither thermoplastics nor conventional rubber alone exhibits this combination of properties.

(18) To achieve satisfactory purposes, conventional rubbers must be chemically crosslinked, a process often referred to as vulcanization. This process is slow, irreversible, and results in the individual polymer chain being linked together by covalent bonds that remain effective at normal processing temperatures. As a result, vulcanized rubbers do not become fluid when heated to these normal processing temperatures (i.e., the rubber cannot be melted). When heated well above normal processing temperatures, vulcanized rubbers eventually decompose, resulting in the loss of substantially all useful properties. Thus, conventional vulcanized rubbers cannot be formed into useful objects by processes that involve the shaping of a molten material. Such processes include injection molding, blow molding and extrusion, and are extensively used to produce useful articles from thermoplastics.

(19) Thermoplastics are generally not elastic when cooled and conventional rubbers are not moldable using manufacturing processes and equipment currently used for working with thermoplastics, such as injection molding and extrusion. These processes, however, are applicable for working with TPEs.

(20) Most TPEs have a common feature: they are phase-separated systems. At least one phase is hard and solid at room temperature and another phase is elastomeric and fluid. Often the phases are chemically bonded by block or graft polymerization. In other cases, a fine dispersion of the phases is apparently sufficient. The hard phase gives the TPEs their strength. Without the hard phase, the elastomer phase would be free to flow under stress, and the polymers would be unusable. When the hard phase is melted, or dissolved in a solvent, flow can occur and therefore the TPE can be processed. On cooling, or upon evaporation of the solvent, the hard phase solidifies and the TPEs regain their strength. Thus, in one sense, the hard phase of a TPE behaves similarly to the chemical crosslinks in conventional vulcanized rubbers, and the process by which the hard phase does so is often called physical crosslinking. At the same time, the elastomer phase gives elasticity and flexibility to the TPE.

(21) Examples of TPEs include block copolymers containing elastomeric blocks chemically linked to hard thermoplastic blocks, and blends of these block copolymers with other materials. Suitable hard thermoplastic blocks include polystyrene blocks, polyurethane blocks, and polyester blocks. Other examples of TPEs include blends of a hard thermoplastic with a vulcanized elastomer, in which the vulcanized elastomer is present as a dispersion of small particles. These latter blends are known as thermoplastic vulcanizates or dynamic vulcanizates.

(22) TPEs can also be manufactured with a variety of hardness values, e.g., a soft gel or a hard 90 Shore A or greater. One characteristic of the TPE material is its ability to return to its original shape after the force against it removed (i.e., TPE material is said to have memory). Other characteristics of TPE include its resistance to tear, its receptiveness to coloring, and its rebound resilience elasticity. Rebound resilience elasticity is the ratio of regained energy in relation to the applied energy, and is expressed as a percentage ranging from 0% to 100%. A perfect energy absorber has a percentage of 0%; a perfectly elastic material has a percentage of 100%. In general, a material with low rebound resilience elasticity absorbs most of the applied energy from an impacting object and retransmits little or none of that energy. To illustrate, a steel ball that falls upon material with low rebound resilience elasticity experiences little or no bounce; the material absorbs the energy of the falling ball. In contrast, the ball bounces substantially if it falls upon material with high rebound resilience elasticity. This characteristic can influence the behavior of the compressible member.

(23) Another advantage of these TPEs is that their favorable characteristics may exist over a wide range of temperatures. Preferably, the TPE material of the compressible member 50 has a glass-transition temperature of less than 20 degrees Fahrenheit. The glass-transition temperature is the temperature below which the material loses its soft and rubbery qualities. A TPE material with an appropriate glass-transition temperature can be selected for the compressible member 50 depending on the particular application of the member (e.g., a glass-transition temperature of 0 degrees Fahrenheit may be sufficient for baseball helmets, whereas a glass transition temperature of 40 degrees Fahrenheit may be needed for football and hockey helmets).

(24) The size of the opening 136 in the compressible member 50 is preferably selected to produce a rate-sensitive response to any impact causing compression of the member 50. For instance, if the application of force upon the member 50 is gradual or of relatively low energy, the opening 136 permits sufficient air to pass through so that the member 50 compresses gradually and presents little resistance against the force. In that case, an individual may be able to compress the member 50 manually with a moderate touch of a hand or finger.

(25) If, as illustrated by FIGS. 1B and 1I-1K, the application of force upon the member 50 occurs instantaneously or is of relatively high energy, laminar or turbulent air flows within the inner chamber 132. The size of the opening 136, which is small relative to the volume of air moved by the force, restricts the emission of the turbulent or laminar air from the chamber 132 and thus causes resistance within the chamber 132. Eventually the resistance is overcome and air flows out, and during this process, a portion of the impact energy is also converted to heat. This variable response, dependent upon the energy input, is termed a rate-sensitive or a non-linear response.

(26) A further important advantage of the compressible member 50 is that it can be compressed ninety percent (90%) or more from its uncompressed thickness before bottoming out, i.e., before the top wall of TPE material comes in contact with the bottom wall of TPE material. This increased ride-down factor compared to conventional foams, which have ride-down factors of only about 70%, increases the distance over which impacts are effectively absorbed and, as a result, decreases the force transferred through the compressible member 50 proportionately to this increased distance. Even when the compressible member 50 bottoms out, a thickness of TPE material (equal to twice the wall thickness) remains, which, because of its compressibility, provides further energy absorption.

(27) Additionally, the geometry of the compressible member 50, the stiffness and elasticity of the TPE material used for its enclosure, and the venting of the member 50 can all be adjusted and optimized to provide a softer landing than conventional foams across a broad range of impact energy levels. Force/time curves for foams are bell-shaped due to the increased stiffness of foams as they are compressed which results in increasing forces with severe peaks. The shape of the force/time curve for foams is similar regardless of the amount of ride-down, which is dependent on the energy of the impact. For low energy impacts, the ride-down distance of foams is low and can result in concussions, even at relatively low impact energies, especially with EPS foams.

(28) The compressible member 50 of the invention, on the other hand, can be engineered to allow optimal ride down for a wide range of impact energies and also to shape the rate at which the forces increase during the impact. This shaping of the force/time curve is accomplished by managing the air pressure in the inner chamber of the member 50 for various impact energies, something foams cannot do. The result is a flatter and broader force/time curve for the compressible member 50 which reduces the force of impact. This broader, flatter curve in essence demonstrates a soft landing.

(29) This technology allows for the manipulation of multiple engineering parameters, such as material properties, chamber geometry, chamber wall thickness, and relative configurations of outflow(s) and inflow(s). Careful calibration of the many design parameters will allow those skilled in the art to determine the optimum combination based on the particular application to which the member 50 is to be put.

(30) In addition to providing this rate-sensitive response, the compressible member 50 can also stretch and bend during tangential impact, as illustrated by FIG. 1C and FIG. 1D. This allows the compressible member 50 to shear in response to the tangential impacts and absorb rotational forces as well as direct forces applied normal to the top surface 120 of the member 50.

(31) FIG. 1E shows the compressible member 50 following an impact. Because of its resilient nature, the tendency of the member 50 is to return to its uncompressed shape. Accordingly, after the impact force is removed from the compressible member 50, it expands in the direction indicated by arrow 146, consequently drawing air in through the opening 136 as indicated by arrows 148. FIGS. 1F-1H illustrate a simulated sequence of expansion of a rate-sensitive compressible member 50, as the impact force is removed.

(32) FIG. 2 shows a cross-section of another embodiment of a rate-sensitive compressible member 150 that is generally rectangular in shape (i.e., a strip). The member 150 has a top surface 160, a bottom surface 164, sidewalls 168-1, 168-2 (generally, 168), and a hollow inner chamber 172. Each sidewall 168 has a respective small opening 176-1, 176-2 (generally, 176) formed therein. (Practice of the invention can be achieved with only one of the sidewalls 168 having an opening). When the member 150 compresses generally in the direction indicated by arrow 180, airflows 184 exit the small openings 176. This embodiment illustrates that a variety of shapes, for example, disc-shaped, cylindrical, and pyramidal, and the like, can be used to implement rate-sensitive compressible members of the invention capable of absorbing impact energy.

(33) FIGS. 3A-3D diagrammatically illustrate another version of a compressible member 250 embodied in accordance with the invention. The compressible member 250 differs from the prior two embodiments in that it includes separate orifices for the inflow and outflow, respectively, of air relative to its inner chamber. More specifically, the compressible member 250 includes a plurality of outflow orifices, in the form of thin slits 254 in the wall of its enclosure 252, spaced about the circumference of the enclosure 252. The compressible member 250 also includes an inflow orifice, which includes a one-way flap valve 256, located at the bottom of the enclosure 252.

(34) As the sequence of FIGS. 3A-3D illustrates, moving from left to right in the figure, upon impact, the one way flap valve 256 is forced closed and air is forced out of the inner chamber of the compressible member 250 through the thin slits 254. Upon removal of the force, the one-way flap valve 256 opens and air returns quickly to the inner chamber of the compressible member 250 through the opening of the valve.

(35) To further enhance the rate-sensitive response of the compressible member 250 of this embodiment, the outflow slits 254 are elastic, being formed directly in the TPE material of the wall of the enclosure 252. Because of this elasticity, the slits 254 provide some resistance to opening and to the escape of the air in the inner chamber during the impact, and close resiliently and quickly following the impact. The slits 254 are also preferably significantly smaller in diameter that the inflow opening of the one-way flap valve 256. As a result, the member 250 provides a greater degree of resistance to compression and collapse depending upon the energy level of the impact force, yet will return quickly to its uncompressed condition upon removal of the force, ready to absorb additional impacts.

(36) FIG. 4A is a partial cross-sectional view of an embodiment of a multilayer shell structure 230 which includes a plurality of the rate-sensitive compressible members 50 (FIG. 1A) disposed therein, configured as a protective helmet 200. In this particular embodiment shown, the compressible members 50 are spaced from one another and sandwiched between an outer layer 220 and an inner layer 228. An internal foam liner 232 of conventional design may be disposed between the inner layer 228 and the wearer's head.

(37) In the shell structure 230 of FIG. 4A, the orifice 136 of each rate-sensitive compressible member 50 preferably aligns with an opening (not shown) in the surface of the inner layer 228 and through any internal liner 232 so that expelled or inhaled air can pass into the interior of the shell structure 230. Similarly, such openings 136 can be on the sides of the compressible members 50, allowing the release and return of air through the interstitial region of the shell structure 230 between the outer and inner layers 220 and 228.

(38) Those desiring further details of the construction of a shell structure such as shell structure 230, and its configuration as a protective helmet, are referred to my copending U.S. patent application Ser. No. 11/059,427, filed Feb. 16, 2005, and my related application filed concurrently herewith, titled EnergyAbsorbing Inner Liners For Use With Protective Headgear, which, as noted above, are incorporated by reference herein.

(39) Those skilled in the art will appreciate that other embodiments of the compressible member, such as the members 150 and 250 shown above, can be substituted for the compressible members 50 in the shell structure 230 of FIG. 4A, and that two or more types or sizes of compressible members can be combined therein. Those skilled in the art will also appreciate that modifications can be made to the shell structure 230 without departing from the scope of the invention. For example, the compressible members 50 may be secured to a single layer, either on their inside or outside, instead of being sandwiched between two layers as shown in FIG. 4A. Additionally, the compressible members 50, instead of being separate from one another, could be interconnected by a thin web of TPE material to form a sheet-like middle layer. The connecting web material could also include internal passageways that communicate with the inner chambers of adjacent ones of the compressible members 50, so that, during an impact, air passes from one chamber or member 50 to another, in addition to venting from the chambers, spreading the impact force among several members 50.

(40) FIG. 4B illustrates an exemplary simulated operation of the shell structure 230, with rate-sensitive compressible members 50, undergoing a direct impact from an object 236. In this example, the shell structure 230 operates to reduce linear-acceleration of the wearer's head 234. When the object 236 strikes the outer layer, the members 50 directly beneath the outer layer 220 at the point of impact compress. The compression of the shell structure 230 also causes air to exit the members 50 (arrows 238) and enter the interior of the shell structure 230 through the openings in the members 50 and in the inner layer 228.

(41) FIG. 4C illustrates an exemplary simulated operation of the shell structure 230, with rate-sensitive compressible members 50, undergoing a tangential impact from an object 236. In this example, the shell structure 230 operates to reduce rotational acceleration of the wearer's head 234. When struck by an object tangentially, the outer layer 220 shears with respect to the inner layer 228 in a direction of motion of the object, as illustrated by arrows 240. Members 50 at the point of impact compress to some extent and shear with the outer layer 220. As with the example of FIG. 4B, the compression causes air to exit the members 50 and to enter the interior of the headgear. The combined effects of the shearing motion of the outer layer 220 and members 50, the rate-sensitive and energy-absorbing compression of the members 50, and the release of air into the interior of the headgear operate to reduce the rotational forces reaching the wearer's head 234.

(42) The layered construction of the invention can be likewise used to construct a variety of types of protective headgear including, but not limited to, safety helmets, motorcycle helmets, bicycle helmets, ski helmets, lacrosse helmets, hockey helmets, and football helmets, batting helmets for baseball and softball, headgear for rock and mountain climbers, and headgear for boxers. Other applications can include helmets used on construction sites, in defense and military applications, and for underground activities.

(43) Although the foregoing description focuses primarily on protective headgear, it is to be understood that the compressible members of the invention can be used in other types of equipment used for sports activities or other applications.

(44) By way of example, FIG. 5 illustrates the shell structure 230 configured as a shin pad which may be removably fastened by any suitable means e.g., elastic straps, to the lower leg of a wearer. Those skilled in the art will appreciate that the shell structure 230 may be similarly configured as a face mask, elbow pad, shoulder pads, chest protector or the like, or as a protective body pad for other sports/activities such as extreme and other outdoor sports, motorcross, car racing, and the like.

(45) FIGS. 6A and 6B illustrate a shell structure 230, similar to, but fabricated in larger scale and dimension than, the shell structure 230 previously described, as an impact absorbing covering for application to the boards of a hockey rink. A similar shell structure 230 could be used as an impact-absorbing covering for basketball gymnasium walls, racket ball walls, indoor soccer or football arenas, and other structures which enclose an athletic event.

(46) FIGS. 7 and 8 illustrate still another version of a shell structure 230, similar to but larger than the shell structure 230 previously described, configured as part of a vehicle bumper and dashboard, respectively. Other similar applications of the shell structure 230 include vehicle decking, highway barriers and the like.

(47) While the invention has been shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the following claims.