MICROLATTICE BALLISTIC HELMET PADS
20230061962 · 2023-03-02
Assignee
Inventors
Cpc classification
International classification
Abstract
A helmet pad includes a substrate having first side attachable to an interior surface of a helmet. The helmet pad includes an outer lattice layer peripherally attached to a second side of the substrate. The second side is opposite to the first side. In one embodiment, the outer lattice layer includes fibers attached in one of: (i) a Voronoi lattice unit cells; and (ii) tetrahedral lattice unit cells. The helmet pad includes padding material received in an enclosure between the second surface of the substrate and the outer lattice layer.
Claims
1. A helmet pad comprising: a substrate having a first side attachable to an interior surface of a helmet; an outer lattice layer peripherally attached to a second side of the substrate, the second side opposite to the first side, the outer lattice layer comprising fibers attached in one of: (i) a Voronoi lattice unit cells; and (ii) tetrahedral lattice unit cells; and padding material received in an enclosure between the second surface of the substrate and the outer lattice layer.
2. The helmet pad of claim 1, wherein the padding material comprises one or more internal lattice layers peripherally attached to the second side of the substrate, the one or more internal lattice layers each comprising fibers attached in one of: (i) a Voronoi lattice unit cells; and (ii) tetrahedral lattice unit cells.
3. A helmet comprising: a helmet shell; and one or more helmet pads, each pad comprising: a substrate having a first side attachable to an interior surface of a helmet, an outer lattice layer peripherally attached to a second side of the substrate, the second side opposite to the first side, the outer lattice layer comprising fibers attached in one of: (i) a Voronoi lattice unit cells; and (ii) tetrahedral lattice unit cells; and padding material received in an enclosure between the second surface of the substrate and the outer lattice layer.
4. The helmet of claim 3, wherein the padding material comprises one or more internal lattice layers peripherally attached to the second side of the substrate, the one or more internal lattice layers each comprising fibers attached in one of: (i) a Voronoi lattice unit cells; and (ii) tetrahedral lattice unit cells.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The various exemplary embodiments of the present invention, which will become more apparent as the description proceeds, are described in the following detailed description in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION
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[0048] In one or more embodiments, the fibers are additively manufactured using EPU 41 elastomeric material from Carbon®, Carbon, Inc., based in Redwoods, CA. In one or more embodiments, the lattice layers are sufficiently small in size to be referred to as “microlattices”. In one or more embodiments, the microlattices are formed using an approach by Carbon® referred to as Carbon Digital Light Synthesis™ (Carbon DLS™), which combines a range of technologies—including digital light projection and specialized resins-to make microscale manufacturing more precise, consistent, and cost-effective. At the heart of Carbon DLS is a process called continuous liquid interface production (CLIP). CLIP reduces the expense of 3D printing significantly, making it possible for more companies to create their own microlattice-based materials. 3D-printed materials typically begin as resins that are hardened using ultraviolet (UV) light. With CLIP, an image made of UV light is projected through a window onto the resin. That causes cross-section of the part to (partially) cure. The printed section moves out of the way and the process is repeated, producing a material with consistent strength and design. The component is then baked in a thermal bath or oven to toughen and cure. Before light hits the resin, each projected image first passes through a “dead zone” that is thinner than a human hair and that is a resin-oxygen mixture that prevents UV curing. In essence, the resin-oxygen mixture serves as a membrane that keeps the printed part from sticking to the machine. The dead zone creates just the barrier needed to skip slow, potentially damaging peeling processes.
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[0057] In one or more embodiments, the microlattice layers may be manufactured from additive manufacturing methods (AM). Such AM methods include VAT photopolymerization, material jetting, binder jetting, material extrusion or fuse deposition modelling (FDM), power bed fusion (e.g., direct metal laser sintering (DMLS), electron beam melting (EBM), selective heat sintering (SHS), selective laser melting (SLM), selective laser melting (SLS), sheet lamination, and/or directed energy disposition (DED), multi-jet fusion, digital light synthesis, and/or any combination thereof.
[0058] VAT polymerization method uses a vat of liquid photopolymer resin, out of which the microlattice structure can be constructed layer by layer. An ultraviolet (UV) light is used to cure or harden the resin where required, while a platform moves the microlattice structure being made downwards after each new layer is cured.
[0059] Material jetting approach can create a microlattice layer similar to using a two-dimensional ink jet printer. Material is jetted onto a build platform using either a continuous or Drop on Demand (DOD) approach. Material is jetted onto the build surface or platform, where it solidifies and the microlattice is built layer by layer. Material is deposited from a nozzle which moves horizontally across the build platform. The material layers are then cured or hardened using ultraviolet (UV) light.
[0060] The binder jetting approach uses two materials; a powder-based material and a binder. The binder acts as an adhesive between powder layers. The binder is usually in liquid form and the build material in powder form. A print head moves horizontally along the x and y axes of the machine and deposits alternating layers of the build material and the binding material. After each layer, the microlattice being printed is lowered on its build platform.
[0061] Fuse deposition modelling (FDM) is a common material extrusion process and is a technique used in domestic or hobby 3D printers. Material is drawn through a nozzle while under continuous pressure, where it is heated and is then deposited layer by layer into the desired cross-sectional area. The nozzle can move horizontally, and a platform moves up and down vertically after each new layer is deposited. Then the layers are fused together upon deposition as the material is in its melted state.
[0062] Powder bed fusion (PBF) methods use either a laser or electron beam to melt and fuse material powder together. All PBF processes involve the spreading of the powder material over previous layers into desired cross-sections. The powders are sintered, layer by layer. The platform lowers the microlattice to add additional layers, accordingly.
[0063] Directed Energy Deposition (DED) is a complex printing process commonly used to repair or add additional material to existing components. A typical DED machine consists of a nozzle mounted on a multi axis arm, which deposits melted material onto the specified surface and cross-section, where it solidifies. The process is similar in principle to material extrusion, but the nozzle can move in multiple directions and is not fixed to a specific axis. The material, which can be deposited from any angle due to 4 and 5 axis machines, is melted upon deposition with a laser or electron beam. The process can be used with polymers, ceramics but is typically used with metals, in the form of either powder or wire. Both conventional and additive manufacturing methods may be used together to create the desired microlattice layer, microlattice pads, and/or any combination thereof.
[0064] The microlattice structure may be manufactured with standard methods known in the art. In one or more embodiments, the microlattice structure may be fabricated by an additive manufacturing process to print a 3D matrix composite part utilizing a nanofunctionalization process created by HRL Laboratories. As disclosed in U.S. Pat. No. 8,663,539, entitled “Process of Making a Three-Dimensional Micro-Truss Structure,” which is incorporated by reference herein in its entirety, discloses a method that forms micro-trusses by using a fixed light input (collimated UV) light to cure (polymerize) polymer optical waveguides, which can self-propagate in a 3D pattern--the propagated polymer optical waveguides form the micro-truss. Furthermore, the microlattice structure may comprise at least a portion of materials such as a metal, polymer, foam and/or any combination thereof. More specifically, it may be a metal, such as magnesium, aluminum, titanium, chromium, iron, cobalt, nickel, copper, zinc and/or an alloy. The polymeric material may include polycarbone, aramid, high impact polysterene, nylon, ultra-high molecular weight polyethylene, poly (p-xylene), and/or any combination of such materials.
[0065] In one or more embodiments, the MLB helmet pads may be a single, continuous layer, and/or a plurality of modular segments. The MLB helmet pads may comprise uniform and/or non-uniform thicknesses, composition, and impact absorption properties. The MLB helmet pads may comprise an active or passive cooling system for thermal management--allowing evaporation of sweat through the active or passive cooling system. The MLB helmet pads may match or substantially match the contours of the wearer’s head.
[0066] In one or more embodiments, the MLB helmet pads may further comprise a comfort layer and/or comfort liner. The comfort layer and/or comfort liner may be coupled and/or fused to an outer surface and/or inner surface of the MLB helmet pads. Alternatively, the comfort layer and/or comfort liner may be coupled or fused to an inner surface of the tactical helmet. The comfort layer and/or comfort liner may comprise a single, continuous layer, and/or a plurality of modular comfort layer or liner segments. The comfort layer may comprise at least one microlattice layer. The comfort layer may further comprise at least one foam layer and/or at least one polymer layer. The polymer layer and/or the outer shell may comprise polycarbonate (PC), polyethylene (PE), high density polyethylene (HDPE), polypropylene (PP), ethylene vinyl acetate (EVA), ABS, polyurethane (PU) and/or any combination thereof.
[0067] The one or more microlattice layers and/or structures may further comprise a continuous, one-piece microlattice layer. The continuous, one-piece microlattice layer may be shaped and configured to any anatomical feature of the body. The continuous, one-piece microlattice layer may match or substantially match any anatomical feature of the body. In one embodiment, the microlattice layer comprises a continuous, one-piece microlattice layer that may be shaped and configured to a head of a wearer. The continuous, one-piece microlattice layer may match or substantially match the bones of the skull to maximize protection. Such regions comprise parietal, temporal, occipital, ethmoid, sphenoid, temporal, nasal, lacrimal, maxilla, zygomatic, mandible, and/or any combination thereof. The continuous, one-piece microlattice layer may comprise a uniform and/or non-uniform compressive strength and stiffness. The continuous, one-piece microlattice layer may comprise a uniform and/or non-uniform microlattice density. The continuous, one-piece microlattice layer comprises a uniform microlattice compressive strain. Alternatively, the plurality of microlattice segments or each of the plurality of microlattice segments may comprise a different microlattice compressive strain. The continuous, one-piece microlattice layer may be coupled to a surface of a protective garment.
[0068] The one or more microlattice layers and/or structures may further comprise a plurality of microlattice segments (not shown). The plurality of microlattice segments may be shaped and configured to any anatomical feature of the body. The plurality of microlattice segments or each of the plurality of microlattice segments may match or substantially match any anatomical feature of the body and/or at least one anatomical feature of the body. In one embodiment, the microlattice layer comprises a plurality of microlattice segments, the plurality of microlattice segments may be shaped and configured to a head of a wearer. The plurality of segments may match or substantially match the bones of the skull to maximize protection. Such regions comprise parietal, temporal, occipital, ethmoid, sphenoid, temporal, nasal, lacrimal, maxilla, zygomatic, mandible, and/or any combination thereof. The plurality of microlattice segments or each of the plurality of microlattice segments may comprise the same microlattice layer compressive strength and stiffness. Alternatively, plurality of microlattice segments or each of the plurality of microlattice segments may comprise a different compressive strength and stiffness. The plurality of microlattice segments or each of the plurality of microlattice segments may comprise the same microlattice density. Alternatively, the plurality of microlattice segments or each of the plurality of microlattice segments may comprise a different microlattice density. The plurality of microlattice segments or each of the plurality of microlattice segments comprises the same microlattice compressive strain. Alternatively, the plurality of microlattice segments or each of the plurality of microlattice segments may comprise a different microlattice compressive strain. The plurality of microlattice segments may be coupled to a surface of a protective garment.
[0069] In another embodiment, the microlattice layer may comprise microlattice pads or microlattice pad assemblies (not shown). The microlattice pad assemblies may comprise at least one microlattice layer and/or structure and at least one base layer. Alternatively, the microlattice pads may comprise a first base layer, a second base layer and a microlattice layer and/or structure. The microlattice pads or pad assemblies may further comprise one or more foam layers. Alternatively, the microlattice pads may comprise a microlattice layer and/or structure and one or more foam layers, the one or more foam layers coupled to a surface of the microlattice layer. The microlattice pads may further comprise one or more material layers. The one or more foam layers may be coupled to the microlattice layer and/or structure, and/or the one or more foam layers positioned between the first base layer and the second base layer. Accordingly, the one or more foam layers may be coupled to a surface of the at least one base layer, the first base layer, or the second base layer. In one embodiment, the microlattice layer and/or structure, one or more impact mitigation layers and/or one or more foam layers is disposed between the first base layer and the second base layer. The first base layer may be coupled to the second base layer to fully enclose the microlattice layer and/or structure, the microlattice layer and/or structure, one or more impact mitigation layers and/or one or more foam layers. The first base layer and the second base layer may comprise the same materials or different materials. The coupling may comprise adhesive, Velcro, melting, welding, thermoforming, and/or any combination thereof.
[0070] The one or more base layers may comprise any suitable material that is compatible with the filaments. For instance, one or more layers may comprise polymer materials (e.g., thermosets or thermoplastics), metal (e.g., aluminum or stainless steel), composites (e.g., carbon fiber, glass fiber reinforced polymer, fiberglass, or ceramic fibers), organic materials (e.g., wood, paper, or cardboard), ceramic cloth, natural cloth, polymeric cloth, metallic cloth, rubber, plastic, or any combination thereof.
[0071] As used herein, “filaments” may be used interchangeably to mean a plurality of filaments, an additional plurality of filaments, the adjacent filaments, and/or the plurality of interconnected filaments. In one embodiment, the filament unit height (H), filament unit cell height (H), filaments dimensions within the microlattice layer and/or structure may be varied. The filament unit height (H), filament unit cell height (H), filaments dimensions within the microlattice layer and/or structure may be the same throughout the microlattice layer for uniformity. Alternatively, the filament unit height (H), filament unit cell height (H), filaments dimensions within the microlattice layer and/or structure may be different in at least a portion of the microlattice layer and/or structure.
[0072] The filaments have a longitudinal axis, a width and/or diameter (W/D) and a length (L). In one or more embodiments, the width and/or diameter of the filaments comprises a range between 0.1 mm to 5 mm. The filaments length may be 0.3 mm to 25 mm, and/or 25 mm or greater. The filaments may further comprise an aspect ratio, the aspect ratio may be 3:1 or greater. The length of the filaments may be uniform and/or non-uniform along its longitudinal axis. In another embodiment, the filaments comprise a cross-section within the microlattice layer and/or structure and the cross-section may be varied. The filaments may comprise a cross-section, the cross-section being solid or hollow. The solid or hollow cross-section may be uniform or substantially uniform along the longitudinal axis. Alternatively, the solid or hollow cross-section may be non-uniform or substantially non-uniform along the longitudinal axis. The cross-section comprises a circle, an oval, a regular polygon and/or an irregular polygon. The polygons comprise a triangle, a square, a rectangle, a pentagon, a hexagon, a septagon, an octagon, a nonagon, a decagon, and/or any combination thereof. The filaments having a uniform and/or a non-uniform cross-section along the longitudinal axis. The non-uniform cross-section comprises a frustum or tapered cross-section, and/or undulated cross-section. In one or more embodiments, the cross-section may further comprise a cross-sectional area, the cross-sectional area is 0.01 mm.sup.2 or greater, 1 mm.sup.2 or greater, 10 mm.sup.2 or greater, 20 mm.sup.2 or greater. Accordingly, the cross-sectional area is between 0.01 to 1 mm.sup.2, or between 1 to 10 mm.sup.2, or between 10 to 20 mm.sup.2 or between 0.01 to 20 mm.sup.2.
[0073] The at least one base layer, the first base layer and/or the second base layer may comprise a foam material, Velcro material, a 2-way stretch, a 4-way stretch, a polymer, and/or any combination thereof. The foam layer may comprise a foam material, the foam material comprising polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, compression foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN 600 foam, Evlon foam, Ariaprene or Ariaprene-like material, PORON XRD, impact hardening foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof. The foam material may be uniform throughout the microlattice layer, and/or non-uniform throughout the microlattice layer. The one or more foam layers may comprise a single, continuous piece, and/or a plurality of foam segments. The polymer may comprise polycarbonate (PC), polyethylene (PE), high density polyethylene (HDPE), polypropylene (PP), ethylene vinyl acetate (EVA), ABS, polyurethane (PU) and/or any combination thereof.
[0074] In some embodiments, the Young’s modulus of the material used to fabricate the filaments 900 can be at least 1 MPa, at least 10 MPa, at least 100 MPa, at least 1000 MPa, and/or at least 10,000 MPa. In other embodiments, the Young’s modulus comprises between 1 MPa and 100 MPa, between about 1 MPa and 1000 MPa, between 1 MPa and 10,000 MPa, between 10 MPa and 1000 MPa, between 10 MPa and 10,000 MPa, and/or any combination thereof. Also, the Young’s modulus can be between 100 MPa to 1000 MPa and 1000 MPa to 10,000 MPa. In some instances, the ratio of the Young’s modulus of the material used to fabricate the filaments 900 can be at least about 0.001:1, at least about 0.01:1, at least about 0.1:1, at least about 1 :1, at least about 10:1, at least about 100 :1, at least about 1000 :1 and/or less than about 10,000.00:1, less than about 1000 :1, less than about 100 :1, less than about 10:1, less than about 1:1, less than about 0.1:1, or less than about 0.01:1.
[0075] It must be noted that, as used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “colorant agent” includes two or more such agents.
[0076] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.
[0077] As will be appreciated by one having ordinary skill in the art, the methods and compositions of the invention substantially reduce or eliminate the disadvantages and drawbacks associated with prior art methods and compositions.
[0078] It should be noted that, when employed in the present disclosure, the terms “comprises,” “comprising,” and other derivatives from the root term “comprise” are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.
[0079] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0080] While it is apparent that the illustrative embodiments of the invention herein disclosed fulfill the objectives stated above, it will be appreciated that numerous modifications and other embodiments may be devised by one of ordinary skill in the art. Accordingly, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which come within the spirit and scope of the present invention.