A Triple Layered Compressible Liner for Impact Protection

Abstract

A compressible liner for a helmet or other apparatus subject to shock loading comprises three substantially co-extensive layers mutually engaged by respective cone-like protuberances and cone-like recesses. The intermediate layer is of a different compressibility and provides for de-coupling of the layers in an oblique impact.

Claims

1. A compressible liner for impact protection, said liner comprising three substantially co-extensive layers mutually engaged by respective arrays of cone-like protuberances and corresponding cone-like recesses, the outer surface of the liner being substantially smooth and at least a portion of the intermediate layer having a different compressibility to that of an adjacent layer.

2. A liner according to claim 1 wherein the intermediate layer has a different compressibility to the inner and the outer layers.

3. A liner according to claim 2 wherein the intermediate layers is of uniform compressibility.

4. A liner according to claim 3 wherein one or more of said layers is unitary.

5. A liner according to claim 4 wherein one or more of said layers is a one-piece moulding.

6. A liner according to claim 5 wherein one or more of said layers comprises an assembly having keys to prevent transverse movement of elements thereof.

7. A liner according to claim 6 wherein said keys prevent transverse separation of elements thereof.

8. A liner according to claim 7 wherein said keys comprises integral orthogonally engageable male and female members.

9. A liner according to claim 8 wherein said protuberances are all outward facing.

10. A liner according to claim 8 wherein said protuberances are all inward facing.

11. A liner according to claim 8 wherein a plurality of smaller protuberances of one layer engage within respective larger protuberances of an adjacent layer.

12. A liner according to claim 8 wherein a protuberance of one layer protrudes to the surface of an adjacent layer.

13. A liner according to claim 12 wherein the protuberances of said one layer are truncated.

14. A liner according to claim 8 wherein protuberances of one layer are of greater height than those of an adjacent layer.

15. A liner according to claim 8 wherein the protuberances of one layer are all of equal size.

16. A liner according to claim 15 wherein the protuberances of two layers are of respective equal size.

17. A liner according to claim 8 wherein the respective compressibilities of the outer, middle and inner layers are selected from one of: inner>intermediate>outer intermediate>inner>outer inner>outer>intermediate outer>inner>intermediate outer>intermediate>inner intermediate>outer>inner intermediate>(inner=outer) (inner=outer)>intermediate.

18. A liner according to claim 8 wherein the respective layers have densities in the ranges: outer: 35-110 kgm.sup.−3 intermediate: 15-100 kgm.sup.−3 inner: 15-90 kgm.sup.−3.

19. A liner according to claim 8 wherein the layers are selected from foam expanded polystyrene and viscoelastic foam.

20. A liner according to claim 19 wherein the intermediate layer has isotropic or anisotropic properties.

21. A helmet incorporating a liner according to any of claims 1-20.

22. An Apparatus for impact protection and comprising a liner of any of claims 1-20 incorporated within one of a motor vehicle, a body capsule, an item of clothing and a protective shell for an item in transit.

23. A method of impact protection comprising providing within a protective shell a liner according to any of claims 1-20.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0024] Other features of the invention will be apparent from the following description of a preferred embodiment illustrated by way of example only in the accompanying drawings in which:

[0025] FIG. 1 illustrates a transverse vertical section through a prior art helmet having a compressible liner.

[0026] FIG. 2 corresponds to FIG. 1 and shows an orthogonal section on line 2-2 of FIG. 1.

[0027] FIG. 3 illustrates in part the inner liner of FIGS. 1 and 2, showing a regular array of outwardly directed conical protuberances.

[0028] FIG. 4 illustrates a straight section of a compressible liner according to a first embodiment of the invention.

[0029] FIG. 5 corresponds to FIG. 4 and illustrates a second embodiment of the invention.

[0030] FIGS. 6 and 7 show alternative conical forms for use in the invention.

[0031] FIG. 8 shows a dual version of the compressible liner of the invention.

[0032] FIGS. 9-15 illustrate the variety of configurations which are possible with the interlocking structure of the present invention, by reference to a curved liner (for example for a helmet).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0033] FIGS. 1-3 illustrate the helmet of WO 2010/001230A.

[0034] A helmet 112 comprises an outer shell 116, typically of a hard plastics material, within which is provided a double compressible layer 124, 128 and an optional soft internal comfort liner 120.

[0035] As best illustrated in FIG. 3, the inner compressible layer 124 comprises an array of integral conical protuberances 130 which fit closely within corresponding conical recesses 132 of the outer compressible layer 128. The materials of the layers 124, 128 are of different compressibility, which gives an advantageous compression characteristic as compared with a conventional unitary liner of single compressibility.

[0036] Particular details of the prior art construction can be obtained by reference to the description of WO 2010/001230A, and will not be further described here.

[0037] The invention will be described with reference to a helmet of the kind illustrated in FIGS. 1-3, it being understood that the compressible liner of the invention may be used in apparatus other than helmets, as previously mentioned.

[0038] FIG. 4 illustrates a first embodiment of the invention. A compressible liner 1110 comprises an inner layer 1124, an outer layer 1128 and an intermediate layer 1160. The inner layer 1124 has many protuberances 1130 which project into matching recesses 1161 of the intermediate layer 1160, and the intermediate layer has many protuberances 1162 which project into matching recesses 1132 of the outer layer 1128. The protuberances 1130, 1162 and corresponding recesses 1161, 1132 are integrally formed from a respective base region 1134, 1163 of relatively uniform thickness, and may have variability in size, shape and spacing, though, as illustrated in this embodiment, the protuberances of the inner and intermediate layers are uniform. In this example the outer layer has a continuous surface layer 1122 of relatively uniform thickness. The inner layer also includes inwardly facing projections or ribs 1164 to engage a comfort liner, but the inner surface may also be smooth.

[0039] Each of the three layers 1124, 1128, 1160 typically comprises a shock absorbing expanded polystyrene material (or other suitable thick absorbing material as previously described). The layers may be respectively homogeneous. Adjacent layers are of different compressibility so as to permit greater variation in the compression and crushing gradients across the thickness of the liner 1110. As will be appreciated the invention permits three different densities of material in three different layers (i.e. a factorial three possibility) which provides many more potential combinations than the prior art, but maintaining a comparatively low manufacturing cost.

[0040] An alternative embodiment is illustrated in FIG. 5, to show a degree of variation which is possible with the invention. In FIG. 5, the inner and outer layers 1224, 1228 have the same compressibility, whereas the intermediate layer 1260 is different. Furthermore the underside of the inner layer 1224 is planar, and at the outer side, the peaks of the protuberances 1262 of the intermediate layer 1260 are permitted to appear through the outer layer 1228, thus permitting a substantial sharing of an orthogonal impact load.

[0041] In both embodiments of FIGS. 4 and 5, it will be understood that a straight liner is shown for ease of illustration, but that in practice a three-dimensional form may be required as in the case of the helmet liner illustrated in FIGS. 1-3.

[0042] FIGS. 6 and 7 illustrate two examples of different shapes of protuberance 1301, 1401 which allow the material of the protuberance to have a changing effect as the degree of compression increases. It will be understood that a corresponding recess is provided in the adjacent layer.

[0043] In FIG. 6, a broad protuberance 1301 has a first portion 1302 comprising a regular conical tip 1303 with an included angle in the range 80-120°. A second portion 1304 comprises a regular circular supporting pillar 1305 which constitutes the main body of the protuberance, and has a slight outward taper in the range 5-15° towards the base. The first portion 1302 has an axial height which is about 25% of the total height of the protuberance. In this embodiment the base region 1306 is of substantially constant thickness across the layer.

[0044] The protuberance 1301 exhibits a resistance to compression which increases quickly over the tapering point 1303. The main body 1305 of the protuberance is of substantially constant section, and exhibits substantially increased stiffness. The shaft taper of the main body ensures a snug fit in the corresponding recess.

[0045] In FIG. 7, a slim protuberance 1401 also has a first portion 1402 comprising a regular conical tip 1403 with an included angle in the range 30-60°. A second portion 1404 comprises a tapering shallow frustoconical base 1405 having an included angle in the range 120-160°. The first portion 1402 has a height which is in the range 75-125% of that of the second portion 1404. As illustrated the height of the first portion 1402 is greater than that of the second portion 1404. In this embodiment the base region 1406, as before is a substantially constant thickness across the layer.

[0046] The protuberance 1401 exhibits a resistance to compression at the tapering point 1403 which is slight. The main body 1403 of the protuberance permits only further compression before the entire base thickness 1404 is engaged to resist compression. It will be appreciated that the protuberance 1401 squashes down more readily than the protuberance 1301.

[0047] FIG. 8 illustrates a double compressible liner, of the kind shown in FIG. 4, incorporating the triple layered construction of the present invention whereby a common inner layer 1524 is surmounted by respective intermediate layers 1560 and outer layers 1528 on either side. In the embodiment of FIG. 8 it will be understood that the inner layer 1524 may be constituted by a single component such as a one-piece moulding, or may comprise two inner layers of single compressible liners placed back to back and secured together, if required, by any suitable means. This embodiment may also be characterised on a common outer layer (placed innermost) surmounted by respective intermediate and inner layers.

[0048] FIGS. 9-15 illustrate the variety of configurations which are possible with the interlocking structure of the present invention, by reference to a curved liner (for example for a helmet).

[0049] FIG. 9 illustrates three layers with relatively small inner cones 1601 aligned with somewhat larger outer cones 1602, the outer cones being somewhat inward of a smooth outer surface 1603, and the inner surface 1604 being also smooth.

[0050] FIG. 10 corresponds to FIG. 9, but in this case the outer cones 1602 just reach the outer surface 1603.

[0051] FIG. 11 corresponds to FIGS. 9 and 10, but in this case the outer cones 1602 appear in truncated form on the outer surface 1603.

[0052] FIG. 12 illustrates a reversed cone arrangement, corresponding to FIG. 10, with the inner and outer cones 1605, 1606 facing inwardly. A reversed arrangement corresponding to FIGS. 9 and 11 is also possible.

[0053] FIG. 13 corresponds to FIG. 9, and illustrates a somewhat narrower intermediate layer 1607 having outer cones 1608 of reduced wall thickness; the inner cones 1609 are of somewhat greater height than those illustrated in FIG. 9.

[0054] FIG. 14 illustrates one element 1701 of an inner or intermediate layer, having cones 1702 in a regular pattern. The edges 1703 of the element 1701 have a male or female locking form or key 1704, 1705 whereby adjacent elements can be retained together against transverse forces, in the manner of a jigsaw puzzle. It will be appreciated that the arrangement of FIG. 14 permits adjacent elements to be of different material, different size and/or different compressibility. The element of FIG. 14 is rectangular, but this aspect of the invention is not limited to edge shape—curved and non-regular shapes are possible, and may be necessary for a helmet liner. The outer layer (not shown) is one piece.

[0055] FIG. 15 illustrates how adjacent elements 1801, 1802 of an intermediate layer have a junction 1803 which does not correspond with junctions 1804, 1805 between adjacent elements 1806, 1807, 1808 of an inner layer. Such an arrangement provides a more stable and strong construction. The outer layer 1809 is one piece.

[0056] In the variations disclosed in FIGS. 9-13, the cones have substantially the same apex angle, it will however be understood that the inner and outer cones may have a different apex angle, and/or be different between adjacent keyed elements.

[0057] The invention comprises layers whose comparative densities (or portions thereof) may be characterized as follows (‘a’ being the outer layer; ‘b’ being the intermediate layer, and ‘c’ being the inner layer):

a>b>c, or a>c>b, or b>a>c, or b>c>a, or c>b>a, or c>a>b, or (a=c)>b, or (a=c)<b.

[0058] It follows that the respective compressibilities are:

c>b>a, or b>c>a, or c>a>b, or a>c>b,
or a>b>c, or b>a>c, or (a=c)<b, or (a=c)>b.

[0059] Densities of the respective layers (or portions thereof) are in the following ranges:

a 35-110 kgm.sup.−3
b 15-100 kgm.sup.−3
c 15-90 kgm.sup.−3

[0060] In an embodiment of the invention, the materials of the respective layers are foam expanded polystyrene and/or a viscoelastic foam material. The material may be isotropic (having a material property that is identical in all directions) or anisotropic (having a material property that preferentially shears in one direction) to give a shearing in the direction substantially parallel to the layer direction.

[0061] Thicknesses of the respective layers in a helmet gives an overall thickness in the range 15-45 mm, but is typically in the range 20-30 mm. The three layers may each have a uniform thickness, which may not be equal between layers, or may have a varying thickness.

EXAMPLE

[0062] A comparative impact test using a variety of anvil shapes and ambient conditions has been carried out, with the following characteristics and results.

[0063] A ‘standard’ single layer liner had a thickness of 30 mm and consisted of expanded polystyrene foam with a density of about 60 kg/m.sup.3.

[0064] A triple layer liner according to the invention had an average thickness of 30 mm (25 mm to 35 mm) and consisted of expanded polystyrene foam having an outer layer density of 60 kg/m.sup.3. The middle layer had bigger cones than the inner layer. The density of the cones of the middle layer at the front, back and sides was 55 kg/m.sup.3, whereas on the top the density was 40 kg/m.sup.3. The density of the cones of the inner layer at the front, back and sides was 45 kg/m.sup.3, whereas on the top the density was 40 kg/m.sup.3 (the same as the corresponding cones of the middle layer).

TABLE-US-00001 TABLE 1 Height above base of Standard Liner Triple Liner Ref Anvil Test Helmet Helmet Compression (mm) Compression (mm) No. Shape Conditions Angle (mm) Test 1 Test 2 Test 1 Test 2 1 Flat Ambient  0 300 21.6 21.7 27.3 27.6 2 Flat Hot 180 140 15.0 14.3 17.8 18.1 3 Hemispherical Cold Right 160 23.4 23.5 26.0 26.1 125 4 Flat Wet Right 180 20.2 19.4 23.0 22.5 120

[0065] The helmet angle is the rotational position of the impact, with respect to the anvil; front being 0°, rear being 180° and so on. The test helmet in which the comparative liners were tested at a standard impact, and included a dummy head of appropriate size and mass (about 5 kg in total). Impacts were in each case translational. For impacts where the helmet was dropped onto a flat steel anvil, the drop height was 1.92 m and for impacts onto hemispherical anvil, the drop height was 1.43 m.

[0066] It may be seen by comparison that the triple layer liner according to the invention provided a substantial percentage improvement (i.e. increased compression) over a single layer liner of the same thickness.

[0067] The comparative g-forces measured during the tests exemplified in Table 1 are as follows:

TABLE-US-00002 TABLE 2 Ref Standard Liner Triple Liner No. Test 1 Test 2 Test 1 Test 2 1 151.6 163.8 126.7 134.4 2 94.1 98.2 79.6 78.3 3 100.5 97.7 84.2 86.9 4 181.5 202.3 140.7 166.1

[0068] The substantial reduction in measured g-force can be clearly seen, and hence the effectiveness of the triple layer liner of the invention.

[0069] A comparative table of the mass of the respective helmets under test now follows:

TABLE-US-00003 TABLE 3 Test Standard Liner Triple Inner Conditions (g) (g) Ambient 275 224 Hot 277 225 Cold 277 227 Wet 280 227

[0070] This comparison clearly shows that the triple layer liner of the invention results in a lighter helmet, typically around 18% less mass.

[0071] By way of illustration an alternative triple layer liner of expanded polystyrene foam could have the following density characteristics:

[0072] Outer layer: uniform 70 kg/m.sup.3

[0073] Middle layer: top 50 kg/m.sup.3; front 55 kg/m.sup.3; back 60 kg/m.sup.3; side 65 kg/m.sup.3;

[0074] Inner layer: top 30 kg/m.sup.3; front 35 kg/m.sup.3; back 40 kg/m.sup.3; side 45 kg/m.sup.3.

[0075] Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiments, it is recognized that departures can be made within the scope of the invention, which are not to be limited to the details described herein but are to be accorded the full scope of the appended claims so as to embrace any and all equivalent assemblies, devices and apparatus.