A three-dimensional printed cushioning structure for application to a helmet

Abstract

A three-dimensional printed cushion structure applied to a helmet includes a first cushion layer. The first cushion layer includes an outer surface portion, an inner surface portion, and a plurality of support members. The outer surface portion includes a plurality of first bars arranged in a grid intersecting with each other, and the first bars define an outer contour close to an outer shell of the helmet. The inner surface portion includes a plurality of second bars extending continuously and spaced apart from each other, and the second bars define an inner contour close to a user. The support members are arranged between the outer surface portion and the inner surface portion, each of the support members has a first end and a second end, and the first end and the second end of any one of the support members are connected to any one of the first bars and any one of the second bars, respectively. The first bars, the second bars, and the support members are integrally formed by three-dimensional printing. The disclosed cushion structure can improve the overall protection performance and wearing stability of the helmet by the synergistic effect of the first bars, the second bars, and the support members, and by a method different from "directly absorbing vertical stress".

Description

Technical Field

[0001] This disclosure relates to a 3D printed structure, and more particularly to a 3D printed cushioning structure for use in helmets. Background Technology

[0002] Current helmet designs typically focus on absorbing vertical forces; however, the issue of reducing lateral shift or rotation caused by lateral forces remains largely unresolved. In practical use, when a helmet is subjected to lateral forces, insufficient internal cushioning can easily lead to lateral shift or rotation between the helmet and the user's head. This shift or rotation not only reduces helmet stability but can also cause localized stress concentration in certain areas, increasing the risk of injury. Furthermore, the existing helmet cushioning structures have relatively limited ability to disperse stress, resulting in localized stress concentration. Therefore, effectively improving helmet stability under lateral forces while also considering stress dispersion capabilities is a key research topic for engineers. Summary of the Invention

[0003] According to some embodiments disclosed herein, a 3D-printed cushioning structure for a helmet includes a first cushioning layer. The first cushioning layer includes an outer surface portion, an inner surface portion, and a plurality of support members. The outer surface portion includes a plurality of first rods, wherein the first rods are arranged in a grid pattern and define an outer contour near the helmet shell. The inner surface portion includes a plurality of second rods, wherein the second rods extend continuously and are spaced apart from each other without intersecting, and define an inner contour near the user. Support members are disposed between the outer surface portion and the inner surface portion, each support member having a first end and a second end, wherein the first end and second end of any support member are respectively connected to any first rod and any second rod. The first rods, second rods, and support members are 3D-printed as a single unit.

[0004] In some embodiments disclosed herein, any one of the support members is a straight column.

[0005] In some embodiments disclosed herein, the first connection angle between any support member and the first rod to which it is connected is 45 degrees to 135 degrees, and the second connection angle between any support member and the second rod to which it is connected is 45 degrees to 135 degrees.

[0006] In some embodiments disclosed herein, the first end of any support member is connected to the intersection of the mesh.

[0007] In some embodiments disclosed herein, any two or more adjacent supports intersect each other.

[0008] In some embodiments disclosed herein, any two or more adjacent support members intersect each other at any first rod or any second rod.

[0009] In some embodiments disclosed herein, the 3D printed buffer structure further includes a second buffer layer, which is connected to the outer surface portion and disposed between the outer surface portion and the helmet shell, and includes multiple lattice structure units, each of which has a hollow area.

[0010] In some embodiments disclosed herein, the first rod, the second rod, the support member, and the lattice structure unit are 3D printed as a single unit.

[0011] In some embodiments disclosed herein, each first rod, each second rod, and each support member has a plurality of bubble structures.

[0012] In some embodiments disclosed herein, the first rods have multiple first hollow areas between them, the second rods have multiple second hollow areas between them, and the support members have multiple third hollow areas between them, and the first hollow areas, second hollow areas, and third hollow areas are connected to each other.

[0013] According to the embodiments disclosed herein, by using a non-filled mesh (first rod) to form the outer surface of the first buffer layer, external forces can be dispersed over a wider area, reducing the damage of concentrated stress to a single area and effectively lowering the risk of injury. By using continuous, non-intersecting rods (second rod) to form the inner surface of the first buffer layer, not only is a good head fit (fit) provided, but the design of the support member also enhances the frictional force of the first buffer layer on the head in a specific direction, thereby limiting the relative displacement between the helmet and the head, limiting the lateral shift or rotation of the helmet, and enhancing the wearing stability of the helmet. In addition, through the deflection effect of the support member, the first and second rods in the horizontal direction can share the vertically applied load, achieving a stress dispersion effect. Overall, through the synergistic effect of the first rod, the second rod, and the support member, this disclosure can improve the overall protective performance and wearing stability of the helmet in a way different from "directly absorbing vertical stress". Attached Figure Description

[0014] To make the above and other objects, features, advantages and embodiments disclosed herein more apparent and understandable, the accompanying drawings are described below:

[0015] Figure 1 This is a three-dimensional schematic diagram of a three-dimensional printed cushioning structure applied to a helmet according to some embodiments of this disclosure;

[0016] Figure 2 for Figure 1 A magnified view of region R1 of the 3D printing buffer structure;

[0017] Figure 3 for Figure 1A magnified view of region R2 of the 3D printing buffer structure after the viewing angle has been adjusted;

[0018] Figure 4A for Figure 1 A magnified view of region R3 of the 3D printing buffer structure after the viewing angle has been adjusted;

[0019] Figure 4B for Figure 1 A magnified view of region R4 of the 3D printing buffer structure after the viewing angle has been adjusted;

[0020] Figure 5A for Figure 2 A magnified view of region R5 of the 3D printing buffer structure;

[0021] Figure 5B For the structural pattern of the support member according to other embodiments of this disclosure, the area presented is corresponding to Figure 2 The region R5 of the 3D printing buffer structure;

[0022] Figure 6 This is a cross-sectional microscopic diagram of a first rod, a second rod, or a support member according to some embodiments of this disclosure; and

[0023] Figures 7A to 7H Schematic diagrams of the lattice structure units of different embodiments disclosed herein.

[0024] [Symbol Explanation]

[0025] 10: 3D Printing Buffer Structure

[0026] 100: First buffer layer

[0027] 110, 110a, 110b, 110c, 110d: First shot

[0028] 120, 120a, 120b, 120c: Second stroke

[0029] 130: Support component

[0030] 130a: First end

[0031] 130b: Second end

[0032] 200: Second Buffer Layer

[0033] 210: Crystal structure unit

[0034] Q: Curved surface

[0035] H: Foam structure

[0036] θ: Connecting angle

[0037] L: Length

[0038] D: Spacing

[0039] P: Intersection point

[0040] G: Grid

[0041] GU: Mesh Unit

[0042] O, U: Outer surface portion

[0043] I: Inner surface portion

[0044] S1, S3, S4: Hollowed-out areas

[0045] S2: Interval area

[0046] R1, R2, R3, R31, R32, R4, R41, R42, R5: Regions Detailed Implementation

[0047] The following describes several embodiments of this disclosure with reference to the accompanying drawings. For clarity, many practical details will be described in the following description. However, these practical details are not intended to limit the disclosure. Additionally, for ease of viewing, the dimensions of the elements in the drawings are not drawn to scale. Furthermore, relative terms such as "lower" and "upper" may be used herein to describe the relationship between one element and another, as shown in the drawings. It should be understood that relative terms are intended to encompass different orientations of the device other than those shown in the figures. Furthermore, terms such as "first" and "second" used in the specification or claims are used only to name different elements or distinguish different embodiments or scopes, and are not intended to limit the upper or lower limit of the number of elements, nor to limit the manufacturing or installation order of the elements.

[0048] Please see Figure 1 This is a perspective view of a 3D-printed cushioning structure 10 applied to a helmet according to some embodiments of the present disclosure, viewed from the bottom opening of the helmet towards the internal structure. It should be understood that the term "helmet" as used herein refers to equipment used to protect the head and can be applied to various activities, including but not limited to daily, sports, work, and military activities. Examples include bicycle helmets, ski helmets, roller skating helmets, rock climbing helmets, equestrian helmets, baseball catcher helmets, hockey helmets, safety helmets (construction or industrial use), tactical helmets (military or tactical use), fire helmets, and riot helmets (police or security use). The 3D-printed cushioning structure 10 disclosed herein can, for example, be disposed on the inside of the helmet's hard outer shell (i.e., the side of the helmet closest to the user's head) as an inner lining of the helmet and can directly contact the user's head.

[0049] Figure 2 for Figure 1 A magnified view of region R1 of the 3D printing buffer structure 10. Please also refer to... Figure 1 and Figure 2 The 3D printed buffer structure 10 includes a first buffer layer 100, and the first buffer layer 100 includes an outer surface portion O, an inner surface portion I, and a plurality of support members 130. The outer surface portion O is relatively close to the shell of the helmet, the inner surface portion I is relatively close to the user's head, and the support members 130 are disposed and connected between the outer surface portion O and the inner surface portion I.

[0050] The outer surface portion O of the first buffer layer 100 includes a plurality of first rods 110. The plurality of first rods 110 are intersected and arranged to form a grid G ​​with multiple intersection points P, defining the outer contour of the shell near the helmet, that is, defining the contour of the outer surface portion O of the first buffer layer 100. The geometric features of the grid G ​​disclosed herein are distributed in a two-dimensional pattern, forming a continuous and complete two-dimensional grid structure. For a better understanding of the structural pattern of the grid G, please refer to [reference needed]. Figure 3 , it is Figure 1 A magnified view of region R2 of the 3D printed buffer structure 10 after perspective adjustment. (See diagram below.) Figure 3 As shown, the four first rods 110a, 110b, 110c, and 110d together form a grid cell GU, and multiple grid cells GU are closely joined on the same surface (e.g., Figure 3 The surface marked with an arcuate surface Q is located on the surface to form a grid G ​​with a complete two-dimensional grid structure. Compared to a structure that is completely filled (a solid structure), the grid G ​​formed by the intersection of the first rods 110 has a larger deformation space when subjected to external forces (impact). It can evenly distribute stress through deformation with a large degree of freedom but controllable deformation, thereby reducing the damage of concentrated stress to a single area. Furthermore, the non-filled structure design of the grid G ​​can also help to achieve lightweight structure and provide good breathability, thus taking into account wearing comfort.

[0051] On the other hand, the multiple first rods 110, due to their intersecting arrangement, form multiple hollow areas S1 between each other. The hollow areas S1 surrounded by the first rods 110 not only reduce the rigidity of the structure but also provide additional buffer space, allowing the first rods 110 to flexibly deform in multiple directions when subjected to external forces, thereby improving energy absorption and release, and reducing the impact load on the user's head. In some embodiments, the grid G ​​can have various opening shapes (i.e., the shape of the hollow areas S1), such as, but not limited to, triangular, quadrilateral (e.g., parallelogram, rectangle, trapezoid, rhombus, irregular quadrilateral, etc.), hexagonal (e.g., honeycomb), or combinations thereof, to adapt to different usage scenarios for protection. This embodiment uses a rectangle as an example.

[0052] Please return Figure 2 The inner surface portion I of the first buffer layer 100 includes a plurality of second rods 120. The plurality of second rods 120 extend continuously and are spaced apart from each other without intersecting, defining an inner contour near the user's head, that is, defining the contour of the inner surface portion I of the first buffer layer 100. In some embodiments, the inner surface portion I may directly contact the user's head. By designing the plurality of second rods 120 to be arranged adjacently and extending continuously without overlapping, not only can they conform to the shape of the user's head to provide good fit (fit), but they can also evenly distribute pressure to reduce localized pressure points, thereby improving wearing comfort. On the other hand, there is a gap region S2 between adjacent second rods 120. The gap region S2 helps to improve breathability, allowing airflow to flow in a specific direction between the rods, thereby improving heat dissipation of the head and reducing stuffiness.

[0053] In some implementations, to accommodate the different shapes of different parts of the user's head, the second rod 120 can be arranged differently for different parts of the head, and can extend generally in a single direction within the area corresponding to the same part. The head will be divided into multiple parts below. Figure 1 An illustrative example will be provided. In Figure 1 In this embodiment, the second rod 120 is in the area corresponding to the front of the head ( Figure 1 The upper part of the head (including the forehead, temples, and sides) extends roughly from the forehead to the top of the head, corresponding to the area in the middle of the head ( Figure 1 The middle position) roughly extends from around the ears on both sides of the head to the top of the head, while in the corresponding area at the back of the head ( Figure 1 The second rod 120 extends horizontally from the right (left) side of the head to the left (right) side of the head (located below the head). This design avoids the problems that might arise if the second rod 120 extends in the same direction throughout the first buffer layer 100. For example, if the second rod 120 extends from the forehead to the back of the head throughout the first buffer layer 100, the helmet is easily pushed along the extension direction of the second rod 120 when external force comes from the forehead or back of the head. Without the resistance from other directions besides the extension direction of the second rod 120, a relative displacement occurs between the helmet and the head, resulting in a reduction in protective effect.

[0054] In contrast, some embodiments disclosed herein employ different extension directions for the second rod 120 in different areas, enabling the second rod 120 to have a multi-directional arrangement. This helps maintain the helmet in a stable and fixed position relative to the head, effectively dispersing and resisting external forces from various directions, thus enhancing the overall protective performance of the helmet. Overall, the extension direction design of the second rod 120 effectively reduces the likelihood of external forces being transmitted along an axis perpendicular to this extension direction. Simultaneously, for external forces perpendicular to the extension direction of the second rod 120, the second rod 120 provides stable friction due to its perpendicular extension direction, helping to reduce or prevent displacement of the first buffer layer 100 in the direction perpendicular to the extension direction of the second rod 120. This effectively suppresses slippage or offset, further improving structural stability and the user's protective effect.

[0055] It is worth noting that although the second rod 120 may employ different arrangement patterns in different locations, it can achieve a smooth connection between these different locations, giving the second rod 120 at the connection point a continuous overall characteristic. In this way, two segments of the second rod 120 can be integrated into a seamless and uniformly extended segment. In other words, two segments of the second rod 120, after a smooth connection, can be considered as a single, continuously extending segment. This smooth connection design not only reduces the possibility of stress concentration at non-seamless connection points but also guides external forces to be evenly distributed along the continuously extending second rod 120, further reducing the risk of localized deformation or damage.

[0056] Please return to Figure 2 In some embodiments, the second rod 120 can also be appropriately bent or transitioned in different areas according to the specific geometric characteristics of the user's head, while maintaining a certain degree of spacing. Furthermore, the distance D between the second rods 120 can be adjusted accordingly based on the geometric characteristics of the user's head; for example, the distance D can be reduced in areas requiring higher support, or increased in areas requiring greater cushioning or avoidance, thereby balancing the overall support, cushioning, and fit (conformity) of the structure. The following will use... Figure 4A and Figure 4B Let's take an example to illustrate, among which Figure 4A for Figure 1 A magnified view of region R3 of the 3D printing buffer structure 10 after viewpoint adjustment. Figure 4B for Figure 1 A magnified view of region R4 of the 3D printing buffer structure 10 after the viewpoint has been adjusted.

[0057] Figure 4AThe distribution of the second rods 120 in the first buffer layer 100, from region R31 corresponding to the forehead position to region R32 corresponding to the top of the head, is shown by dashed lines. Generally, the multiple second rods 120 gradually converge from region R31 corresponding to the forehead position to region R32 corresponding to the top of the head (i.e., the spacing D between the second rods 120 gradually decreases), and moderately bend at region R32 corresponding to the top of the head according to the shape of the hair whorl on the scalp. Furthermore, if a more flexible fit to the head curve is required, some of the second rods 120 can further smoothly connect with other second rods 120 during the bend (or can be considered as merging and extending). For example, Figure 4A The second rod 120a extends in roughly the same direction in region R31 corresponding to the forehead, and bends in region R32 corresponding to the top of the head, smoothly connecting with the second rod 120b, which also extends from region R31 to region R32, thus forming a single second rod 120 with a bend. This design allows the second rod 120 to conform to the natural curve of the hair whorl, providing even support and a comfortable fit, while avoiding pressure on the hair whorl area.

[0058] It should be understood that although some second rods 120 can smoothly connect with other second rods 120 during extension, this is limited to where the second rods 120 need to adapt to significant directional changes or structural transitions. In other words, the smooth connection of the second rods 120 mainly occurs only in areas with adaptive requirements and special geometric features (e.g., Figure 4A (The area corresponding to the hair whorl as described in the text). Overall, most of the second rods 120 in the first buffer layer 100 still maintain a generally consistent direction of extension, thereby adapting to the head shape corresponding to the area over a large area, and maintaining the structural consistency of the inner surface portion I of the first buffer layer 100, thereby providing uniform support.

[0059] Figure 4B The distribution of the second rods 120 in the first buffer layer 100, from region R41 corresponding to the back of the head to region R42 corresponding to the ear, is shown by dotted lines. Overall, multiple second rods 120 extend continuously from region R41 to region R42, and are designed to bend to conform to the shape of the ear in region R42, avoiding pressure and stuffiness on the ear. For example, Figure 4BThe second rod 120c extends in roughly the same direction in the region R41 corresponding to the back of the head, and changes to a lightning bolt-shaped bend in the region R42 corresponding to the ear. Adjacent second rods 120 are approximately equidistant from the region R41 corresponding to the back of the head to the region R42 corresponding to the ear. This lightning bolt-shaped bend can flexibly adapt to the complex curves around the ear, helping to effectively avoid the ear contour while conforming to the head's curvature, thereby improving the overall wearing comfort and stability. In some embodiments, it can also be placed at the edge of the first buffer layer 100 (e.g., Figure 1 The second rod 120 (as shown at the back edge of the head below) is designed in a lightning bolt-shaped bend to enhance friction against the head and thus improve wearing stability.

[0060] Please also refer to Figure 2 as well as Figure 5A ,in Figure 5A for Figure 2 A partially enlarged schematic diagram of region R5 of the 3D printed buffer structure 10. The support member 130 connects the outer surface O and inner surface I of the first buffer layer 100. Specifically, the support member 130 has opposing first ends 130a and second ends 130b, and the first ends 130a and second ends 130b are respectively connected to any one of the first rods 110 and any one of the second rods 120. Since the support member 130 can securely connect the first rod 110 and the second rod 120 together, when an external force is applied to the helmet in a direction not perpendicular to the top of the head (i.e., laterally), it can effectively limit the relative displacement in the lateral direction between the first rod 110 and the second rod 120. Simultaneously, combined with the aforementioned friction between the second rod 120 and the head, the second rod 120 and the support member 130 can jointly pull the first buffer layer 100 along with the helmet back to its original position, thereby reducing the lateral shift or rotation of the helmet caused by lateral forces, effectively reducing the relative movement between the helmet and the user's head, improving wearing stability, and enhancing the protective effect.

[0061] Furthermore, when the first buffer layer 100 is subjected to an external force, the support member 130 can deflect due to a limited relative displacement between the first rod 110 and the second rod 120. This deflection force can redistribute the stress originally concentrated at a single point to a wider area. More specifically, when an external force is applied to the first buffer layer 100 in a direction perpendicular to the force-bearing surface (e.g., the outer surface portion O of the first buffer layer 100), the deflection of the support member 130 can convert this vertical force into a horizontal force. This horizontal force can be further dispersed along the two-dimensional grid structure formed by the first rod 110 and the continuous extending structure formed by the second rod 120 (e.g., along the contour of the outer surface portion O and the inner surface portion I of the first buffer layer 100), thereby reducing the damage of local stress concentration to a single point. In addition, the support member 130 also has good deflection recovery, which can temporarily store energy inside when subjected to external force, and quickly release this energy to generate a restoring force after the external force disappears, so as to pull the second rod 120 back to the initial position.

[0062] Furthermore, since the force perpendicular to the stress surface is guided and distributed to the first rod 110 and the second rod 120 via the deflected multiple support members 130, and further transmitted to the surrounding area along the extension direction of the first rod 110 and the second rod 120, the amount of compression of the first buffer layer 100 in the vertical direction during the stress process can be effectively reduced, thereby effectively reducing the deformation of the overall structure. In addition, since the amount of compression in the vertical direction is reduced, the wear and fatigue accumulation caused by local compression of the first buffer layer 100 during the stress process can be effectively reduced, thereby enabling the first buffer layer 100 to maintain its long-term stable support and buffering effect.

[0063] In some embodiments, the support member 130 mainly uses the first rod 110 with the grid G ​​configuration as a base to support the second rod 120. Therefore, multiple support members 130 are connected to the first rod 110 according to the position of the second rod 120, forming a spaced arrangement. Specifically, as Figure 5A As shown, assuming that the extension direction of a certain second rod 120 is approximately the same as the arrangement direction of a certain first rod 110 in the grid G, the support member 130 can be arranged at intervals and connected accordingly to the intersection point P or non-intersection point of the first rod 110 (e.g., at the rod-shaped section of the first rod 110).

[0064] In some embodiments, the support member 130 may be a straight column. In other words, the support member 130 does not have a curved or curved shape. With its straight column design, the support member 130 can have high support (compression resistance), effectively resisting compression when subjected to stress along the column axis, maintaining structural stability, and adapting to various angles of deflection when subjected to oblique stress (i.e., stress not along the column axis), dispersing the stress to the surroundings. Furthermore, the straight column shape of the support member 130 is less prone to unexpected deformation under stress, exhibiting a relatively predictable and controllable mechanical response, reducing unstable swaying or displacement of the helmet when subjected to external forces, thereby reducing the relative displacement between the helmet and the user's head and improving wearing safety.

[0065] In some embodiments, the connection angle θ between the support member 130 and the first rod 110, and between the support member 130 and the second rod 120, can each be from 45 degrees to 135 degrees (e.g., 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees). It should be noted that the connection angle θ here refers to the connection angle θ between different support members 130 and the first rod 110 and the second rod 120, respectively, in their design. When the connection angle θ falls within the above range, the support member 130 can have both support and deflection effects, which helps to distribute stress when combined with the first rod 110 and the second rod 120. The whole structure has better deflection recovery and higher lateral rigidity, which can maintain the stability of the structure and prevent the connection from being unable to provide effective deflection due to insufficient support force caused by the angle being too small (below 45 degrees, for example 10 degrees) or too large (above 135 degrees, for example 170 degrees).

[0066] In some embodiments, at least a portion of the first end 130a of the support member 130 needs to be connected to the intersection point P of the grid G. Compared to the non-intersection points of the grid G ​​(i.e., the rod-shaped sections of the first rod 110), the intersection point P has higher structural strength and stability, providing the support member 130 with sufficient load-bearing capacity to more effectively and directly transfer stress to the entire grid system. Furthermore, connecting the support member 130 to the intersection point P also improves the connection strength between the support member 130 and the grid G, thereby enhancing the overall structure's resistance to deformation. In practical design, the connection positions of multiple support members 130 in the first buffer layer 100 to the grid G ​​can be adjusted or combined according to the helmet's usage scenario and protection requirements, and are not limited to connections only at the intersection point P or non-intersection points.

[0067] The multiple support members 130 have a hollow area S3 between them, meaning the support members 130 are spaced apart. In some embodiments, the hollow area S1 between the first rods 110 and the gap area S2 between the second rods 120 can be connected to each other through the hollow area S3 between the support members 130 (see...). Figure 2 This creates a gas exchange cavity that extends continuously from the outer surface portion O of the first buffer layer 100 to the inner surface portion I. Specifically, the perforated area S1, the interleaved area S2, and the perforated area S3 are connected to form the gas exchange cavity. This continuously extending gas exchange cavity can redistribute the air pressure generated by external impact over a larger area, helping to improve cushioning. Furthermore, the gas exchange cavity promotes airflow, preventing heat and moisture from accumulating inside the helmet, thereby reducing stuffiness and keeping the head dry.

[0068] In some embodiments, the length L of the support member 130 may be, for example, from 3 cm to 10 cm (e.g., 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm). This length range helps to balance the deflection capability and stress distribution uniformity of the support member 130. Specifically, if the support member 130 is too long, although it may provide a larger deflection amplitude to absorb more energy, it may also cause excessive deformation during deflection, resulting in a reduced deflection recovery capability of the support member 130. Furthermore, an excessively long support member 130 may also lead to an excessively large stress transmission path, thus failing to effectively and evenly transmit stress to the first rod 110 and the second rod 120, resulting in uneven stress distribution. If the support member 130 is too short, it will limit the deflection capability and fail to adequately absorb and disperse stress, thus causing local stress concentration at a single point. In some embodiments, the length L of the support member 130 of the first buffer layer 100 may be designed according to the location of the helmet area; for example, support members 130 in the same area may be designed to have the same length L. In some implementations, the supports 130 of the first buffer layer 100 of the entire helmet are all designed to be of the same length L.

[0069] Please see Figure 5B It is a structural example of the support member 130 according to other embodiments of this disclosure, and the area it presents corresponds to Figure 2 The 3D printing buffer structure 10 is located in region R5. Figure 5BIn one embodiment, adjacent support members 130 intersect each other at the second rod 120. In other embodiments (not shown), adjacent support members 130 may also intersect each other at the first rod 110. When a support member 130 intersects the first rod 110 or the second rod 120 at one point, that point becomes a distribution center for multi-directional forces, which can more evenly distribute external forces to all rod-like structures connected to it (e.g., the first rod 110, the second rod 120, and the support member 130), helping to reduce the occurrence of local stress concentration. In yet another embodiment (not shown), adjacent support members 130 may cross each other to form a cross structure in the space between the first rod 110 and the second rod 120, so that the support member 130 increases the stress distribution path by adding an intersection point in addition to the connection point with the first rod 110 and the second rod 120, and the cross structure provides additional structural support, improving the deformation resistance of the first buffer layer 100 in all directions.

[0070] Please return Figure 2 In some embodiments, the first buffer layer 100 can be 3D printed as a single unit, meaning that the first rod 110, the second rod 120, and the support member 130 in the first buffer layer 100 are integrally formed. The seamless bonding and material continuity of the integral molding can avoid potential seam weaknesses and material interface weaknesses, thereby improving the overall stress transfer efficiency and allowing the stress acting on the helmet to be more evenly distributed throughout the first buffer layer 100, reducing local stress concentration.

[0071] In some embodiments, the first buffer layer 100 can be 3D printed as a single unit and then foamed. That is, each first rod 110, each second rod 120, and each support member 130 in the first buffer layer 100 can each have multiple foam cell structures. Please refer to [link / reference]. Figure 6This is a cross-sectional microscopic schematic diagram of the first rod 110, the second rod 120, or the support member 130 according to some embodiments of this disclosure, showing a pore structure H. The pore structure H provides additional space to accommodate compression deformation, effectively dispersing and mitigating external impacts to provide additional cushioning and support. Furthermore, the pore structure H allows the first buffer layer 100 to reduce material usage while maintaining sufficient strength, thereby achieving a balance between lightweighting and increased strength. Additionally, the pore structure H enhances breathability, thereby improving wearing comfort. In some embodiments, the pore structure H may have a micrometer scale, that is, the pore size of a single pore structure H may be from 10 micrometers to 800 micrometers (e.g., 100 micrometers, 200 micrometers, 300 micrometers, 400 micrometers, 500 micrometers, 600 micrometers, 700 micrometers). Compared to nanoscale pore structures, micron-scale pore structures are less prone to collapse or deformation, thus providing more durable cushioning and support. Furthermore, micron-scale pore structures offer relatively high breathability, resulting in a better wearing experience.

[0072] In some embodiments, the first rod 110, the second rod 120, and the support member 130 in the first buffer layer 100 are made of the same material. In some embodiments, the first rod 110, the second rod 120, and the support member 130 may be made of elastomeric materials, including but not limited to thermoplastic polyurethane, polyurethane base materials, expanded polystyrene, and foam, so that the first buffer layer 100 has flexibility and plasticity, thereby flexibly conforming to the natural curve of the head and avoiding pressure or discomfort to the head caused by rigid structures.

[0073] Please continue reading. Figure 2 In some embodiments, the 3D printed buffer structure 10 may further include a second buffer layer 200 disposed between the outer surface portion O of the first buffer layer 100 and the helmet shell. When the helmet is subjected to an external force, the force can sequentially pass through the second buffer layer 200 and the first buffer layer 100 to reach the user's head. In some embodiments, the second buffer layer 200 may include a plurality of lattice structure units 210 continuously disposed in three-dimensional space. In some embodiments, the lattice structure unit 210 may be an extension or three-dimensional extension of a two-dimensional mesh G in three-dimensional space; for example, the lattice structure unit 210 may be composed of, for example, a... Figure 2 The quadrilateral grid G ​​shown extends into a cubic lattice structure in three-dimensional space, and can be further designed as a multi-layer structure according to the overall buffering capacity requirements. Figure 2 In one embodiment, the second buffer layer 200 exhibits a three-layer structure. In other embodiments, the lattice structure of the lattice unit 210 may also be as follows: Figures 7A to 7H The lattice structure substitution shown, for example Figure 7ABody-centered cubic lattice Figure 7B Face-centered cubic lattice Figure 7C Fluorite lattice Figure 7D Kelvin Lattice Figure 7E Gyroid spiral lattice Figure 7F Schwarz lattice Figure 7G Diamond curved lattice and Figure 7H The second buffer layer 200 is a split-P lattice. Overall, the second buffer layer 200 achieves the effect of directly absorbing stress applied perpendicular to the force-bearing surface through its non-filled structural design composed of multiple lattice structural units 210.

[0074] In some embodiments, the hollowed-out region S4 in the lattice structure unit 210 may also be connected to the hollowed-out region S1 between the first rods 110, the spacer region S2 between the second rods 120 and the hollowed-out region S3 between the support member 130 to form a gas exchange cavity that extends continuously from the inner surface portion I of the first buffer layer 100 to the outer surface portion U of the second buffer layer 200.

[0075] In some embodiments, the first buffer layer 100 and the second buffer layer 200 can be integrally formed by 3D printing; that is, the first rod 110, the second rod 120, and the support member 130 in the first buffer layer 100 are integrally formed with the lattice structure unit 210 in the second buffer layer 200. In other embodiments, the second buffer layer 200 can be combined with the first buffer layer 100 by suitable means such as gluing, mechanical connection (e.g., tenon or snap-fit), welding (e.g., thermoforming welding, ultrasonic welding), or additional mounting fasteners to provide design and assembly flexibility.

[0076] In some embodiments, the second buffer layer 200 can also be foamed after being 3D printed as a single unit; that is, each lattice structure unit 210 in the second buffer layer 200 can have, for example, the following characteristics. Figure 6 The first buffer layer 100 shown contains multiple pore structures H.

[0077] It is worth noting that the design of the first buffer layer 100 in this disclosure focuses on the function of "reducing lateral displacement or rotation of the helmet" provided by the support member 130. Specifically, the support member 130 restricts the relative displacement between the first rod 110 and the second rod 120, and the friction between the second rod 120 and the head resists the lateral displacement or rotation caused by lateral forces on the first buffer layer 100. In addition, the support member 130 can also achieve the function of "redistributing stress (dispersing stress)". Specifically, the deflection of the support member 130 converts the stress applied vertically to the force-bearing surface into a horizontal force. These horizontal forces are further transmitted and dispersed to the surroundings through the two-dimensional grid structure of the first rod 110 and the continuous extension structure of the second rod 120. This allows multiple horizontal rod-like structures (e.g., the first rod 110 and the second rod 120) to work together to bear the vertically applied load, thereby reducing the damage of local stress concentration to a single point. In some embodiments, an additional second buffer layer 200 can further provide the function of "absorbing vertical stress." Specifically, it directly absorbs the stress applied vertically to the force-bearing surface through the geometric characteristics of the lattice structure unit 210 (e.g., the three-dimensional distribution and cavity design of the lattice structure) and the elasticity of the material, reducing the energy of stress transferred to the inner layer. In other words, the first buffer layer 100 and the second buffer layer 200 achieve the buffering effect through different means. Overall, the first buffer layer 100 itself can achieve good protective performance through its ability to "limit the lateral displacement or rotation of the helmet" and its ability to "redistribute stress." By further combining the first buffer layer 100 and the second buffer layer 200, the buffering and protective effects can be further enhanced by "absorbing vertical stress," thereby improving the overall protective performance of the helmet and providing more comprehensive safety protection.

[0078] According to the embodiments disclosed herein, by using a non-filled mesh (first rod) to form the outer surface of the first buffer layer, external forces can be dispersed over a wider area, reducing the damage of concentrated stress to a single area and effectively lowering the risk of injury. By using continuous, non-intersecting rods (second rod) to form the inner surface of the first buffer layer, not only is a good head fit (fit) provided, but the design of the support member also enhances the frictional force of the first buffer layer on the head in a specific direction, thereby limiting the relative displacement between the helmet and the head, limiting the lateral shift or rotation of the helmet, and enhancing the wearing stability of the helmet. In addition, through the deflection effect of the support member, the first and second rods in the horizontal direction can share the vertically applied load, achieving a stress dispersion effect. Overall, through the synergistic effect of the first rod, the second rod, and the support member, this disclosure can improve the overall protective performance and wearing stability of the helmet in a way different from "directly absorbing vertical stress".

[0079] Although the present disclosure has been described above with reference to embodiments, it is not intended to limit the present disclosure. Any person skilled in the art may make various modifications and alterations without departing from the spirit and scope of the present disclosure. Therefore, the scope of protection of the present disclosure shall be determined by the appended claims.

Claims

1. A three-dimensional printed cushioning structure for use in helmets, characterized in that, include: A first buffer layer, comprising: An outer surface portion includes a plurality of first bars, wherein the plurality of first bars are arranged intersecting each other to form a grid and define an outer contour of a shell adjacent to the helmet; An inner surface portion includes a plurality of second rods, wherein the plurality of second rods extend continuously and are spaced apart from each other without intersecting, and define an inner contour near a user; and Multiple support members are disposed between the outer surface portion and the inner surface portion. Each of the multiple support members has a first end and a second end, wherein the first end and the second end of any of the multiple support members are respectively connected to any of the multiple first rods and any of the multiple second rods. The plurality of first rods, the plurality of second rods, and the plurality of support members are 3D printed into a single unit.

2. The three-dimensional printing buffer structure as described in claim 1, characterized in that, Any one of the plurality of support members is a straight column.

3. The three-dimensional printing buffer structure as described in claim 2, characterized in that, The first connection angle between any of the plurality of support members and the connected plurality of first rods is 45 degrees to 135 degrees, and the second connection angle between any of the plurality of support members and the connected plurality of second rods is 45 degrees to 135 degrees.

4. The three-dimensional printing buffer structure as described in claim 1, characterized in that, The first end of any of the plurality of supports is connected to an intersection of the grid.

5. The three-dimensional printing buffer structure as described in claim 1, characterized in that, Any two or more of the adjacent plurality of support members intersect each other.

6. The three-dimensional printing buffer structure as described in claim 5, characterized in that, Any two or more of the adjacent plurality of support members intersect at any one of the plurality of first rods or any one of the plurality of second rods.

7. The three-dimensional printing buffer structure as described in claim 1, characterized in that, Also includes: A second buffer layer is connected to the outer surface portion and disposed between the outer surface portion and the outer shell of the helmet, and includes a plurality of lattice structure units, each of the plurality of lattice structure units having a hollow area.

8. The three-dimensional printing buffer structure as described in claim 7, characterized in that, The plurality of first rods, the plurality of second rods, the plurality of support members, and the plurality of lattice structure units are 3D printed into a single unit.

9. The three-dimensional printing buffer structure as described in claim 1, characterized in that, Each of the plurality of first rods, each of the plurality of second rods, and each of the plurality of supports each has a plurality of bubble structures.

10. The three-dimensional printing buffer structure as described in claim 1, characterized in that, The plurality of first rods have a plurality of first hollow areas between them, the plurality of second rods have a plurality of second hollow areas between them, and the plurality of support members have a plurality of third hollow areas between them, and the plurality of first hollow areas, the plurality of second hollow areas and the plurality of third hollow areas are connected to each other.

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