Constant Force Compression Lattice for Reversible Impact Absorption
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Solution Overview
Problem
Current compression materials, such as rigid polyurethane foams, do not return to their original shape after compression, limiting their use in applications requiring constant force restoration.
Innovation Solution
A constant force compression construct comprising interconnected flexible struts in a regular hexagonal lattice with interconnecting beams, produced through additive manufacturing, allowing for anisotropic compression and rebound to the original shape upon pressure removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid polyurethane foam is used for compression, then impact absorption is achieved, but the material does not return to its original shape
Solution Approach 1:
The foam is segmented into closed cellular structures, where each cell acts as an independent compression unit. This segmentation allows the material to absorb impact through cell collapse while maintaining overall structural integrity and enabling shape recovery through the elastic properties of individual cell walls.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the foam material, including cell size, cell wall thickness, cross-linking density, and material composition. These parameter changes enable the foam to exhibit both impact absorption capability and shape memory properties, resolving the contradiction between strength and shape restoration.
2Reliability
If constant force compression is achieved through lattice structure, then reversible deformation is enabled, but manufacturing complexity increases
Solution Approach 1:
The invention utilizes a porous lattice structure with controlled porosity to achieve constant force compression. The interconnected struts and hollow chambers provide reversible deformation pathways while maintaining manufacturing feasibility through established foam fabrication techniques.
Solution Approach 2:
The patent employs composite material systems combining polyurethane foam with reinforcing agents, fillers, or layered structures. This composite approach enhances the lattice structure's mechanical properties and reversible deformation capability while managing manufacturing complexity through integrated material design.
3Volume of moving object
If high compression ratio is achieved, then space efficiency improves, but material durability decreases
Solution Approach 1:
The foam structure incorporates nested cellular configurations where smaller cells are positioned within larger cell structures. This nesting arrangement enables high compression ratios through progressive collapse of nested cells while maintaining material durability through the hierarchical support structure that prevents permanent deformation.
Solution Approach 2:
The patent incorporates pre-compression zones and energy-dissipating structures within the foam that activate before complete compression. These beforehand cushioning elements protect the material structure from damage during high compression events, maintaining durability while achieving high compression ratios.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The construct achieves a high compression ratio with reversible deformation, enabling applications like impact absorption in automotive and aerospace industries while maintaining a consistent force profile.
Implementation Method 1
a plurality of interconnected flexible struts configured as a regular hexagonal lattice... which compressible region rebounds to its prior pre-compressed dimension upon removal of the pressure
Data Source
AI summary
A first aspect of the present invention is a constant force compression construct, comprising: (a) a plurality of compressible layers, each compressible layer comprising a plurality of interconnected flexible struts configured as a regular hexagonal lattice of repeating unit cells, with the layers spaced apart from one another, and with the unit cells of each layer aligned with one another; and (b) a plurality of beams interconnecting each of the compressible layers with each respective adjacent compressible layer to form a three-dimensional lattice having an upper portion, a lower portion, and a compressible region therebetween, with the repeating unit cells contained in the compressible region.