Segmented Foam Pad with Beads for Impact and Breathability
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Solution Overview
Problem
Existing padding technologies in various products lack simultaneous effectiveness in impact force attenuation, breathability, flexibility, low mass, and launderability, often compromising on one or more of these properties.
Innovation Solution
A pad element comprising a base member with apertures, covered by two layers and filled with compressible beads, made from polymer foam and textile materials, which compresses to absorb impact while allowing air and moisture passage, maintaining flexibility and low mass, and can be laundered without shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid padding materials are used, then impact force attenuation is improved, but breathability and flexibility deteriorate
Solution Approach 1:
The base member is divided into multiple cells formed by interconnected walls, creating a segmented structure that provides impact protection while allowing air circulation through the cell pathways, thus maintaining breathability
Solution Approach 2:
The base member utilizes a porous foam structure with interconnected cells that attenuate impact forces through controlled compression while permitting moisture vapor transmission and air flow, achieving both protection and breathability
2Strength
If thick padding layers are added, then impact protection is improved, but mass and flexibility worsen
Solution Approach 1:
The pad element combines a porous foam base member with discrete bead elements and textile cover layers to create a composite structure that provides enhanced impact protection without proportionally increasing mass, as the beads can be strategically placed in high-impact zones
3Strength
If dense padding materials are used, then impact force attenuation is improved, but breathability and launderability deteriorate
Solution Approach 1:
The porous foam base member allows moisture vapor to pass through during wear (breathability) and enables water and detergent penetration during washing (launderability), while the cell structure maintains impact attenuation capabilities
Solution Approach 2:
The segmented cell structure of the base member creates pathways for air and moisture flow, improving breathability while the modular design allows for easier drying and laundering compared to solid dense materials
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 pad element effectively attenuates impact forces, provides breathability, flexibility, and maintains a low mass while being launderable, enhancing comfort and protection in athletic and everyday applications.
Implementation Method 1
The beads are located within the apertures and between the first cover layer and the second cover layer. As examples, the base member and the beads may be formed from polymer foam materials
Implementation Method 2
Materials or elements that impart padding or cushioning (i.e., attenuate impact forces) are commonly incorporated into a variety of products
Implementation Method 3
The base member has a first surface, an opposite second surface, and a plurality of apertures extending from the first surface to the second surface
Implementation Method 4
The first cover layer is secured to the first surface of the base member and extends across portions of the apertures positioned adjacent to the first surface
Data Source
AI summary
A pad element may include a base member, a pair of cover layers, and a plurality of beads. The base member defines a plurality of apertures. The cover layers are secured to opposite surfaces of the base member and extend across the apertures. The beads are located within the apertures and between the cover layers. As examples, the base member and the beads may be formed from polymer foam materials, and the cover layers may be formed from textile materials. The pad element may be utilized to attenuate impact forces and provide one or more of breathability, flexibility, a relatively low overall mass, and launderability.