Interdigitated Cellular Cushioning for Controlled Impact Absorption
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Solution Overview
Problem
Conventional cushioning systems often break down over time and lack a controlled spring rate throughout their deformation range, failing to effectively absorb kinetic energy and protect against impacts.
Innovation Solution
An interdigitated cellular cushioning system comprising two sheets of resilient material with arrays of void cells that monotonically collapse under load, where each void cell's peak contacts the opposing binding layer, providing a configurable spring rate profile and enhanced energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cushioning systems (foam, closed-cell air chambers, elastomeric honeycomb) are used, then cushioning function is provided, but they break down over time and lack controlled spring rate
Solution Approach 1:
The cushioning system is divided into multiple discrete void cells arranged in arrays within binding layers. Each void cell acts as an independent energy-absorbing unit with controlled collapse characteristics, preventing progressive failure across the entire structure and maintaining reliability over time
Solution Approach 2:
The system combines resilient material sheets with void cell structures and binding layers to create a composite cushioning system. This composite structure integrates the energy absorption capabilities of void cells with the structural support of binding layers, achieving both durability and controlled deformation
2Force
If conventional cushioning structures are used, then impact protection is provided, but they lack a controlled spring rate over the entire deformation range
Solution Approach 1:
Each void cell is designed with specific geometric characteristics (size, shape, wall thickness) that determine its local spring rate and collapse behavior. By varying these local properties across different cells or regions, the system achieves a controlled overall spring rate profile without requiring complex global structural designs
Solution Approach 2:
The spring rate characteristics are controlled by adjusting parameters such as void cell dimensions, wall thickness, material properties, and cell density. These parameter variations allow tuning of the force-deformation relationship across the entire deformation range, providing controlled energy absorption without increasing structural complexity
3Use of energy by moving object
If conventional cushioning systems are used, then basic cushioning function is provided, but they fail to effectively absorb kinetic energy
Solution Approach 1:
The void cells are pre-configured with specific geometries and material properties that enable them to undergo controlled monotonous collapse during impact. This predetermined collapse mechanism ensures efficient kinetic energy absorption by converting impact energy into deformation work, maximizing energy dissipation before the binding layers are engaged
Solution Approach 2:
The system ensures continuous energy absorption throughout the deformation process by designing void cells that collapse monotonously from initial contact through to binding layer engagement. This continuous collapse process maintains consistent energy dissipation rates, preventing energy rebound and maximizing kinetic energy absorption efficiency
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 interdigitated system effectively absorbs kinetic energy, reduces the transmission of impact forces, and maintains structural integrity across various load ranges, offering improved protection and durability compared to traditional cushioning systems.
Implementation Method 1
The void cells are configured to monotonically collapse under a load, wherein a peak of each void cell in the first array contacts the second binding layer
Implementation Method 2
effectively absorbs kinetic energy, reduces the transmission of impact forces
Implementation Method 3
An interdigitated cellular cushioning system comprising a first sheet of resilient material including a first binding layer and a first array of void cells protruding from the first binding layer
Data Source
AI summary
An interdigitated cellular cushioning system includes an array of void cells protruding from each of two binding layers interdigitated between the two binding layers. Peaks of each of the void cells are attached to the opposite binding layer forming the interdigitated cellular cushioning system. The interdigitated cellular cushioning system may be used to absorb and distribute a source of kinetic energy incident on the interdigitated cellular cushioning system (e.g., an impact or explosion) so that the amount of force transmitted through the interdigitated cellular cushioning system is low enough that it does not cause injury to personnel or damage to personnel and/or equipment adjacent the interdigitated cellular cushioning system.