Interdigitated Cellular Cushioning for Progressive Impact Absorption
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Solution Overview
Problem
Conventional cushioning systems, such as those used in impact protection and comfort applications, often lack a controlled spring rate over their deformation range and can break down over time, failing to effectively absorb kinetic energy across various load ranges.
Innovation Solution
An interdigitated cellular cushioning system comprising two sheets of resilient material with arrays of void cells, where each void cell's peak contacts the opposing binding layer, allowing for monotonically collapsing cells that absorb kinetic energy without collapsing the binding layer, providing a configurable spring rate profile and enhanced energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cushioning systems use closed-cell air chambers or foam structures, then impact protection is provided, but the structures 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, allowing the structure to maintain integrity while individual cells deform. This segmentation prevents catastrophic failure and enables controlled collapse characteristics.
Solution Approach 2:
The binding layers are designed as flexible yet strong structures that contain the void cells and maintain the overall cushioning system integrity. The binding layers flex during compression to accommodate void cell collapse while preventing structural failure, providing durability over repeated use cycles.
2Ease of operation
If conventional cushioning systems use foam or elastomeric structures, then comfort is provided, but they lack a controlled spring rate over the entire deformation range
Solution Approach 1:
Different regions of the cushioning system can have different void cell geometries, sizes, and distributions to provide varying spring rates in different areas. This allows optimization of both comfort (softer regions) and impact protection (stiffer regions) within the same cushioning system.
Solution Approach 2:
The spring rate characteristics are controlled by varying geometric parameters of the void cells including size, shape, wall thickness, and arrangement. These parameters can be adjusted to achieve desired force-displacement characteristics across the entire deformation range, from initial compression to full collapse.
3Loss of energy
If conventional cushioning systems are used for impact protection, then energy absorption is provided, but they fail to effectively absorb kinetic energy across various load ranges
Solution Approach 1:
The cushioning system exhibits dynamic characteristics through the progressive collapse of void cells. As load increases, different void cells collapse in sequence, providing a progressive energy absorption response that adapts to various impact intensities. This dynamic behavior enables effective energy absorption across multiple load ranges.
Solution Approach 2:
The cushioning system combines resilient material with void spaces to create a composite structure that exhibits superior energy absorption characteristics. The combination of solid binding layers and void cell structures provides both strength and energy absorption capability across different impact conditions.
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 cellular cushioning system effectively absorbs kinetic energy across multiple load ranges, reducing the transmission of energy to users or surfaces, and can alter the path of projectiles, enhancing protection and comfort by maintaining structural integrity and consistent performance.
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
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.