Microlattice Layer Structure for Impact Absorption and Stiffness
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Solution Overview
Problem
Conventional foamed materials used in sporting goods and personal protective equipment have homogeneous, isotropic properties, leading to limitations such as stochastic mechanical characteristics, porosity-related strength loss, and inability to handle multifunctional and multi-cyclic applications, with a need for improved stiffness, strength-to-weight ratio, and energy absorption.
Innovation Solution
Development of a microlattice layer with an interconnected network of filaments that can be tailored to specific applications by modifying filament dimensions, materials, unit cell shape, and geometry, allowing for hyper-elastic buckling and energy absorption, with strains exceeding 50% recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foamed materials are used for impact absorption, then energy absorption is provided, but stiffness and strength-to-weight ratio are insufficient
Solution Approach 1:
The foam material is segmented into a lattice structure composed of interconnected struts forming repeating unit cells. This segmentation creates a hierarchical structure where the overall foam provides energy absorption while the lattice framework maintains stiffness and strength-to-weight ratio, resolving the contradiction between these two properties.
Solution Approach 2:
The invention combines the lattice structure with foam material infill to create a composite structure. The lattice provides the structural framework for stiffness and strength, while the foam infill contributes to energy absorption, achieving both properties simultaneously.
2Reliability
If homogeneous foamed materials are used, then manufacturing is simple, but mechanical characteristics are stochastic and not controllable in specific directions
Solution Approach 1:
The lattice structure enables local quality by allowing different unit cell types, orientations, and densities to be placed in specific regions. This provides directional control over mechanical properties where needed while maintaining manufacturing feasibility through standardized lattice components.
Solution Approach 2:
The invention controls mechanical characteristics by changing lattice parameters such as strut thickness, unit cell geometry, and lattice orientation. These parameter changes allow precise control over directional mechanical properties while maintaining manufacturing precision through systematic design approaches.
3Reliability
If conventional lattices are used, then ventilation and heat exchange are improved, but moisture absorption leads to material properties degradation
Solution Approach 1:
The lattice structure inherently provides porosity for ventilation and heat exchange. By optimizing the lattice geometry and pore size distribution, the invention maintains effective core ventilation while the hydrophobic coating on lattice surfaces prevents moisture absorption that would degrade material properties.
Solution Approach 2:
A hydrophobic coating is applied as an intermediary layer on the lattice surfaces. This coating acts as a barrier that prevents moisture absorption while allowing air and heat to pass through, thus protecting the lattice material properties while maintaining ventilation and heat exchange functionality.
4Duration of action of moving object
If foamed materials are compressed, then energy absorption occurs, but they lose strength over time and cannot handle multi-cyclic applications
Solution Approach 1:
The lattice structure provides dynamic response to compression loads, allowing the struts to bend and deform elastically during impact events. This dynamic behavior enables the structure to absorb energy during compression while recovering its shape, maintaining strength and energy absorption capacity across multiple cyclic applications without permanent deformation.
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 microlattice layer provides enhanced stiffness, strength-to-weight ratio, and energy absorption, offering improved comfort and durability with customizable properties for various applications, including athletic and occupational protective gear.
Implementation Method 1
The microlattice layer and/or structure is capable of hyper-elastic or elastic buckling, giving the microlattice layer and/or structure the resilience to recover their energy-absorbing shape and properties after impact
Data Source
AI summary
A three-dimensional microlattice layer comprising a plurality of interconnected filaments extending along at least three different directions from a plurality of nodes. The microlattice layer may further comprise at least one material layer extending laterally between and interconnecting at least two or more nodes. The at least one material layer may be configured to transversely and rotationally constrain the nodes to increase the overall compressive strength and stiffness of the microlattice structure. The at least one material layer may comprise a single, continuous layer and/or a plurality of material layer segments. The microlattice layer may comprise a single, continuous layer or a plurality of microlattice layer segments. The microlattice layer may be stacked, the stacked microlattice layers may further comprise one or more material layers and/or one or more impact mitigation layers.