Nonlinear Tear-Path Energy Absorber for Compact Fall Arrest

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Solution Overview

Problem

Existing energy absorbers in fall arrest systems are bulky due to their need for long lengths to absorb sufficient energy, and there is a need for more reliable and safer alternatives that do not increase in size.

Innovation Solution

An energy absorber with a non-linear line of weakness along its elongate member, allowing it to tear effectively without increasing size, utilizing laser-etched grooves or perforations for enhanced energy absorption and control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the energy absorber is made longer to absorb sufficient energy, then the energy absorption capacity is improved, but the equipment becomes bulky and inconvenient

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidequipment size

Core Design Contradiction:

Use of energy by moving objectVSVolume of moving object

Solution Approach 1:

The patent transforms the traditional linear tear path into a non-linear path by incorporating zig-zag patterns, waves, or serpentine configurations in the line of weakness. This dimensional transformation allows the tear path to traverse a longer effective distance through the material, increasing energy absorption capacity without proportionally increasing the overall length of the energy absorber, thus reducing bulkiness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent applies curved and wavy patterns in the line of weakness design, replacing straight linear tear paths with curved zig-zag, wave, or serpentine configurations. These curved paths increase the effective tear distance and energy absorption capacity within a compact footprint, allowing the energy absorber to achieve sufficient energy absorption without being excessively long or bulky.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Use of energy by moving object

If a thicker elongate member is used to increase energy absorption, then the energy absorption capacity is improved, but the weight and bulkiness increase

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidabsorber weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent compensates for using thinner material by implementing non-linear tear paths (zig-zag, wave, serpentine) that extend the effective tear distance in multiple dimensions. This allows thinner elongate members to achieve the same energy absorption capacity as thicker members would provide through a straight tear path, reducing weight while maintaining performance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The line of weakness is segmented into multiple sections with varying depths, orientations, and spacings, creating a complex tear propagation path. This segmentation allows the energy absorber to distribute the tearing process over a longer effective path, enabling thinner material to absorb sufficient energy through extended tear distance rather than increased material thickness.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If a linear line of weakness is used, then the manufacturing is simpler, but the energy absorption capacity for a given size is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidenergy absorption capacity

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent incorporates curved, wavy, zig-zag, or serpentine patterns in the line of weakness design, which can be effectively implemented through laser scoring or perforation techniques. These curved patterns increase the effective tear distance and energy absorption capacity while remaining compatible with standard manufacturing processes, balancing manufacturing simplicity with enhanced performance.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent varies parameters such as the depth, orientation, spacing, and configuration of the line of weakness features (scored lines, perforations, grooves) to create non-linear tear paths. By adjusting these parameters, the energy absorber achieves enhanced energy absorption capacity through extended tear paths while maintaining manufacturability through conventional laser scoring or perforation methods.

Inventive Principle:

Principle #35Parameter changes

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 non-linear line of weakness enables the absorber to absorb the same amount of energy as thicker absorbers while being thinner and less bulky, improving safety and convenience.

Implementation Method 1

the elongate member is configured to tear along the line of weakness, thereby at least partially absorbing the energy of a user's fall

Methodology Applied

Scientific EffectEnergy absorption through plastic deformation: Plasticity

Data Source

PatentUS12447363B2Energy absorber

Publication Date: 2025.10.21 MSA TECHNOLOGY LLC

AI summary

An energy absorber (10) for use in a fall arrest system includes an elongate member (11) having a proximal end (14), a distal end (12), and a line of weakness (15, 16) extending in a longitudinal direction (A) along at least a portion of the elongate member between the proximal end (14) and the distal end (12). The line of weakness (15, 16) is at least partially non-linear. In response to application of a predetermined force, the elongate member (11) is configured to tear along the line of weakness (15, 16), thereby at least partially absorbing energy of a user's fall.