Segmented Cushioning Pads for Joint Protection
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Solution Overview
Problem
Conventional impact protection pads for joints are either heavy, restrictive, or offer insufficient protection, often compromising on range of motion and durability, and are not aesthetically pleasing or cost-effective.
Innovation Solution
A cushioning pad design featuring a combination of continuous upper and lower layers with a cushioning region and a perimeter flange, where the cushioning material is bonded between the layers, and channels and grooves function as hinges to provide flexibility and impact resistance while maintaining direct contact with the body, integrated into garments for targeted protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid foam pads are used for impact protection, then protection capability is improved, but range of motion is restricted
Solution Approach 1:
The pad is divided into multiple foam pieces arranged in a grid pattern, with each piece separated by gaps. This segmentation allows the pad to flex and conform to body movements while maintaining impact protection capability, resolving the contradiction between protection strength and range of motion.
Solution Approach 2:
The pad features varying foam thicknesses and densities in different regions - thicker and denser in high-impact areas, thinner in areas requiring flexibility. This local variation optimizes both protection capability and range of motion by placing material where it is most needed.
2Ease of operation
If softer foam materials are used, then range of motion is improved, but impact protection is insufficient
Solution Approach 1:
The pad uses composite construction with multiple foam pieces of varying densities and thicknesses, combined with a flexible fabric cover. This composite structure provides both the softness needed for range of motion and the density required for impact protection.
Solution Approach 2:
The flexible fabric cover allows the foam pieces to move and deform dynamically with body motion, maintaining range of motion while the foam pieces themselves provide impact resistance when needed.
3Strength
If multiple layers of fabric and padding are added, then impact protection is improved, but weight and discomfort increase
Solution Approach 1:
The segmented foam structure provides multiple protection zones without requiring additional layers, reducing overall weight while maintaining protection capability through strategic material placement.
Solution Approach 2:
Material is concentrated only where impact protection is needed, with thinner or absent material in areas where protection is less critical, optimizing the weight-protection ratio.
4Ease of operation
If padding material is placed in thinner regions to improve flexibility, then range of motion is improved, but material breaks apart when flexed
Solution Approach 1:
The foam is divided into separate pieces with gaps between them, allowing each piece to flex independently without breaking. The gaps act as hinges that accommodate movement while maintaining material integrity.
Solution Approach 2:
A flexible fabric cover encases the foam pieces, providing structural support and preventing the foam from breaking apart during flexing, while allowing the necessary range of motion.
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 solution provides enhanced protection, flexibility, and durability while allowing for a full range of motion, is aesthetically pleasing, and cost-effective, with the pads being able to withstand harsh conditions and repeated use.
Implementation Method 1
cushioning material disposed between and bonded to the continuous upper layer and the continuous lower layer
Implementation Method 2
Flexible cushioning pads, items incorporating such pads, and methods of making and using
Implementation Method 3
continuous upper layer at least partially bonded to the continuous lower layer
Implementation Method 4
a first channel comprising a thickness and a width, the first channel functioning as a first hinge
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Disclosed herein are conformable protection pads, which can be integrated into articles such as clothing and protective cases. In one embodiment, an exemplary cushioning pad includes a first channel comprising a thickness and a width. The first channel comprises a continuous upper layer and a continuous lower layer, which is at least partially bonded to the continuous lower layer. The cushioning region is disposed adjacent to the first channel, and has a thickness greater than the thickness of the first channel. The cushioning region further includes a cushioning material disposed between and bonded to the continuous upper layer and the continuous lower layer. A groove maybe defined in the upper surface of the cushioning region, with a thickness less than the thickness of the cushioning region and greater than the thickness of the first channel..