US20180027914A1 - An impact absorbing structure and a helmet comprising such a structure - Google Patents

An impact absorbing structure and a helmet comprising such a structure Download PDF

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Publication number
US20180027914A1
US20180027914A1 US15/549,145 US201615549145A US2018027914A1 US 20180027914 A1 US20180027914 A1 US 20180027914A1 US 201615549145 A US201615549145 A US 201615549145A US 2018027914 A1 US2018027914 A1 US 2018027914A1
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cells
impact absorbing
absorbing structure
impact
helmet
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James Cook
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Oxford University Innovation Ltd
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Oxford University Innovation Ltd
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    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/10—Linings
    • A42B3/12—Cushioning devices
    • A42B3/124—Cushioning devices with at least one corrugated or ribbed layer
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/10—Linings
    • A42B3/12—Cushioning devices
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/28—Ventilating arrangements
    • A42B3/281—Air ducting systems
    • A42B3/283—Air inlets or outlets, with or without closure shutters

Definitions

  • the present invention relates to an impact absorbing structure. More particularly, the present invention relates to a hollow-cell impact absorbing structure. Even more particularly, the present invention relates to an impact absorbing structure formed as a stretch-dominated hollow-cell structure. The present invention also relates to impact absorbing structures where the impact surface is curved, such as a sports helmet or aerospace nose bumpers, at least part of the structure formed from a hollow-cell impact absorbing structure, and even more particularly a stretch-dominated hollow-cell impact absorbing structure.
  • Impact protection is particularly important for preventing head injury.
  • a blow to the head can result in severe traumatic brain injury (TBI). It is common for brain trauma to occur as a consequence of either a focal impact upon the head, or by a sudden acceleration/deceleration within the cranium, or from a combination of both impact and movement. Traumatic brain injury can cause long-term issues, and there are limited treatment options.
  • head injury is participation in sports. For example, a fall from a bicycle when riding may result in the head striking against a solid unyielding object or surface such as a road surface or similar.
  • helmet usage is customary or mandatory in many sports such as bicycle, motorcycle and horse riding, rock climbing, American football and also winter or ice sports such as skating, ice hockey, and skiing.
  • Another common cause of head injury is an impact caused by a falling object on a building or construction site.
  • Sports helmets and safety helmets are individually designed so as to be particularly suited to their particular use.
  • most or all of the helmets have common design elements such as a hard outer shell (formed from a stiff thermoplastic or composite) and a lining/liner, softer than the outer shell, but still stiff enough to retain it's shape when unsupported.
  • the shell and liner act to absorb the force of an impact and to help prevent this force being transmitted to the head and brain.
  • Virtually all helmets use expanded polystyrene as the energy absorbing liner.
  • the expanded polystyrene is formed as a unitary structure (that is, without gaps) in the required shape.
  • U.S. Pat. No. 3,447,163 describes and shows a safety or crash helmet intended for use by motorcyclists and/or racing motorists.
  • the helmet has an outer shell formed as a double-skinned member, the two skins of the shell joined to one another around the periphery of the shell by a gently curved peripheral portion that has no sharp edges, and the space between the skins contains a layer of a honeycomb type of material, the cells of the honeycomb layer filled with an energy-absorbing foamed material.
  • U.S. Pat. No. 7,089,602 describes and shows an impact absorbing, modular helmet having layers on the outer side of a hard casing that increase the time of impact with the intention of reducing the intensity of the impact forces.
  • the layers are made up of a uniformly consistent impact absorbing polymer material, a polymer layer filled with air or a polymer structure.
  • These impact-absorbing layers can also be made and used as an independent, detachable, external protective cover that can be attached over a hard casing helmet.
  • U.S. Pat. No. 6,247,186 describes and shows a helmet having a housing, an inner impact resistant layer shaped to the head of rider, a protective covering spaced above and formed integrally with the housing, and a chamber enclosed by the housing and protective covering that is open in the front for ventilation.
  • the chamber has a net strap in the front side for preventing foreign objects from entering and one or more inner channels in communication with the inner space of helmet through a passageway. In use, fresh air flows through the passageway and into the impact resistant layer.
  • Sports helmets and safety helmets often have to be worn for extended periods, and the weight of the helmet is an important design consideration.
  • the overall weight (and shape and size) of the helmet and the impact-absorbing properties.
  • Increasing the amount of impact-absorbing material will increase the overall weight of the helmet, and may also result in an increase in the external dimensions, which can in turn make wearing the helmet relatively more unwieldy and uncomfortable to wear, especially where aerodynamic considerations may also be important.
  • impact protection can be compromised if the helmet has too little impact-absorbing material.
  • Foams such as the foams used in helmets are typically excellent energy absorbers because they are characterised by a long plateau stress, and in most impacts the area is constant so the stress can be directly converted to force, providing a long plateau force. This means all the energy can be absorbed whilst maintaining a low peak force and acceleration, optimal in reducing brain damage.
  • the area when crushing is not constant.
  • the present invention may broadly be said to consist in an impact absorbing structure, comprising a unitary material formed as a stretch-dominated hollow cell structure.
  • substantially all the cells of the hollow cell structure are 2D hollow-cells.
  • substantially all the cells are aligned substantially out of plane.
  • the cells are formed as a micro-truss lattice.
  • the cells are formed as a crystal lattice structure.
  • At least a plurality of the cells are configured to tessellate.
  • At least a plurality of the cells are configured to tessellate with a cell axis normal to the surface or out-of-plane.
  • At least a plurality of the cells are hexagonal.
  • At least a plurality of the cells are triangular.
  • At least a plurality of the cells are square.
  • At least a plurality of the cells are a combination of octagons and squares co-located in a tessellating pattern.
  • the unitary material is formed to have a relative density substantially between 0.05 and 0.15.
  • the cell shape, size, cell wall thickness, cell width and cell length can be freely varied relative to one another.
  • the ratio of cell wall thickness to cell length is significantly small.
  • the wall has a maximum thickness of substantially 1 mm.
  • the unitary material is a polymer material.
  • the unitary material is an elastomer.
  • the unitary material is elastic-plastic and elastic-brittle.
  • the unitary material is Nylon 11.
  • the unitary material is ST Elastomer.
  • the hollow cell structure is manufactured by Laser Sintering.
  • the present invention may broadly be said to consist in a helmet, comprising an inner impact resistant liner at least partly formed form an impact absorbing structure as claimed in any one of the preceding statements.
  • the helmet further comprises an outer shell formed to substantially cover the inner impact resistant liner.
  • the outer shell is at least partly formed from a composite material.
  • the outer shell is at least partly formed from a thermoplastic material.
  • At least one vent slot is formed in the outer shell.
  • the invention may broadly be said to consist in a method of optimising an impact absorbing structure for improved impact absorption, comprising the steps of:
  • substantially all the cells of the hollow cell structure are formed as 2D hollow-cells.
  • substantially all the cells are formed so as to be aligned substantially out of plane.
  • the cells are formed as a micro-truss lattice.
  • the cells are formed as a crystal lattice structure.
  • At least a plurality of the cells are formed so as to tessellate.
  • At least a plurality of the cells are formed so as to tessellate with a cell axis normal to the surface or out-of-plane.
  • the hollow cells are formed to have a topology that propagates radially to a curved surface.
  • At least a plurality of the cells are formed as hexagons.
  • At least a plurality of the cells are formed as triangles.
  • At least a plurality of the cells are formed as squares.
  • At least a plurality of the cells are formed as a combination of octagons and squares co-located in a tessellating pattern.
  • the material is formed in such a manner that the material has a relative density substantially between 0.05 and 0.15.
  • the cells are formed so that the cell shape, size, cell wall thickness, cell width and cell length can be freely varied relative to one another.
  • the cells are formed so that the ratio of cell wall thickness to cell length is significantly small.
  • the cells are formed so that the wall has a maximum thickness of substantially 1 mm.
  • the unitary material is a polymer material.
  • the unitary material is an elastomer.
  • the unitary material is elastic-plastic and elastic-brittle.
  • the unitary material is Nylon 11.
  • the unitary material is ST Elastomer.
  • the hollow cell structure is manufactured by Laser Sintering.
  • This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
  • FIGS. 1 a - c show schematic views of single cells that form part of a cellular solid, showing the joints j and struts s which the cell shares with adjoining cells, the struts s forming surrounding faces that enclose the cells, FIG. 1 a showing a bending-dominated structure where the joints are locked and the frame bends as the structure is loaded, stretch-dominated structures shown in FIGS. 1 b and 1 c where the members carry tension or compression when loaded, giving higher modulus and strength.
  • FIGS. 2 a and 2 b show plots summarising the difference between stretch and bending-dominated structures in terms of relative modulus E/E s and relative strength ⁇ / ⁇ s against relative density p/p s .
  • FIG. 3 shows a perspective view from above, looking downwards and sideways, of a honeycomb hollow cell structure according to an embodiment of the present invention.
  • FIG. 4 shows a top view from directly above of the hollow cell structure of FIG. 3 .
  • FIG. 5 shows a section of a periodic lattice of hexagonal cells, showing the positions of the joints j and struts s for this stretch dominated structure.
  • FIG. 6 shows a perspective view from one side of an inner impact resistant liner of a cycle helmet, the inner impact resistant liner formed from a hollow cell structure similar to that shown in FIGS. 3, 4, and 5 , the liner shaped to follow and substantially conform to the top portion of a user's head.
  • FIG. 7 shows a perspective view directly from the rear of the inner impact resistant liner of FIG. 3 , with an outer shell covering the inner impact resistant liner, vent slots formed in the outer shell to allow air to circulate within the inner impact resistant liner.
  • FIG. 8 shows a perspective schematic view from the front and to one side of a test rig used to test samples of a hollow cell structure.
  • FIG. 9 is a graph showing the Head Injury Criterion (HIC) and peak acceleration for a range of test samples.
  • FIGS. 10 to 12 show test samples of honeycomb hollow cell structure according to embodiments of the present invention post-testing, each sample having a different relative density, FIG. 10 showing brittle failure at a relative density of 0.111, FIG. 11 showing plastic work at a relative density of 0.143, and FIG. 12 showing linear elastic deformation at a relative density of 0.25.
  • FIG. 13 shows a graphical plot of energy per volume vs peak acceleration for a range of test materials and conditions.
  • FIG. 14 shows graphical plots of acceleration vs time and force vs displacement for test pieces formed from Nylon 11, Elasto and EPS.
  • the liner foam is entirely responsible for dissipating the impact energy.
  • the reaction force is determined by the compressive strength of the foam.
  • a foam lattice is assumed to have a flat plateau compressive strength over its densification strain.
  • the foam only provides an ideal force-displacement curve if the compressed region is uniform in area.
  • the impact area or crush area is not constant, or planar: the contact area increases with displacement. This causes the reaction force to also increase.
  • the force-displacement gradient will be further reduced.
  • a foam liner needs to be thicker in order to provide adequate energy absorption by maintaining the peak acceleration below the safety legislation.
  • the consistent plateau stress of foam limits it's effectiveness as an energy absorbing structure when used as a curved structure (such as for example in a helmet) due to the inherent curved contact surface.
  • the other assumption is that the liner is formed as a unitary structure (that is, without gaps).
  • a structure that has a stiffness and strength higher than would otherwise be the case if creating the structure as a unitary structure formed from e.g. foam, for a given relative density p/p s (where p is the density of the foam and p s that of the bulk material), and this allows more energy to be dissipated per volume. It is also possible to create a structure that provides an initially high strength when the contact area is very low and which has a gradual post-yield softening proportional to the increase in contact area.
  • the impact-absorbing structure is formed as a hollow-cell structure which is stretch-dominated, such as for example a micro-truss lattice or out-of-plane honeycomb.
  • ⁇ d 1 - ( ⁇ ⁇ s ) / ( ⁇ crit ⁇ s )
  • p is the density of the structure and p s that of the bulk material
  • p crit /p s is the relative density (or volume fraction solid) at which the structure locks up.
  • the post-yield softening counteracts the area increase of a oval shaped helmet dissipating energy at a more uniform plateau force.
  • the relative density of a stretch-dominated structure can be much lower providing a greater densification strain and therefore increasing the potential energy dissipated over the same displacement.
  • stretch-dominated structure is a cellular solid.
  • a cellular solid is one made up of an interconnected network of solid struts or plates that form the edges and faces of cells.
  • the mechanical behaviour of cellular solids can be distinguished by bending-(foam) and stretch-(lattice) dominated mechanisms.
  • the Maxwell stability criterion is used to distinguish between bending- and stretch-dominated structures.
  • Cellular solids can be thought of as joints j, joined by struts s, which surround faces that enclose cells, as shown in FIG. 1 .
  • FIG. 1 a when the frame is compressed it has no stiffness or strength in the loading direction. If the joints are frozen (locked) the frame in FIG. 1 a will bend as the structure is loaded and can be called a bending-dominated structure.
  • the members carry tension or compression when loaded, giving higher modulus and strength. This is shown in FIGS. 2 a and 2 b , which summarise the difference between stretch and bending-dominated structures in terms of relative modulus E/E s and relative strength ⁇ / ⁇ s against relative density p/p s .
  • FIGS. 2 a and 2 b which summarise the difference between stretch and bending-dominated structures in terms of relative modulus E/E s and relative strength ⁇ / ⁇ s against relative density p/p s .
  • the structure carries self-stress, which means the struts carry stress even though the structure carries no external load (this is prevalent in FIG. 1 c ). For example if the vertical strut is shortened, it pulls the other struts into compression.
  • stretch-dominated structures as impact absorbing structures are as follows: firstly, the post-yield softening counteracts the area increase of a oval shaped helmet dissipating energy at a more uniform plateau force, and; secondly, for a given yield stress, the relative density of a stretch-dominated structure can be much lower providing a greater densification strain and therefore increasing the potential energy dissipated over the same displacement. This is discussed in detail in Appendix E.
  • the impact absorbing structure is formed as a lattice—i.e. from interconnected hollow cells.
  • a periodic lattice i.e. the cells are regularly shaped and sized. Hexagonal cells were used as this shape has the largest number of side and which will still regularly tessellate—i.e. without requiring a second shape to fill gaps (for example, if a regular octagon lattice was chosen, a regular square shape would be inherent). Hexagonal honeycomb cells have the highest number of cell walls for each cell, and therefore the lowest connectivity. which has been shown to be effective in high specific strength.
  • stretch dominated structures will also provide the same advantages.
  • 3-D stretch-dominated structures such as a truss structure or a structure similar to a crystal lattice structure can also be formed, which will provide the same impact absorption benefits.
  • the hollow cell stretch dominated structure 1 used in a first embodiment of the present invention is a unitary material formed into a honeycomb structure. It is preferred that the cells are hexagonal, as hexagonal cells 2 such as those used in the hollow cell structure 1 tessellate and so form a structure where each cell wall is common with an adjacent cell.
  • a grid formed from hexagonal cells also provides a balance between overall grid density (the total amount of material), and the layout/location of the cell wall material and the empty space which the cell walls encompass. That is, tessellation is achieved with the cell walls distributed over a given planar or curved surface as evenly as possible, with no overloaded focal areas, or over-large uncovered areas.
  • Hexagonal honeycomb can be thought of as a stretch dominated structure by applying the Maxwell criterion:
  • FIG. 4 shows a section of a periodic lattice of hexagonal cells, showing the positions of the joints j and struts s for this stretch-dominated structure.
  • the honeycomb structure In practical use, and when experiencing an impact, the honeycomb structure will experience both in-plane and out-of-plane loading.
  • Stretch-dominated structures such as the hexagonal hollow cell structure 1 are generally used in a planar or sheet form, either flat or curved, and the impacts received by the hollow cell structure have a primary force component directed into the plane perpendicular to the point of impact. That is, in the opposite direction to out-of-plane arrow 3 in FIG. 1 .
  • the forces received by the hollow cell structure have a primary force component directed into the plane perpendicular to the point of impact. That is, in the opposite direction to out-of-plane arrow 3 in FIG. 1 .
  • the theory behind this is discussed in detail in Appendix C.
  • the impact absorption properties of a stretch-dominated structure such as the hollow cell structure 1 are determined by the material used to form the structure, and the specific geometry of the structure: i.e. cell size, cell wall thickness, cell width and cell length as shown in FIG. 4 .
  • the lattice is designed so that the axial part of the cell is always perpendicular to the surface of the head. This is important as the crush strength of honeycomb significantly diminishes as the impact angle increases away from perpendicular to the axial part of the cell.
  • h is assigned a value of 1
  • ⁇ has a value of 30 (degrees)
  • the ratio of cell wall thickness (t) to cell length (l) is significantly small.
  • the material used to create the hollow cell structure 1 in this embodiment is Nylon 11 and ST Elastomer. This is a readily available material, which is lightweight, easily formed and malleable, and is therefore suitable or at least analogous to the type of material that would be used for mass-manufactured helmets.
  • the hollow cell structure 1 was manufactured by additive manufacturing. The process is briefly described in Appendix B.
  • Tests were carried out as detailed in Appendix A, and Appendix D, with the objective of determining how varying the relative density of the honeycomb hollow cell structure 1 (this type of structure also known as ‘out-of-plane honeycomb’) would affect the hollow cell structure 1 when subjected to impact testing.
  • the relative density was varied between 0.1 and 0.33 by changing the cell size (s) from between a minimum of 6 mm and a maximum of 20 mm, with the wall thickness maintained at a constant 1 mm.
  • results indicate that an acceptable range of optimum relative densities lies between 0.125 and 0.175 for this material and for the particular cell/lattice size and shape used during testing, for the reasons outlined in the ‘Results from Impact Testing’ section of Appendix A, and Appendix D.
  • results indicate that the cell size, cell wall thickness, cell width and cell length can be freely varied relative to one another, and as long as the relative density lies between 0.03 and 0.17, then the structure will provide optimised impact absorption properties.
  • helmet design is generally a trade-off between the overall weight of a helmet, and the impact-absorbing properties.
  • a helmet such as helmet 5 shown in FIGS. 3 and 4 , constructed using a structure the same as or similar to the inner impact resistant liner 7 (formed as a hexagonal hollow-cell stretch-dominated structure) covered by an outer shell 6 , formed from nylon 12 or a similar material, will provide a lightweight structure capable of meeting and exceeding the relevant standards for impact absorption, in particular BS EN 1078.
  • the test results indicate the elastic-plastic honeycomb has a 3 ⁇ greater EPV than a typical expanded polystyrene helmet. This is clearly shown by the plots of the experimental results shown in FIGS. 13 and 14 .
  • 2D hollow cells are referred to in this specification, this indicates a three-dimensional structure, with the cells of the structure formed in such a way as to have depth, but so that when viewed at a certain angle the cells will have a uniform or identical cross-section at any position perpendicular to the view angle. That is, a cross section taken at any position would be identical to one taken at any other position.
  • a honeycomb cell structure viewed in plan or from directly above will provide a uniform cross-section at any depth through the cells.
  • stretch-dominated this is according to the Maxwell criterion as outlined herein.
  • the phrases ‘relative density’ and ‘volume fraction solid’ essentially have the same meaning and are used interchangeably within this specification.

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US15/549,145 2015-02-04 2016-02-04 An impact absorbing structure and a helmet comprising such a structure Abandoned US20180027914A1 (en)

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GB1501834.4 2015-02-04
GBGB1501834.4A GB201501834D0 (en) 2015-02-04 2015-02-04 An impact absorbing structure
PCT/IB2016/050587 WO2016125105A1 (en) 2015-02-04 2016-02-04 An impact absorbing structure and a helmet comprising such a structure

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US (1) US20180027914A1 (de)
EP (1) EP3253243B1 (de)
CN (1) CN107635424B (de)
GB (1) GB201501834D0 (de)
WO (1) WO2016125105A1 (de)

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EP3253243A1 (de) 2017-12-13
EP3253243B1 (de) 2020-04-01

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