Helmet designs utilizing foam structures having graded properties

Abstract

Disclosed herein is a composite structure for deflecting and spreading kinetic energy transmission after various types of impacts utilizing foam structures having graded properties. The structure has a first composite layer, composed of a discrete reinforcement and a continuous binder. The helmet receives contact of an object that transfers kinetic energy to a first composite layer. The helmet uses a second composite layer adjacent to the first composite layer designed such that the second composite layer compresses and expands into an expansion zone in the second composite layer. The second composite layer has expansion structures with a graded modulus such that the material at the tip of an expansion structure has a low modulus and the modulus in the expansion structure increases as it moves from the tip to the base of the expansion structure.

We claim: 
     
         1 . A structure for reducing kinetic energy transmission, the structure comprising:
 a first composite layer configured as an outside layer that serves as first contact with a source of kinetic energy; and   a second composite layer, adjacent to the first composite layer comprising a first plurality of expansion structures in which each expansion structure of the first plurality of expansion structures has a base configured adjacent to the first composite layer and each expansion structure having a first tip, and a second plurality of expansion structures configured such that a respective second tip of each expansion structure of the second plurality of expansion structures is in contact with the first tip of a corresponding expansion structure of the first plurality of expansion structures in a mirrored configuration, such that when the source comes in contact with the first composite layer, the second composite layer compresses and at least one expansion structure of the first plurality of expansion structures and the second plurality of expansion structures expands into an expansion zone in the second composite layer.   
     
     
         2 . The structure of  claim 1 , wherein the first composite layer comprises a composite of at least two materials. 
     
     
         3 . The structure of  claim 2 , wherein the composite has a polymer matrix and a ceramic reinforcement. 
     
     
         4 . The structure of  claim 2 , wherein the composite has a polymer matrix and a glass reinforcement. 
     
     
         5 . The structure of  claim 3 , wherein the ceramic reinforcement is a fiber. 
     
     
         6 . The structure of  claim 1 , wherein the second composite layer comprises material that deforms under impact to transfer kinetic energy. 
     
     
         7 . The structure of  claim 1 , wherein the first plurality of expansion structures and the second plurality of expansion structures each comprises expansion structures having a graded modulus. 
     
     
         8 . The structure of  claim 7 , wherein the graded modulus comprises material at the tip of the expansion structure having a low modulus and the modulus in each expansion structure increasing as it moves from the tip to the base of each expansion structure. 
     
     
         9 . The structure of  claim 7 , wherein the graded modulus comprises material at the tip of the expansion structure having a high modulus and the modulus in each expansion structure decreasing as it moves from the tip to the base of each expansion structure. 
     
     
         10 . The structure of  claim 1 , wherein the expansion structures are comprised of flexible foam. 
     
     
         11 . The structure of  claim 10 , wherein the foam is comprised of polyurethane. 
     
     
         12 . The structure of  claim 1 , wherein each expansion structure in the first plurality of expansion structures has one of the same shape or a different shape. 
     
     
         13 . The structure of  claim 1 , wherein each structure of the first plurality of expansion structures differs in shape from each structure of the second plurality of expansion structures.