Impact absorbing devices and processes of operation of the impact absorbing devices

An impact absorbing device is disclosed for reducing a force exerted against a falling object upon impact of a falling object, the device comprising: a first layer including one or more baffles configured to undergo compression in response to the impact of the falling object, wherein pressure is increased as a result of restriction of air displacement and/or contents in the one or more baffles upon the compression of the one or more baffles and wherein increased pressure in the one or more baffles increases compression resistance of the one or more baffles causing the one or more baffles to exert a force which decelerates the falling object; and a second layer including one or more baffles layered on the one or more baffles of the first layer, wherein the one or more baffles of the second layer are configured to undergo compression in response to the compression of the one or more baffles of the first layer, wherein pressure is increased in the one or more baffles as a result of restriction of air displacement and/or contents in the one or more baffles upon the compression of the one or more baffles and wherein increased pressure in the one or more baffles increases compression resistance of the one or more baffles causing the one or more baffles into contact the first layer and exert a force which decelerates said falling object.

FIELD OF THE INVENTION

The present invention relates to impact absorbing devise and the process of operation of the impact absorbing devices.

BACKGROUND OF THE INVENTION

Impact absorbing devices such as impact absorbing mats are commonly used to prevent injuries from falls or tumbles in activities such as gymnastics, rock climbing, and any other activity where there is a risk of injury from falling from a height. Early impact absorbing devices include nets, spring beds, hay or cotton filled containers. Today, the most popular impact absorbing devices are foam based impact absorbing mats. Many of these devices largely consist of a block of foam or layers of foam, some of which include cavities, spaces or holes. Sealed air bladders are also a common impact absorbing device. Other examples of impact absorbing mats are disclosed in U.S. Pat. No. 4,137,583 to Baldwin, U.S. Pub. No. 20130043627 A1 to Chu, U.S. Pub. No. 2013/0086744 A1 to Silverman and WO2015197804 A1 to Lindsay. The ultimate goal of an impact absorbing device is to return as much force as the force produced by the object upon approach and impact. The return force should be consistent force over time to absorb the force or impact. However, most impact absorbing mats like these fail to provide the proper force as described.

BRIEF SUMMARY OF THE INVENTION

Impact absorbing devices and processes of operation of the impact absorbing devices are disclosed.

In accordance with an example of the present disclosure, an impact absorbing device is disclosed for reducing a force exerted against a falling object upon impact of a falling object, the device comprising: a first layer including one or more baffles configured to undergo compression in response to the impact of the falling object, wherein pressure is increased as a result of restriction of air displacement and/or contents in the one or more baffles upon the compression of the one or more baffles and wherein increased pressure in the one or more baffles increases compression resistance of the one or more baffles causing the one or more baffles to exert a force which decelerates the falling object; and a second layer including one or more baffles layered on the one or more baffles of the first layer, wherein the one or more baffles of the second layer are configured to undergo compression in response to the compression of the one or more baffles of the first layer, wherein pressure is increased in the one or more baffles as a result of restriction of air displacement and/or contents in the one or more baffles upon the compression of the one or more baffles and wherein increased pressure in the one or more baffles increases compression resistance of the one or more baffles causing the one or more baffles into contact the first layer and exert a force which decelerates said falling object.

In accordance with another example of the present disclosure, an impact absorbing device is disclosed for reducing a force exerted against a falling object upon impact of a falling object, the device comprising: a baffle configured to undergo compression in response to the impact of the falling object, wherein pressure is increased as a result of restriction of air displacement and/or contents in the baffle upon the compression of the baffle and wherein increased pressure in the baffle increases compression resistance of the baffle causing the baffle to exert a force which decelerates the falling object, and wherein the baffle includes one or more cells, each cell housing material configured to compress in response to compression of the impact of the object.

In accordance with another example of the present disclosure, a method is disclosed of decelerating a falling object by an impact absorbing device including a baffle with one or more cells configured to undergo compression in response to the impact of the falling object, each cell including a plurality of apertures, the method comprising: applying a first force on a first layer by a falling object; transferring the first force into a second layer by the first layer, wherein the second layer spreads the first force orthogonally to a direction of the first force; transferring the first force to a third layer by the second layer, thereby distributing the first force over a wider of the third layer than the second layer; compacting the third layer in response to the first force transferred, thereby expelling air out of the one or more cells by pressure and creating a second force created by air expulsion; transferring the second force to the first layer and object impacting the first layer; and reducing the velocity of the object in response to the second force.

DETAILED DESCRIPTION OF THE INVENTION

FIG.1illustrates a perspective view of an example impact absorbing mat100. The impact absorbing mat100is a form of an impact absorbing device. Impact absorbing devices are configured to reduce the force exerted against a falling object upon impact. An object may be any item or thing such as a gym weight or a body or body part (e.g., human, animal or other) as known to those skilled in the art. The impact absorbing mat100includes a damper layer110, a linear layer120and a top layer130. The downward arrow shown represents a downward force exerted by a falling object. InFIG.1, the layers are shown as horizontal layers when the impact absorbing mat100is positioned on a surface. However, these layers may be configured as vertical in other examples and configurations as known to those skilled in the art.

The damper layer110is positioned, i.e., sandwiched between the top layer130and the linear layer120. The damper layer110is in substantial contact with the top layer130and the linear layer120. The damper layer110is described below in further detail with respect toFIG.2andFIG.3. The linear layer120is described below in further detail with respect toFIG.4andFIG.5. The top layer130is described below with respect toFIG.6.

In operation, a falling object such as a gym weight exerts a downward force on the top layer130. A percentage or portion of the energy from the downward force is used to compress the top layer130. A percentage or portion of the remaining force presses or pushes the top layer130down into the damper layer110, distributing and transferring energy to the damper layer110. A portion of the energy transferred from the top layer130to the damper layer110is used to compress the damper layer110. The compression resistance of the damper layer110is related to the velocity of the falling object exerting the downward force on to the damper layer110. A portion of the remaining energy pushes the damper layer110down into the linear layer120, transferring energy from the damper layer110to the linear layer120. A portion of the energy transferred from the damper layer110to the linear layer120is used to compress the linear layer120. The compression resistance of the linear layer120is related to the depth of compression of the linear layer120from the downward force.

The shape of the impact absorbing mat100disclosed herein may be any three-dimensional shape as known to those skilled in the art including, for example, triangular prism, hexagonal block, cuboid, tetrahedron, cone, and cylinder. The impact absorbing mat100may be of any length, width and/or depth. Further, the impact absorbing mat100may be any volume. For example, a volume of 2 cubic feet to 1000 cubic feet may be used.

In other examples of the impact absorbing mat, the linear layer120may be excluded from the impact absorbing mat100or the damper layer110may excluded from the impact absorbing mat100and the linear layer110is in substantially contact with the top layer130. Alternatively, the linear layer120and the damper layer110of the impact absorbing mat100may be switched so the linear layer120is positioned between the top layer130and the damper layer110. The impact absorbing mat100may include 2 to 5 linear layers120. In one example, the impact absorbing mat100includes 2 to 3 linear layers120. In another example, the impact absorbing mat100includes 4 to 5 linear layers120. In examples of the impact absorbing mat with more than one linear layer120, the linear layers120may or may not be in contact with another linear layer120. In one example, the impact absorbing mat100may include 2 to 5 damper layers110. The damper layers110may or may not be in contact with another damper layer110. In one example, the impact absorbing mat100includes more than one damper layer110and more than one linear layer120. The damper layers110and the linear layers120may be configured in series or in parallel.

In one example of the impact absorbing mat, the damper layer110is combined with the linear layer120within the same layer. In this respect, the makeup of the materials inside the baffles of the damper layer110and the makeup of the materials inside the baffles of the linear layer120are combined within one baffle.

Now,FIG.2illustrates a perspective view of a damper layer110of the impact absorbing mat100inFIG.1. The damper layer110includes damper baffles210, a damper layer top surface220, a damper layer bottom surface230, and a damper layer perimeter surface240. The damper baffles210are described in further detail in the description ofFIG.3. The bold downward arrow shown represents a downward force exerted by a falling object. The damper baffles210are arranged to form the damper layer (110) top surface220, the damper layer bottom surface230, and the damper layer perimeter surface240of the damper layer110. The horizontal surfaces of the damper layer110include the damper layer top surface220and the damper layer bottom surface230. The vertical surfaces defining the outer edges of the damper layer110include the damper layer perimeter surface240. The damper layer top surface220is in contact with the top layer130, and the damper layer bottom surface230is in contact with the linear layer120as shown inFIG.1.

In operation, a falling object exerts a downward force on the damper layer110. The damper baffles210are compressed by the downward force. The damper baffles210resist compression, exerting a counter-force against the falling object. The magnitude of counter-force exerted by the damper baffles210is related to the velocity at which the object exerting the downward force is falling. The force exerted by the damper baffle210decelerates the falling object, while the compression of the damper baffle210extends the distance and period of time over which the deceleration takes place. This reduced rate of deceleration results in a smaller average force being exerted against the falling object. When the downward force is removed the damper baffles210expand back to substantially their original shape. The damper baffles210and internal operation are described below in further detail in the description ofFIG.3.

The damper baffles210may be any number of actual baffles as known to those skilled in the art to achieve desired results. In the example depicted inFIG.2, the damper layer110includes forty two damper baffles210. The distance separating the damper baffles210from adjacent damper baffles210(damper baffle separation) may be any distance in accordance with the number and composition of the baffles to achieve desired results as known to those skilled in the art. The damper baffles are configured in the shape of rectangular blocks and are arranged in a grid pattern to form rectangular block-shaped damper layer110. However, the baffles may have any shape as known to those skilled in the art to achieve desired results. For example, damper baffles201may be shaped as a cylinder as shown inFIG.11. Other examples, include triangular prims, hexagonal blocks, cuboid, sphere, tetrahedron and cone. The damper baffles may have any volume to achieve desired results. For example each baffle may have a volume of 0.25 feet3to 25 feet3. The damper layer110is a single damper baffle210. However, damper layer110may include any number of stacked layers of damper baffles210.

FIG.3illustrates a perspective view of a damper baffle210of the damper layer110of the impact absorber mat100inFIG.1.FIG.3excludes a portion of the front surface of the damper baffle210to expose (show) the inside of the damper baffle210. The damper baffle210includes a damper baffle compression resistance system310, a damper baffle casing320and a plurality of damper baffle air outlet/inlets350. The damper baffle casing320includes a damper baffle ceiling326, a damper baffle floor329, and a damper baffle side wall323. The damper baffle compression resistance system310includes sheeting315. The sheeting315includes a number of small apertures (holes) to enable air to pass through sheeting315upon impact. The sheeting315is arranged inside the damper baffle210to form a plurality of cells (or bags or cavities of air (i.e., air-filled cells). Sheeting315may thus also be referred to as cells315. The cells315are configured as bags that will crumple or compress under pressure. Sheeting315may be made of a single sheet folded or two or more sheets that create the cells as described in more detail below. The bold downward arrow represents a downward force exerted by a falling object. The damper baffle210includes air inlet/outlets350that extend through the damper baffle casing320. In this example, the sheeting315is made of plastic but it can be made of any material known to those skilled in the art configured to bend or move in response to force.

In the example depicted, the cells315are crumpled and balled. The crumpling of the cells315forms a large number of creases in a variety of directions in the sheeting315. The creases in the cells315create a complex geometry with a large number of surfaces (crumple surfaces) oriented in a variety of directions. Some of the crumple surfaces are in contact with other crumple surfaces. The crumpled sheeting315is packed into the damper baffle casing320within the damper baffle210. The pressure may be 1 psi or any pressure known to those skilled in the art.

In operation, a falling object exerts a downward force on the damper baffle210. The damper baffle210is compressed as the downward force deforms the damper baffle casing320and compacts the cells315. The bending stiffness of the damper baffle casing320causes the damper baffle casing320to resist deformation, exerting a force against the downward force. The term bending stiffness refers to the resistance of a material against bending deformation. Air is displaced from the damper baffle210through the damper baffle air outlet/inlets350as the volume of the damper baffle210is reduced from compression. The rate at which air flows through the air outlet-inlets350is limited. The velocity of air being displaced is proportional to the speed of the falling object. As the speed changes, so does the force. Thus, the increased pressure inside the damper baffle210increases the compression resistance of the damper baffle210, causing the damper baffle210to exert a force, i.e., a counter-force against the falling object.

In more detail, just after the object exerting the downward force impacts the mat, the downward force on the damper baffle210is at a maximum, resulting in an initial rapid compression of the damper baffle210and compaction of the crumpled sheeting or cells315. The air in the air-filled cells is either trapped or restricted from being freely displaced from the air-filled cells upon compression of the damper baffle210. The apertures in the cells315are of a size that restrict the rate that air moves through the apertures and out of the air-filled cells formed by the plastic sheeting315. The restricted air displacement results in a smaller volume of air being displaced over time from the air-filled cells than the reduction in volume over time to the air-filled cells from compression, causing the pressure inside the air-filled cells to increase. This increased pressure in the air-filled cells increases the compression resistance of the air-filled cells, and the damper baffle210as a whole. The increased compression resistance of the damper baffle210exerts an increased counter-force against the falling object. The counter-force exerted by the damper baffle210pushes against the falling object exerting the downward force, decelerating the falling object and reducing the downward force.

An object falling at a greater velocity results in a faster initial compression of the damper baffle210and the air-filled cells formed by the sheeting315than an object falling at a lower velocity. The more rapidly the air-filled cells are compressed, the more the volume reduction to the air-filled cells will also compress. Therefore, compared to an object falling at a lower velocity, an object falling at a greater velocity results in higher pressure inside the air-filled cells. The increased pressure in the air-filled cells increases the compression resistance of the air-filled cells, and the damper baffle210as a whole. The increased compression resistance of the damper baffle210results in a larger counter-force being exerted by the damper baffle210against the falling object. The compression resistance of the damper baffle210being dependent of the velocity of the falling object allows the damper baffle210to exert enough force to substantially decelerate an object falling at a high velocity while still being compressible by an object falling at a lower velocity.

As the downward force dissipates with time following the moment of impact, air continues to be displaced from the air-filled cells and the damper baffle210, reducing the pressure in the air-filled cells and the damper baffle210. This reduction in pressure results in a decreasing counter-force exerted by the damper baffle210against the falling object. This reduced counter-force exerted by the damper baffle210continues to push against the falling object, further decelerating the falling object until either the damper baffle210is fully compressed or the magnitude of the force exerted by the damper baffle210meets or exceeds the magnitude of the downward force, ceasing the downward motion of the falling object. The compression of the damper baffle210extends the distance and period of time over which the deceleration of the falling object takes place. This reduced deceleration rate results in less force being exerted against the falling object.

When the downward force is removed, the elasticity of the cells315cause the compacted sheeting315to expand and push the damper baffle casing320outward, expanding the damper baffle210to substantially its original shape. Expansion of the damper baffle210results in negative pressure inside the damper baffle210, causing air to be drawn into the damper baffle210through the damper baffle air outlet/inlet350.

Compression resistance of the damper baffle210may be tuned in a variety of ways. First, tuning maybe achieved through adjusting the packing pressure of the sheeting315inside the damper baffle210. The term packing pressure refers to the internal pressure in a container caused by packing a material into the container. Increasing the packing pressure of the plastic sheeting315increases the compression resistance of the damper baffle210. Decreasing the packing pressure of the sheeting315decreases the compression resistance of the damper baffle210. The packing pressure of the sheeting315in the damper baffle210, for example maybe between 0 psi to 5 psi but could be designed to be any pressure to achieve desired results.

Second, compression resistance of the damper baffle210may be tuned through the thickness of the sheeting315. Increasing the thickness of the sheeting315increases bending stiffness, and thus increases the compression resistance of the damper baffle210. Decreasing the thickness of the sheeting315decreases bending stiffness, and thus decreases the compression resistance of the damper baffle210. In addition, the sheeting315may be have a variety of thicknesses. For example, sheeting315may have a thickness of 0.05 millimeters to 1.5 millimeters. However, the thickness may be of any measurement as known to those skilled in the art to achieve desired results.

Third, compression resistance of the damper baffle210may be tuned through using sheeting315with differing bending stiffness. A material with a lower bending stiffness will deform under a lower magnitude of pressure than a material with a higher bending stiffness. Increasing the bending stiffness of the sheeting315increases the compression resistance of the damper baffle210. Decreasing the bending stiffness of the sheeting315decreases the compression resistance of the damper baffle210. In yet another example (fourth), compression resistance of the damper baffle210may be tuned through the selection of the type of material of the sheeting315. The sheeting315may be of a material that is easy to manufacture (or having a low compression resistance, i.e., Young's modulus). If the sheeting is made of plastic(s), examples of the materials include commodity and engineering thermoplastics and thermosets such as polyethylene, polyurethane, polyvinyl, polypropylene, polycarbonate and polystyrene. In yet another example, (fifth), compression resistance of the damper baffle210may be tuned through the air permeability of the sheeting315. Increasing the air permeability of the sheeting315decreases the compression resistance of the damper baffle210. Decreasing the air permeability of the plastic sheeting315increases the compression resistance of the damper baffle210. In yet another example (sixth), compression resistance of the damper baffle210is tuned by including apertures in the plastic sheeting315. The addition of apertures to the plastic sheeting315increases the air permeability of the plastic sheeting315and decreases the compression resistance of the damper baffle210.

In yet another example, compression resistance of the damper baffle210is tuned through the air permeability of the material comprising the damper baffle casing320. Increasing the air permeability of the damper baffle casing320decreases the compression resistance of the damper baffle210. Decreasing the air permeability of the damper baffle casing320increases the compression resistance of the damper baffle210. In yet another example, compression resistance of the damper baffle210is tuned through the bending stiffness of the material comprising the damper baffle casing320. For the damper baffle210to compress, the damper baffle casing320deforms. Increasing the bending stiffness of the damper baffle casing320increases the deformation resistance of the damper baffle casing320and thus increases the compression resistance of the damper baffle210. Decreasing the bending stiffness of the damper baffle casing320decreases the compression resistance of the damper baffle210.

In the example described above with respect to the baffles210, the cells315includes apertures. The size of the apertures may between may have a diameter of 0.1 millimeters to 30 millimeters. However, the size of the apertures may be varied to achieve desired results. In addition, sheeting315need not include apertures. The number of apertures may also vary to achieve desired results. Examples include 1 to 10000 apertures per square foot. The damper baffles210are packed with sheeting315having varying levels of air permeability.

In the example described above, the sheeting or cells315are plastic bags.

Examples of the damper baffle casing320construction includes synthetic textile, natural textile, plastic, foam, epoxy, mesh, plastic sheets, and paper. The damper baffle ceiling326, the damper baffle floor329, and the damper baffle side wall323may be made of the same or different materials. In on example, the damper baffle casing320includes a breathable textile which functions as the damper baffle air inlet/outlet350. The damper baffle air inlet/outlet350includes one or more apertures in the damper baffle casing320. In one example, the damper baffle air inlet/outlet350includes one or more valves connected to the damper baffle casing320.

In one example, a continuous piece of material may be used for the damper baffle ceiling326of multiple damper baffles210. In another example, a continuous piece of material may be used for the damper baffle ceiling326of all of the damper baffles210in the damper layer110. In another example, a continuous piece of material may be used for the damper baffle floor329of multiple damper baffles210. A continuous piece of material comprises the damper baffle floor329of all of the damper baffles210in the damper layer110.

The shape of the damper baffle210may be any three-dimensional shape. For example, the shape of the damper baffle210may be triangular prism, hexagonal block, cuboid, sphere, tetrahedron, cone, and cylinder.

In one example, the elasticity of the damper baffle casing320is sufficient to restore the damper baffle210to its original shape when the downward force is removed. In another example, the damper baffle210includes an internal structure. The flexible internal structure resists compression and provides sufficient elasticity to return the damper baffle210to its original shape when the downward force is removed.

FIG.4illustrates a perspective view of a linear layer120of the impact absorbing mat100inFIG.1. The linear layer120includes a plurality of linear baffles410, a linear layer top surface420, a linear layer bottom surface430, and a linear layer perimeter surface440. The linear baffles410are described in further detail in the description ofFIG.5. The bold downward arrow shown represents a downward force exerted by a falling object.

The plurality of linear baffles410are arranged to form the linear layer top surface420, the linear layer bottom surface430, and the linear layer perimeter surface440of the linear layer120. The horizontal surfaces of the linear layer120are comprised of the linear layer top surface420and the linear layer bottom surface430. The vertical surfaces defining the outer edges of the linear layer120include the linear layer perimeter surface440. In the example depicted, the linear layer120includes forty two linear baffles410. The distance separating the linear baffles410from adjacent linear baffles410(linear baffle separation) is about 1 inch. However, any number of baffles410with a specified separation may be used as known to those skilled in the art to achieve desired results. The linear baffles410are roughly in the shape of rectangular blocks and are arranged in a grid pattern to form a rectangular block-shaped linear layer120. However, baffles410may have any shape and arrangement to achieve desired results. As discussed above in the description ofFIG.1, the damper layer110is positioned above and rests on top of the linear layer120in this example.

In operation, a falling object exerts a downward force on the linear layer120. The downward force compresses the linear baffles410. The linear baffles410resists compression, exerting a force back against the downward force. The more the linear baffle410is compressed, the greater the counter-force exerted by the linear baffle410against the falling object. The counter-force exerted by the linear baffle410decelerates the falling object, while the compression of the linear baffle410extends the distance and period of time over which the deceleration takes place. This reduced rate of deceleration results in less force being exerted against the falling object. When the downward force is removed, the linear baffles410expand back to their original shape. The linear baffles410are described in further detail in the description ofFIG.5.

The shape of the linear baffles410may be any number of baffles and may be any three-dimensional shape. For example, the shape of the linear baffles410may be a triangular prism, hexagonal block, cuboid, sphere, tetrahedron, cone and cylinder as shown inFIG.12and described below. The linear baffles410may be in contact with each other or separated. In one example, the shape of the linear layer top surface420and the linear layer bottom surface430of the linear layer120may be oval, circle, square, rectangle, triangle, pentagon, hexagon, heptagon, octagon, nonagon, and dodecagon. The linear layer120includes a single linear baffle410, but layer120may include two or more stacked layers baffles410.

FIG.5illustrates a perspective view of a linear baffle410according to an embodiment of the present disclosure.FIG.5excludes a portion of the front surface of the linear baffle410to expose (show) the inside of the linear baffle410. The linear baffle410includes a linear compression resistance system510, a linear baffle casing520(comprised of a synthetic textile or other material known to those skilled in the art), and linear baffle air outlet/inlets550. The linear compression resistance system510includes a linear filling material515. In this example, the linear filling material515includes irregularly shaped three-dimensional pieces of expanded polystyrene foam. The pieces of expanded polystyrene foam may be of any size to achieve desired results For example, the foam may be between about 0.1 and 0.5 inches wide in each direction. The linear baffle casing520includes a linear baffle ceiling526, a linear baffle floor529, and a linear baffle side wall523. The bold downward arrow shown represents a downward force exerted by a falling object.

The linear baffle side wall523defines the vertical surfaces of the linear baffle410, and the linear baffle ceiling526and the linear baffle floor529define the horizontal surfaces of the linear baffle410to form a container. In this example, the linear baffle casing520is arranged to form a rectangular block shaped linear baffle410. The linear baffle air inlet/outlet550is connected to the linear baffle casing520. The linear filling material515is packed into the linear baffle casing520to any pressure to achieve desired pressure. For example, linear baffle410may have a pressure of about 2 psi.

In operation, a falling object exerts a downward force on the linear baffle410. The linear baffle casing520deforms and the linear filling material515is compressed in the direction of the downward force. The reduction in volume to the linear baffle410cause the air in the linear baffle410to be displaced through the linear baffle air outlet/inlets550. The bending stiffness of the linear baffle casing520causes the linear baffle casing520to resist deformation, exerting a counter force against the falling object. The linear filling material515also resists compression, also exerting a counter-force against the falling object.

Consistent with the Poisson effect, compression of the linear filling material515in the direction of the downward force causes the linear filling material515to expand in the two axes perpendicular to the downward force. The expansion of the linear filling material515in the two axes perpendicular to the downward force exerts a force outward against other linear filling material515of the linear baffle410in the two axes perpendicular to the downward force. The force exerted against the other linear filling material515in the two axes perpendicular to the downward force compress the other linear filling material515, and also pushes the other linear filling material515into the linear baffle side wall523. The other linear filling material515resists compression, exerting a force back inward against the expansion of the linear filling material515in the two axes perpendicular to the downward force. The bending stiffness of the material comprising the linear baffle side wall523and the tension in the linear baffle side wall523from the linear baffle side wall523being attached to the linear baffle ceiling526and the linear baffle floor529cause the linear baffle side wall523to resist deformation. The deformation resistance of the linear baffle side wall523causes the linear baffle side wall523to exert a force back inward against the expansion of the linear filling material515in the two axes perpendicular to the downward force. The inward forces exerted by the other linear filling material515and the linear baffle side wall523restrict compression of the linear filling material515in the direction of the downward force. The restricted compression of the linear filling material515exerts an additional counter-force against falling object.

As the linear baffle410is compressed further, the linear filling material515expands further in the two axes perpendicular to the downward force. The further expansion of the linear filling material515in the two axes perpendicular to the downward force exerts additional force outward against the linear baffle side wall523, and other linear filling material515of the linear baffle410, in the two axes perpendicular to the downward force. The bending stiffness of the linear baffle side wall523causes the linear baffle side wall523to continue resisting deformation, and the other linear filling material515continue to resist compression, exerting additional force back inward against the expansion of the linear filling material515in the two axes perpendicular to the downward force. The additional inward force exerted by the linear baffle side wall523further restricts compression of the linear filling material515in the direction of the downward force. The further restricted compression of the linear filling material515causes the linear filling material515to exert an increased counter-force against falling object.

The more the linear baffle410is compressed in the direction of the downward force, the more force the linear baffle410exerts back against the downward force. The compression-depth-dependent compression resistance of the linear baffle410results in the falling object being more rapidly decelerated as the linear baffle410becomes more compressed. The falling object is initially decelerated at a slower rate, minimizing the force exerted on the falling object. As the downward force of the falling object further compresses the linear baffles410, the falling object is decelerated at a faster rate, resulting in a greater force being exerted against the falling object, but preventing the force of the falling object from completely compressing the linear baffle410. Complete compression of the linear baffle410can result in a sudden deceleration of the falling object exerting the downward force, and a large amount of force being exerted against the falling object.

When the downward force is removed, the elastic properties of the linear filling material515and the linear baffle casing520cause the pieces of linear filling material515to return to substantially their original shape, returning the linear baffle casing520inward, expanding the linear baffle410to substantially its original shape. Expansion of the linear baffle410results in negative pressure inside the linear baffle410, causing air to be drawn into the linear baffle410through the linear baffle air outlet/inlet550.

In one example, compression resistance of the linear baffle410is tuned through adjusting the packing pressure of the linear filling material515. Increasing the packing pressure of the linear filling material515increases the compression resistance of the linear baffle410. Decreasing the packing pressure of the linear filling material515decreases the compression resistance of the linear baffle410.

In one embodiment, the packing pressure of the linear filling material515in the linear baffle410is 0 psi to 5 psi but the packing pressure could be any number.

Linear baffle may be tuned to any compression as follows. For example, compression resistance of the linear baffle410is tuned through the compression resistance of the linear filling material515. Increasing the compression resistance of the linear filling material515increases the compression resistance of the linear baffle410. Decreasing the compression resistance of the linear filling material515decreases the compression resistance of the linear baffle410.

For example, compression resistance of the linear baffle410is tuned through the selection of the type of material comprising the linear filling material515. In yet another example, compression resistance of the linear baffle410is tuned through the Poisson ratio of the linear filling material515. Increasing the Poisson ratio of the linear filling material515increases the compression resistance of the linear baffle410. Decreasing the Poisson ratio of the linear filling material515decreases the compression resistance of the linear baffle410.

The linear filling material515is a closed cell foam such as polyethylene foam, open cell foam such as polyurethane foam, and latex rubber foam, expanded polystyrene, polystyrene, polyvinyl, polypropylene, polycarbonate, shredded paper, shredded plant product, shredded plastic, shredded cloth or any other material known to those skilled in the art.

The shape of the pieces of linear filling material515may be any three-dimensional shape. For example, the shape of the pieces of linear filling material515may be triangular prism, hexagonal block, cuboid, sphere, tetrahedron, cone, irregular shapes and cylinder. In one example, the linear baffles410are packed with linear filling material515pieces having a variety of volumes. In another example, the linear filling material515includes multiple types of different material. The linear filling material515includes one type of material or may include many materials. The linear baffle casing520may include one or more materials such as synthetic textile, natural textile, plastic, foam, epoxy, mesh, and paper. The linear baffle ceiling526, the linear baffle floor529, and the linear baffle side wall523may be the same materials or different materials. The linear baffle casing520may include a breathable textile which functions as the linear baffle air inlet/outlet550. Alternatively, the linear baffle air inlet/outlet550may be one or more apertures in the linear baffle casing520or one or more valves connected to the linear baffle casing520. The valves communicate air between the inside of the linear baffle410and the outside environment.

In another example, compression resistance of the linear baffle410is tuned through the air permeability of the material comprising the linear baffle casing520. Increasing the air permeability of the linear baffle casing520decreases the compression resistance of the linear baffle410. Decreasing the air permeability of the linear baffle casing520increases the compression resistance of the linear baffle410.

In another example, of linear baffle compression, compression resistance of the linear baffle410may be tuned through the bending stiffness of the material comprising the linear baffle casing520. Increasing the bending stiffness of the linear baffle casing520increases the compression resistance of the linear baffle410. Decreasing the bending stiffness of the linear baffle casing520decreases the compression resistance of the linear baffle410. A continuous piece of material may be used for the linear baffle ceiling526of multiple linear baffles410. A continuous piece of material may be used for the linear baffle floor529of multiple linear baffles410.

The linear baffle410may be configured to be any three-dimensional shape. For example, the shape of the linear baffle410is selected from a list including: triangular prism, hexagonal block, cuboid, sphere, tetrahedron, cone, and cylinder.

In one example, the elasticity of the linear baffle casing520is sufficient to restore the linear baffle410to its original shape when the downward force is removed.

In one example, the expansion of the linear baffles410in the two axes perpendicular to the downward force causes the linear baffles410to exert a force in the two axes perpendicular to the downward force against adjacent linear baffles410in the linear layer120. This force further increases compression resistance of the adjacent linear baffles410and increases the compression resistance of the linear layer120. In another example, the linear baffle410includes an internal structure that resists compression and provides sufficient elasticity to return the linear baffle410to its original shape when the downward force is removed. In another example, the baffles in linear layer120may be entirely hollow, housing only air. In this example, the linear baffle casing may be non-porous (i.e., the baffle encapsulates air).

FIG.6illustrates a perspective view of a top layer130according to an embodiment of the present disclosure. The top layer130includes a sheet of expanded polystyrene foam610. The bold downward arrow represents a downward force exerted by a falling object.

In operation, a falling object exerts a downward force on the top layer130. The sheet of expanded polystyrene foam610provides an even surface upon which the falling object makes impact. The sheet of expanded polystyrene foam610is relatively rigid, and thus distributes the downward force over a greater area. If the sheet of expanded polystyrene foam610is rigid enough, the downward force will be distributed over more than just the area compressed by the falling object on the top layer130. The downward force is spread over multiple of the plurality of damper baffles210comprising the damper layer110. The even surface provided by the sheet of expanded polystyrene foam610also makes the impact absorbing mat100easier to walk on. Top layer130may include any number of sheets of foam (e.g. 1, 2 or more).

The foam610may be closed cell foam such as polyethylene foam, open cell foam such as polyurethane foam or latex rubber foam, expanded, polystyrene, polyvinyl, polypropylene, and polycarbonate. In one example, the top layer130includes multiple sheets of foam610of one type or multiple types. In one example, the shape of the horizontal surfaces of the top layer130may include any two-dimensional shape such as oval, circle, square, rectangle, triangle, pentagon, hexagon, heptagon, octagon, nonagon, and dodecagon.

FIG.7illustrates a front view of the impact absorbing mat100encased in an impact absorbing mat cover710. The impact absorbing mat cover710includes a mat cover material720with a zipper723, a cover aperture725and a mat cover air outlet/inlet728. The bold downward arrow shown represents a downward force exerted by a falling object.

The zipper723is fastened to the mat cover material720. The zipper723defines the border of the cover aperture725in the mat cover material720. The impact absorbing mat100is placed inside the impact absorbing mat cover710through the cover aperture725. The zipper723closes to fully encase the impact absorbing mat100in the impact absorbing mat cover710. The mat cover air outlet/inlet728is connected to the mat cover material720.

In operation, a falling object impacts the impact absorbing mat cover710. Most of the downward force exerted by the falling object is passed through the impact absorbing mat cover710and to the top layer130of the impact absorbing mat100. Air is displaced through the mat cover air outlet/inlet728upon compression of the impact absorbing mat100. The impact absorbing mat cover710protects the impact absorbing mat100from direct contact with the falling object and assists in keeping the impact absorbing mat100clean and protected from outside environmental conditions.

In one example, the mat cover material720is made of a material that has durable properties such as vinyl, synthetic textile, natural textile, plastic sheet, foam, epoxy, mesh, and paper. In another example, the zipper723is replaced with Velcro, clips, buttons, stitching and ties or any combination of these attachment mechanisms. The mat cover air outlet/inlet728may be a valve and/or an aperture. In an example mat cover, the mat cover material720includes an air permeable material which functions as the mat cover air outlet/inlet728.

FIG.8illustrates a perspective view of another example (second) impact absorbing mat800. The impact absorbing mat800includes a damper layer110, a linear layer120and a top layer130. The bold downward arrow shown represents a downward force exerted by a falling object.

The second impact absorbing mat800differs from the first impact absorbing mat100in that the positions of the damper layer110and the linear layer120are switched. The linear layer120is positioned between the top layer130and the damper layer110(bottom). The linear layer120is in substantial contact with the top layer130and the damper layer110.

In operation, a falling object exerts a downward force on the top layer130. A percentage or portion of the energy from the downward force is used to compress the top layer130. The top layer130functions as described above in the description ofFIG.6. A percentage or portion of the remaining energy pushes the top layer130down into the linear layer120, distributing and transferring energy to the linear layer120. A percentage or portion of the energy transferred from the top layer130to the linear layer120is used to compress the linear layer120. The compression resistance of the linear layer120is related to the depth of compression of the linear layer120from the downward force. The linear layer120functions as described above in the descriptions ofFIG.4andFIG.5. A percentage or portion of the remaining energy pushes the linear layer120down into the damper layer110, transferring energy from the linear layer120to the damper layer110. A portion of the energy transferred from the linear layer120to the damper layer110is used to compress the damper layer110. The compression resistance of the damper layer110is related to the velocity of the falling object exerting the downward force on the damper layer110. The damper layer110functions as described above in the descriptions ofFIG.2andFIG.3.

FIG.9illustrates another example of the damper baffle210. This particular example differs from the example of the damper baffle210depicted inFIG.3in that the sheeting315of the damper baffle compression resistance system310is arranged differently to form the air-filled cells. The sheeting315contains apertures as described above with respect to the description ofFIG.3. In this example, the sheeting315includes several sheets made of plastic (or plastic sheeting). Each of the plastic sheets are connected to the damper baffle ceiling326, the damper baffle floor329, and two parallel surfaces of the damper baffle side wall323. In this example, the air-filled cells are rectangular-block-shaped and are defined by the sheeting315and the damper baffle floor329, damper baffle ceiling326and the damper baffle side wall323.

In operation, this particular example, the damper baffle210differs from the example of the damper baffle210described above inFIG.3in that the sheeting315is not crumpled or packed into the damper baffle210. The sheeting315does not cause the damper baffle210to expand and return to its original shape due to lack of packing pressure and elasticity of the sheeting315. Instead, in this example, the damper baffle floor329, damper baffle ceiling326and the damper baffle side wall323have sufficient elasticity for the damper baffle210to return to substantially its original shape when the downward force is removed.

In one example, the damper baffle210includes a semi-rigid internal structure that resists compression and provides sufficient elasticity to return the damper baffle210to its original shape when the downward force is removed. The sheeting315in this example is oriented horizontally. Each sheet is connected to each surface of the damper baffle side wall323.

The damper baffle compression resistance system310may have any number of sheets for sheeting315. Examples include 2 to 30 sheets. In one example, the damper baffle210includes linear filling material515inside the air-filled cells.

In one example, the packing pressure and elasticity of the linear filling material515in the damper baffle210cause the damper baffle210to expand and return to substantially its original shape when the downward force is removed. In another example, the damper baffle210includes crumpled sheeting315inside the air-filled cells.

In one example, the air-filled cells are configured as an envelope including the aperture-containing sheeting315. The linear filling material515is included inside the air-filled cells formed by the sheeting315. The air-filled cells are packed inside the damper baffle210. The elasticity of the linear filling material515causes the linear filling material515to re-expand when the downward force is removed, causing the air-filled cells to self-inflate.

FIG.10illustrates another (third) impact absorbing mat. The impact absorbing mat1000includes a top layer130and a combined damper/linear layer1010. The combined damper/linear layer1010includes damper/linear baffles1020. The damper/linear baffles1020include a damper compression resistance system, a linear compression resistance system and a damper/linear baffle casing material1030. The damper compression resistance system includes sheeting. The sheeting is a plastic sheeting. The linear compression resistance system includes a linear filling material. The damper/linear baffle casing material1030includes a damper/linear baffle air outlet/inlet1040. The bold downward arrow shown represents a downward force exerted by a falling object.

The impact absorbing mat1000differs from the impact absorbing mat100in that the damper compression resistance system and the linear compression resistance system are both included in each of the damper/linear baffles1020. The impact absorbing mat100includes one layer (the linear layer120) with baffles containing the linear compression resistance system510, and a separate layer (the damper layer110) with baffles containing the damper compression resistance system310.

The walls of the damper/linear baffles1020are defined by the damper/linear baffle casing material1030to form a container. The damper/linear baffle air outlet/inlet1040is connected to the damper/linear baffle casing material1030. The crumpled sheeting and the linear filling material is packed inside each of the damper/linear baffles1020. Adjacent damper/linear baffles1020of the damper/linear layer1010are distance (e.g., about 3 inches) from each other.

The damper/linear baffles1020are sized and arranged such that they combine to form a surface that has suitable dimensions for the top layer130to be stacked on top of the damper/linear layer1010. In the example depicted the damper/linear baffle casing material1030is arranged so that the damper/linear baffles1020are roughly in the shape of rectangular blocks. In the example depicted, the damper/linear baffles1020are arranged in a grid pattern to form a roughly rectangular block-shaped damper/linear layer1010.

In operation, a falling object exerts a downward force on the top layer130. A percentage or portion of the energy from the downward force is used to compress the top layer130. A percentage or portion of the remaining energy pushes the top layer130down into the damper/linear layer1010, distributing and transferring energy to the damper/linear layer1010. A percentage or portion of the energy transferred from the top layer130to the damper/linear layer1010is used to compress the damper/linear layer1010.

The compression resistance of the damper/linear layer1010is related to the velocity of the falling object exerting the downward force on the damper/linear layer1010and the depth of compression of the damper/linear layer1010from the downward force. The damper/linear baffles1020are compressed as the downward force deforms the damper/linear baffle casing material1030and compresses the crumpled sheeting and the linear filling material. Air is displaced from the damper/linear baffle1020through the damper/linear baffle air outlet/inlet1040as the volume of the damper/linear baffle1020is reduced from compression. The damper/linear baffle casing material1030, the crumpled sheeting and the linear filling material each resist compression/deformation, exerting a force against the downward force. Just after the falling object impacts the mat, the downward force on the damper/linear baffle1020will be at a maximum, resulting in an initial rapid compression of the damper/linear baffle1020

The packed crumpled sheeting operates in the same way as the crumpled sheeting315described above in the description ofFIG.3. The linear filling material operates in the same way as the linear filling material515described above in the description ofFIG.5.

When the downward force is removed, the crumpled sheeting and the linear filling material expand and push the damper/linear baffle casing material1030outward, restoring the damper/linear baffle1020to substantially its original shape. Air is drawn into the damper/linear baffle1020through the damper/linear baffle air outlet/inlet1040as expansion of the damper/linear baffle1020results in negative pressure inside the damper/linear baffle1020.

In one example, the damper/linear baffles1020are filled so that the crumpled sheeting is packed in a portion of the damper/linear baffles1020that is further from the top layer130than the linear filling material, and the linear filling material is packed in a portion of the damper/linear baffles1020closer to the top layer130than the crumpled sheeting.

In one embodiment, the damper/linear baffles1020are filled so that the linear filling material is packed in a portion of the damper/linear baffles1020that is further from the top layer130than the crumpled sheeting, and the crumpled sheeting315are packed in a portion of the damper/linear baffles1020closer to the top layer130than the linear filling material.

In one example, the damper/linear baffles1020are filled so that the linear filling material and crumpled sheeting are both distributed throughout the damper/linear baffle1020. In one example, the ratio by volume of linear filling material to crumpled sheeting packed in the damper/linear baffles1020may be 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:12, 1:14, 1:16, 1:18, 1:20, 1:30 or any ratio known to those skilled in the art to achieve desired results.

The packing pressure of the linear filling material and the crumpled sheeting inside the damper/linear baffles1020may be configured to be from 0 psi to 5 psi. However, any pressure may be used to achieve desired results as known to those skilled in the art.

FIG.11illustrates a flowchart1100of an example process for reducing the force exerted against a falling object upon impact by the impact absorbing mat100inFIG.1. The process begins at step1110wherein the falling object impacts the top layer130of the impact absorbing mat100, exerting a downward force on the top layer130. Then, at step1140, the downward force pushes the top layer130down into the damper layer110, distributing and transferring energy to the damper layer110. The top layer130is described in further detail above with respect toFIG.6.

Next, at step1150, a percentage or portion of the energy transferred from the top layer130to the damper layer110is used to compress the damper layer110. Next, at step1160, the damper layer110resists compression, exerting a first counter-force against the falling object. The first counter-force further decelerates the falling object. The damper layer110is described in further detail above in the descriptions ofFIG.2andFIG.3.

Next, at step1170, a portion of the remaining energy pushes the damper layer110down into the linear layer120, transferring energy from the damper layer110to the linear layer120. Next, at step1180, a portion of the energy transferred from the damper layer110to the linear layer120is used to compress the linear layer120. Next, at step1190, the linear layer120resists compression, exerting a second counter-force against the falling object. The second counter-force further decelerates the falling object. The linear layer120is discussed in further detail above with respect toFIG.4andFIG.5.

As described above, the steps depicted inFIG.11apply to the impact absorbing mat100ofFIG.1. The process steps however also apply to the impact absorbing mat800ofFIG.8(for example), but the layers shown in steps in steps1140,1150,1160,1170,1180and1190are switched. That is, in this in step1140, the motion of an object induces the top layer of the mat into contact with the linear layer (instead of damper layer) of the mat. In step1150, the linear layer of the mat is compressed. In step1160, the compression resistance of linear layer exerts a first (counter) force against the falling object and the motion of the object induces the linear layer of the mat into contact with the damper layer of the mat at step1170. At steps1180and1190, the damper layer of the mat is compressed and the compression resistance of the damper layer exerts a second counter-force against the falling object.

FIG.12illustrates a section of a perspective view of another example impact absorbing mat1200.FIG.13illustrates a cross sectional view of the impact absorbing mat1200inFIG.12along line13-13.FIG.14illustrates a cross sectional view of a cell within a baffle of the impact absorbing mat inFIG.12. The arrow shown represents force from an object on the impact absorbing mat1200.

Impact absorbing mat1200actually extends a length defined by several walls including walls1202,1204,1206that function (in part) as boundaries for several layers within mat1200. The walls themselves function as a durable cover for the mat1200that are (walls) made of material such as vinyl, synthetic textile, natural textile, plastic sheet or any other durable material known to those skilled in the art. The layers within walls include a top layer1208, a linear layer1210and a damper layer1212. In this example (as opposed to the example mat100inFIG.1), the linear layer1210is sandwiched in between the top layer1208and the damper layer1212. The top layer1208is a solid layer constructed of a closed cell foam such as polyethylene foam or an open cell foam such as polyurethane foam.

The linear layer1210includes several baffles1214that are each configured in a cylindrical shape that extends across the mat1200(in a parallel to each other). Each baffle1214is filled with expanded polystyrene pellets, but it may be filled with other materials or the same material in different size or form to achieve desired results.

The damper layer1212also includes several baffles1216that extend across the mat1200in parallel to one another. Each baffle1216in the damper layer1212incorporates several holes in the walls that define the shape of the baffle1214to enable air to escape when the baffle1214is compressed. Alternatively, each baffle1214may be made of a material that is porous to enable air to escape when the baffle1214is compressed. Linear layer baffles1214are wedged in between, i.e., staggered with respect to damper layer baffles1216. This construction creates air pockets or cavities between the linear layer1210and damper layer1212. This configuration helps support and maintain a compact, uniform and slender profile of impact absorbing mat1200

The baffles1216of damper layer1214incorporate or house a number of cells1218similar to the cells described above that are defined by the sheeting. In this example, each cell1218(sheeting) forms an enclosure or balloon which functions to house several strips1222or other material within its walls as described in detail below. Each cell1218also has several small holes (apertures)1220in the sheeting walls thereof that enable air to escape when the cell1218is compressed and crumpled. Alternatively, the cells may be made of a porous material that enables air to escape through the holes (apertures) as part of the material.

As indicated above, cells1218each incorporate content in the form of strips1220that are configured in a confetti like shape. The strips1220are made of plastic material known as beta (β) crystalline polypropylene (BCPP). BCPP is used as the strip material for the content of each cell as it enables the impact attenuation device to return to its original shape from a compressed state when under no external loading. BCPP has unique properties which enable this happen. In this respect, the plastic strips will deform upon impact, but deformation will not decrease the strength of the strips even when the plastic exceeds its yield point. This ultimately enables the BCPP strips to maintain their elastic even upon deformation. BCPP composition and use are described in more detail below.

The layers inFIG.12are shown as horizontal layers when the impact absorbing mat100is positioned on a surface. However, these layers may be configured as vertical layers in other examples and configurations as known to those skilled in the art.

FIG.15illustrates example steps of the process1500for creating a cell1218for the baffle1216as well as the strips1220that form the content of the cells. In this respect, execution proceeds to step1502wherein thin long narrow strips are made of BCPP during the manufacture process. Then, execution proceeds to step1504wherein the BCPP strips are randomly bent in a crumpling fashion to make a nest structure. Next, execution proceeds to step1506wherein creases are formed which deform the plastic strips to the full execute of the largest possible mat compression. Then, at step1508, the beta crystals of the BCPP strips are converted into alpha (a) crystals as a result of the plastic deformation. The formation of alpha crystals ensures that the strength of the strips are maintained even after deformation. (However, in this state, the undeformed sections of the strips remain as beta (β) crystals.) Once this happens, nest structure is inserted into a cell (sheeting) and sealed at step1510. At this stage, the cell is ready to be used.

FIG.16illustrates a flowchart of example process steps1600of the operation of the impact absorbing mat ofFIG.12upon impact of an object. In operation, at step1602, an object impacts and applies force to the top layer1408of the impact absorbing mat1200. At step1604, the top layer1408transfers the force to the linear layer1210of the impact absorbing mat1200. (However, force on the top layer has negligible effect on the impact of the object.) Then, at step1606, the linear layer spreads out the force in all directions orthogonally with respect to the direction of velocity of the object (i.e., perpendicular to direction of object). As a result, the force is transferred to the damper layer1212over a wider area. The damper layer1212compacts thereby expelling air out of the cells under pressure and expulsion force at step1608. (As indicated above, the baffle fabric material is porous or has holes to enable air to pass.) At step1610, the expulsion force propagates up to the linear layer1210and transfers the expulsion force to the top layer1208, thereby impacting the object. As a result, the object's velocity reduces until the object rests, resulting from the force on the object. The steps described inFIG.16depict the actions or reactions by the impact absorbing mat1200resulting from an object impact.

FIGS.17-19illustrates graphs of force over time for certain layers of the impact absorbing mat1200ofFIG.12. InFIG.17, the force on the object by the linear layer1210is generally increasing linearly as time progresses while the force on the object decreases linearly by the damper layer over time (FIG.18).FIG.19represents the ideal force on the object by a perfect mat. The impact absorbing mat1200generally produces the results shown in these graphs as a result of the layer structure and composition of baffles.

It is to be understood that the disclosure teaches examples of the illustrative embodiments and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the claims below.