Abstract: An energy-absorbing pad structure includes an energy-absorbing pad that is encapsulated by a polymeric film. The polymeric film is sufficiently air-permeable to permit air to escape during rapid compression of the pad structure, such as from a high-speed dynamic impact, but nonetheless is water resistant under ordinary conditions. It is desirable that the polymeric film is made from an elastic polymer. The air-permeability can be provided from a series of perforations such that the film's elastic quality tends to contract the perforations thereby impeding the progress of water through them under normal conditions. The energy-absorbing pad can be a semi-rigid viscoelastic foam.

Abstract: An energy-absorbing pad structure includes an energy-absorbing pad that is encapsulated by a polymeric film. The polymeric film is sufficiently air-permeable to permit air to escape during rapid compression of the pad structure, such as from a high-speed dynamic impact, but nonetheless is water resistant under ordinary conditions. It is desirable that the polymeric film is made from an elastic polymer. The air-permeability can be provided from a series of perforations such that the film's elastic quality tends to contract the perforations thereby impeding the progress of water through them under normal conditions. The energy-absorbing pad can be a semi-rigid viscoelastic foam.

Abstract: An energy-absorbing pad structure includes an energy-absorbing pad that is encapsulated by a polymeric film. The polymeric film is sufficiently air-permeable to permit air to escape during rapid compression of the pad structure, such as from a high-speed dynamic impact, but nonetheless is water resistant under ordinary conditions. It is desirable that the polymeric film is made from an elastic polymer. The air-permeability can be provided from a series of perforations such that the film's elastic quality tends to contract the perforations thereby impeding the progress of water through them under normal conditions. The energy-absorbing pad can be a semi-rigid viscoelastic foam.

Abstract: A composite armor including a disrupting layer and a backing layer provides protection against blast and ballistic threats. The disrupting layer includes ceramic particles or tiles that disrupt the incoming projectile, while the backing layer prevents penetration past the armor by the disrupted projectile. The disrupting layer may include a layer of polygonal ceramic tiles with a deflecting front surface, encased by a retaining polymer, and may also include fire-retarding particles.

Abstract: A hybrid armor architecture is provided that is effective against explosively-formed and other high-energy ballistic projectiles. The architecture includes at least one laminate reactive armor panel including a layer of non-explosively reactive material sandwiched between outer layers of a ductile material, an armor plate disposed behind the laminate reactive armor panel, and a flyer plate disposed behind the armor plate. The flyer plate or a portion thereof is configured to move toward and impact a body panel that is being protected on impact of a high-energy ballistic projectile with the flyer plate or the portion thereof, to thereby increase the total area of impact with the body panel relative to the projectile alone.

Abstract: A composite armor including a disrupting layer and a backing layer provides protection against blast and ballistic threats. The disrupting layer includes ceramic particles or tiles that disrupt the incoming projectile, while the backing layer prevents penetration past the armor by the disrupted projectile. The disrupting layer may include a layer of polygonal ceramic tiles with a deflecting front surface, encased by a retaining polymer, and may also include fire-retarding particles.

Abstract: An exhaust manifold is provided having substantially ceramic inner and insulation layers. The manifold preferably has a metal outer structural layer to impart strength to the manifold. The ceramic layers are made of ceramic fibers with the interstitial spaces between the fibers being filled with ceramic filler material. The preferred ceramic fibers are aluminosilicate fibers. The preferred ceramic filler material is alumina, silica, glass-ceramic or other metal oxide. A method of making an exhaust manifold having a substantially ceramic inner and insulation layer is also provided.

Abstract: A protective helmet is provided which preferably has a hard outer shell and an energy-absorbing liner. The liner is made of low resilience or slow-recovery viscoelastic foam which is compression rate sensitive.

Abstract: An exhaust manifold for conducting heated exhaust gas from an internal combustion engine to an exhaust system. The exhaust manifold includes a preform and a metal layer enclosing the preform. The preform has an inner layer of silicon carbide, a middle layer of insulating material, and an outer layer to seal the middle layer from molten metal used to form the metal layer.

Abstract: A protective helmet made from a resilient shell. The shell has a plurality of slits. Each slit has a first end located at a lower edge of the shell and has an adjustable width effective for adjusting the size of the shell. The helmet also has an energy absorbing liner disposed inside the shell. The shell is very stiff to effectively distribute an impact force.

Abstract: A removable insole is provided which includes a layer of thermoplastic material, the thermoplastic material preferably including ethylene vinyl acetate and ethylene vinyl acetate modified by the addition of carbonyl groups. A custom-fitting insole is preferably produced by heating a substantially flat insole in a microwave oven until the thermoplastic material softens, placing the heated insole in a shoe, and having a person insert their foot into the shoe and walk around to form an impression.

Abstract: A damped heat shield for a high temperature portion of a vehicle exhaust system. The heat shield has inner and outer metal layers of substantially different thicknesses and substantially different resonant frequencies, which causes the shield to damp vibrational energy and reduce radiated sound energy and noise. Between the metal layers is a layer of sound and heat shielding material such as aluminum foil or ceramic fiber paper. The metal layers are preferably stainless steel, cold rolled steel, aluminized steel, aluminum-clad steel, or aluminum. If cold rolled steel is used, the exterior of the shield is preferably coated with a corrosion-resistant coating.

Abstract: A method of producing a custom-fitting article such as a custom-fitting footbed (for example, a removable insole), a custom-fitting hand grip, a custom-fitting body pad, and a custom-fitting orthopedic cast. A member for producing same and a composition for use in connection therewith are also provided. A member, such as a gel pad or gel-filled envelope, is provided which comprises a body of formable material having a minimum setting temperature greater than 130.degree. F. and being setable by heating for a period not exceeding 30 minutes and subsequent cooling. The member is conformed by biasing it against a body part of a person or mammal with sufficient pressure to conform the member to the shape of the body part. The member is then heated for a period not exceeding 30 minutes and thereafter cooled so that the formable material is set and the member remains flexible while resiliently retaining an impression of the body part.

Abstract: An exhaust manifold for conducting the heated exhaust gas from an internal combustion engine. The exhaust manifold has a thin noncast metal inner layer, a thicker sheet metal outer layer, and a layer of insulating material, preferably ceramic beads, between the inner and outer layers. The method of making the exhaust manifold is also disclosed. The exhaust manifold is damped, insulated, and permits quicker light off of the catalytic converter.

Abstract: A damped heat shield for a vehicle exhaust manifold includes inner and outer thin steel layers. An intermediate aluminum layer is located between the two steel layers. A high temperature corrosion-resistant coating is applied to the exterior surfaces and the edges of the shield. Such coating along the edges prevents the entry of corrosion producing substances into the interior of the shield. The outer steel layer has a thickness greater than the inner steel layer, so that the two layers do not resonate at the same frequency, and therefore, tend to damp vibrational energy more efficiently and reduce radiated sound energy and noise.

Abstract: A method for making a sound-dampened automotive enclosure, such as an oil pan, having a metal constraining layer, a metal housing layer, and a viscoelastic layer sandwiched therebetween. In a preferred embodiment, the constraining layer and viscoelastic layer are between the housing layer and the die while the housing layer is being drawn. This results in a very close and snug fit between the layers, leading to enhanced sound-dampening effectiveness. The article thus produced is also disclosed.

Abstract: A damped heat shield for a vehicle exhaust manifold includes inner and outer thin steel layers. An intermediate aluminum layer is located between the two steel layers. A high temperature corrosion-resistant coating is applied to the exterior surfaces and the edges of the shield. Such coating along the edges prevents the entry of corrosion producing substances into the interior of the shield. The outer steel layer has a thickness greater than the inner steel layer, so that the two layers do not resonate at the same frequency, and therefore, tend to damp vibrational energy more efficiently and reduce radiated sound energy and noise.

Abstract: The invention concerns a method of using constrained layer sound damping. A composition and a laminated structure are provided for the reduction of noise coming from housings such as oil pans for automobiles. The composition comprises a rubbery polyurethane, an olefin polymer, and a filler. The laminated structure comprises the housing, the composition, and a sheet metal liner. The composition contains a blowing agent which is activated to provide a single unitary structure which dampens noise. The polyurethane and olefin polymer are thoroughly intermixed with each other, but maintain their separate identities in the blend.

Abstract: A barrier to the passage of sound, vibration, and moisture through a hollow channel in a motor vehicle body and a method for producing same are provided. The barrier is comprised of a resilient body such as flexible foam and a heat-deformable member such as a tube which defines a passageway between the ends of the resilient body when the resilient body and the member are mounted in the hollow channel. The barrier may be coated with hot melt adhesive. The barrier is mounted in the hollow channel and the motor vehicle body is dipped in a paint bath and drained. Paint flows in and out through the passageway in the barrier, thus coating the interior of the hollow channel. When the motor vehicle body is passed through the bake oven, the heat-deformable member collapses, the barrier is closed, and the hot melt adhesive bonds the barrier to the channel.

Abstract: The invention concerns constrained layer sound damping. A composition and a laminated structure are provided for the reduction of noise coming from housings such as oil pans for automobiles. The composition comprises a rubbery polyurethane, an olefin polymer, and a filler. The laminated structure comprises the housing, the composition, and a sheet metal liner. The composition contains a blowing agent which is activated to provide a single unitary structure which dampens noise. The polyurethane and olefin polymer are thoroughly intermixed with each other, but maintain their separate identities in the blend.