Abstract: A multi-tiered recoiling energy absorbing system has an upper impact surface that is exposed to percussive impact. At least one energy absorbing layer is positioned below or inside the upper impact surface. The energy absorbing layer includes one or more energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform. A lateral reinforcement member secures the energy absorbing units to prevent them from splaying. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.

Abstract: A modular energy absorbing system sandwiched between an impact-receiving upper surface and a lower foundation. The energy absorbing system has one or more interconnected modules that cooperate to absorb and distribute impact forces applied thereto. Each module has one or more frustoconical support structures. At least some of the frustoconical support structures have bases that underlie the upper impact-receiving surface such as a football field or a basketball court.

Abstract: A recoiling energy absorbing system is interpositioned between an outer shell that is exposed to percussive impact and a foundation. An energy absorbing layer with friction lugs is positioned inside the outer shell. The energy absorbing layer includes one or more energy absorbing modules with optional veins and drain holes. At least some of the modules are provided with one or more energy absorbing units that extend from an upper basal layer. At least some of the energy absorbing units are provided with a flexible wall that extends from the upper basal layer. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its undeflected configuration.

Abstract: An energy absorber includes a base sheet and a plurality of energy absorbing units with end walls and associated leaf spring or helicoid accessories extending from the base sheet. The accessories reduce buzzes, squeaks and rattles associated with an environment of use. In one embodiment, the leaf springs are defined by slits in a domed portion of the end walls. In another embodiment, the helicoid is formed by for example a milling step performed on an end wall. The side walls buckle or bend after absorbing energy. Methods related to the above are also described.

Abstract: A recoiling energy absorbing system has an upper impact surface that is exposed to percussive impact. An energy absorbing layer is positioned below or inside the upper impact surface. The energy absorbing layer includes one or more thermoformed energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform. A lateral reinforcement member secures the energy absorbing units to prevent them from splaying. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.

Abstract: A recoiling energy absorbing system has an outer shell that is exposed to percussive impact. An energy absorbing layer is positioned inside the outer shell. The energy absorbing layer includes one or more thermoformed energy absorbing modules, at least some of the modules being provided with one or more energy absorbing units that extend from an upper basal layer. At least some of the energy absorbing units are provided with a flexible wall that extends from the upper basal layer. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its undeflected configuration.

Abstract: An energy absorber 10 that has a spine 12 which has a relaxed configuration and a deployment configuration. In the deployment configuration, the spine 12 lies proximate to a substrate 14 to protect the substrate 14 from an impacting object 16. Preferably, the spine 12 is bendable to conform to the substrate 14. The spine includes a number (N) of energy absorbing modules 18, 20, 22, 24, . . . , where 1<=N<=1000. At least some of the modules have a number (L) of mutually supporting energy absorbing vertebral members 30, where 1<=L<=100. Each vertebral member 30 includes a number (U) of coalesced energy absorbing units 32, 34, were 2<=U<=10. At least some of the energy absorbing units 32, 34 have a base 36 that preferably but not necessarily is oriented toward the impacting object 16.

Abstract: An energy absorber includes a base sheet and a plurality of recovering crush lobes extending from the base sheet. The crush lobes protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Each crush lobe includes a side wall that is oriented to buckle or bend and then spring back after absorbing energy when impacted. At least one of the base sheet and an end wall of at least one crush lobe optionally includes a number (X) of integrally-formed protruding countermeasures where 0<=X<1000 of lower standing strength than the crush lobes. Methods related to the above are also described.

Abstract: A recoiling energy absorbing system has an outer shell that is exposed to percussive impact. An energy absorbing layer is positioned inside the outer shell. The energy absorbing layer includes one or more thermoformed energy absorbing modules, at least some of the modules being provided with one or more energy absorbing units that extend from an upper basal layer. At least some of the energy absorbing units are provided with a flexible wall that extends from the upper basal layer. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its undeflected configuration.

Abstract: A grille 10 for covering an aperture in a panel 16 that supports audio equipment behind a back face of the panel 16, the grille 10 being installed upon a front face of the panel. The grille comprises a formed sheet of pierced and expanded sheet material that has a major axis (A-A) running parallel to a direction in which the sheet is introduced to a forming machine and a minor axis (B-B) that extends orthogonally to the major axis (A-A). The formed sheet has a central portion with surface discontinuities selected that are swirls 18, stiffening furrows 22 and ridges 20 running substantially parallel to the major axis (A-A) and combinations thereof.

Abstract: A recoiling energy absorbing system has an upper impact surface that is exposed to percussive impact. An energy absorbing layer is positioned below or inside the upper impact surface. The energy absorbing layer includes one or more thermoformed energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform. A lateral reinforcement member secures the energy absorbing units to prevent them from splaying. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.

Abstract: An energy absorber includes a base sheet and a plurality of recovering crush lobes extending from the base sheet. The crush lobes protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Each crush lobe includes a side wall that is oriented to buckle or bend and then spring back after absorbing energy when impacted. At least one of the base sheet and an end wall of at least one crush lobe optionally includes a number (X) of integrally-formed protruding countermeasures where 0<=X<1000 of lower standing strength than the crush lobes. Methods related to the above are also described.

Abstract: An energy absorber includes opposing aligned crush lobes expandable in opposite directions, and when expanded, potentially collapse with different energy-absorbing rates and stroke distances. The energy absorber forms a subassembly design that is adaptable and easily modified for predetermined energy absorption crush curves and specific energy-absorbing circumstances, such that it can be used inside a vehicle passenger compartment or outside a vehicle in different locations, such as for a knee bolster on the instrument panel, or on a door inner panel, or on an under-knee seat component, or on a headliner or A-pillar cover, or hood-lifter for pedestrian safety. One version of the energy absorber includes formed sheets bonded along a perimeter to define two cavities and an inflator-holding pocket connected to the cavities by integrally-formed tunnels.

Abstract: A liner system and method of thermoforming. A helmet has an energy absorbing inner system positioned inside the shell. The liner has thermoformed interconnected energy absorbing modules. At least some of the modules in the layer have a basal portion with upper and lower sections when viewed in relation to the wearer's head. The upper section has one or more energy absorbing units. At least some of the units are provided with a wall with a domed cap that faces the outer shell. The units at least partially cushion the blow by absorbing energy imparted by an object that impacts the outer shell. The lower comfort section has a tiered arrangement of layers. The layers are relatively compliant and thus provide a comfortable yet firm fit of the helmet upon the wearer.

Abstract: An energy absorbing liner system and method of making it, preferably by thermoforming. A helmet has an energy absorbing inner system positioned inside the shell. The liner has thermoformed interconnected energy absorbing modules that non-destructively rebound after one or more impacts. At least some of the modules in the layer have a basal portion with upper and lower sections when viewed in relation to the wearer's head. The upper section has one or more energy absorbing units. At least some of the units are provided with a wall with a domed cap that faces the outer shell. The units at least partially cushion the blow by absorbing energy imparted by an object that impacts the outer shell. The lower comfort section has a tiered arrangement of layers. The layers are relatively compliant and thus provide a comfortable yet firm fit of the helmet upon the wearer.

Abstract: An energy absorber includes a base sheet and a plurality of crush lobes extending from the base sheet. Each crush lobe includes a side wall oriented to crush and collapse to absorb energy when impacted in a first direction and includes an end wall. At least one of the base sheet and the end wall of at least one crush lobe includes an integrally-formed protruding countermeasure of lower standing strength than the crush lobes so that the protruding countermeasure acts to dampen movement causing buzzes, squeaks and/or rattles between the end wall and an adjacent structure. The countermeasure can be integrally formed or an insert, such as a magnet or other insert. Methods related to the above are also described.

Abstract: A process for producing a speaker grille cover having bands of imperforate metal that have a physical appearance and or audio performance which can be altered or improved to meet styling and/or audio performance objectives. The process comprises these steps, not necessarily executed in the sequence listed: piercing and expanding a sheet of metal to manufacture an area of expanded metal; and interposing an area of imperforate metal between areas of expanded metal. The product made thereby is a speaker grille cover having an area of expanded metal; and bands of imperforate unexpanded metal that are bounded by an area of expanded metal.

Abstract: A display sign for use with a display system includes a thermoplastic sheet having a first region having a first thickness, a second region having a second thickness less than the first thickness, and at least one fastener. The second region is adjacent to the fastener. A volume of material in the fastener plus a volume of material in the second region is generally equivalent to a volume of material in an area of the first region, the area of the first region being equivalent to the area of the second region. A method of forming a display sheet includes providing a thermoplastic sheet, and drawing at least one fastener from the thermoplastic sheet while in a plastic state. The material drawn from the sheet to form the at least one fastener results in a region of reduced thickness of the sheet adjacent to the respective fastener.

Abstract: A thermoformed product formed during a thermoforming process includes a thermoformed sheet of polymeric material having front and rear surfaces defining a thickness, and having a first section thermoformed to include a non-planar three-dimensional useful structure and at least one second section. Each of the at least one second sections have a first area of reduced thickness and have a second area including attachment structure, with the attachment structure being formed in part by material extruded from the first area into the attachment structure while the polymeric material of the sheet is hot during the thermoforming process.

Abstract: An energy absorber includes opposing aligned crush lobes expandable in opposite directions, and when expanded, potentially collapse with different energy-absorbing rates and stroke distances. The energy absorber forms a subassembly design that is adaptable and easily modified for predetermined energy absorption crush curves and specific energy-absorbing circumstances, such that it can be used inside a vehicle passenger compartment or outside a vehicle in different locations, such as for a knee bolster on the instrument panel, or on a door inner panel, or on an under-knee seat component, or on a headliner or A-pillar cover, or hood-lifter for pedestrian safety. One version of the energy absorber includes formed sheets bonded along a perimeter to define two cavities and an inflator-holding pocket connected to the cavities by integrally-formed tunnels.