Abstract: A force-attenuating system that is interposed between an exterior surface and an interior surface, either or both of which may be subjected to percussive forces. The system has a ceiling that is positioned proximate the exterior surface and one or more inverted hat-shaped force-attenuating units with sidewalls extending inwardly convergingly away from the ceiling. Some of the units have a floor that is positioned proximate the interior surface. Optionally the force-attenuating units may be configured as clover-leaf structures with a central region and hemi-pear-shaped lobes extending therefrom. Within the lobes is a floor that is positioned proximate the interior surface. The force-attenuating system may be deployed in an automotive or non-automotive environment.

Abstract: A force-attenuating system that is interposed between an exterior surface and an interior surface, either or both of which may be subjected to percussive forces. The system has a ceiling that is positioned proximate the exterior surface and one or more inverted hat-shaped force-attenuating units with sidewalls extending inwardly convergingly away from the ceiling. Some of the units have a floor that is positioned proximate the interior surface. Optionally the force-attenuating units may be configured as clover-leaf structures with a central region and hemi-pear-shaped lobes extending therefrom. Within the lobes is a floor that is positioned proximate the interior surface. The force-attenuating system may be deployed in an automotive or non-automotive environment.

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: 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 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 energy absorbing units with domed countermeasures extending from the base sheet. The countermeasures have slits in a domed portion thereof. The side walls of the energy absorbing units protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Preferably the side walls are oriented to buckle or bend after absorbing energy when impacted. The countermeasures primarily deaden any associated buzzes, squeaks or rattles. The integrally-formed countermeasures have a lower standing strength than the energy absorbing units. Methods related to the above are also described.

Abstract: An energy absorber includes a base sheet and a plurality of energy absorbing units with domed countermeasures extending from the base sheet. The countermeasures have slits in a domed portion thereof. The side walls of the energy absorbing units protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Preferably the side walls are oriented to buckle or bend after absorbing energy when impacted. The countermeasures primarily deaden any associated buzzes, squeaks or rattles. The integrally-formed countermeasures have a lower standing strength than the energy absorbing units. Methods related to the above are also described.

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: 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 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: An energy absorbing structure 10 for protecting an impacted body, such as a pedestrian 12. The structure has an incident surface that meets the pedestrian and has at least some expanded metallic structure 18. A pair of wall support surfaces 20, 22 lie substantially in-plane with respect to a normal component of the impacting force. They extend from the incident surface in a direction opposite to the direction of the impact. The substantially in-plane surfaces also have at least some expanded metallic structure. A pair of basal surfaces 26, 28 support the in-plane surfaces, and also have at least some expanded metallic structure.

Abstract: A bumper system includes a bumper beam having top and bottom attachment features, such as apertures or concavities for attachment. A thermoformed polymeric energy absorber includes a base flange for engaging the face of the beam, protruding crush lobes for absorbing energy upon an impact, and top and bottom rear flanges. The top and bottom rear flanges include inwardly-facing protrusions defining a second dimension less than a first dimension of the beam's face, but the base flange is sufficiently resilient and flexible at desired locations and with desired force of flexures to provide tunable flexure points so the protrusions can be temporarily resiliently flexed apart to the first dimension for assembly and then upon release, the protrusions flex back to the second dimension engaging the attachment features to temporarily but positively retain the energy absorber on the beam.

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: An energy absorbing structure 10 for protecting an impacted body, such as a pedestrian 12. The structure has an incident surface that meets the pedestrian and has at least some expanded metallic structure 18. A pair of wall support surfaces 20, 22 lie substantially in-plane with respect to a normal component of the impacting force. They extend from the incident surface in a direction opposite to the direction of the impact. The substantially in-plane surfaces also have at least some expanded metallic structure. A pair of basal surfaces 26, 28 support the in-plane surfaces, and also have at least some expanded metallic structure.

Abstract: A multi-sectional, modular energy absorber 10 comprising one or more modules, which have one or more energy absorbing units 12. Some have a first section 14 and a second section 16 in some embodiments that are united like a clamshell to form the energy absorbing unit 12. There is a means for locating the sections 18 in relation to each other. First and second flange sections 20,22 extend from at least some of the first and second sections. There are means for coordinating energy absorbing units 24 in one of the one or more modules, the means for coordinating 24 having a topography including a number (n) of apertures 26 defined therein, where n is an integer?0. At least some of the sections include an upper perimeter 28, a lower perimeter 30 and an intermediate wall 32 extending therebetween with a number (m) of breaches defined in the intermediate wall before impact, where m is an integer?0.

Abstract: A modular energy absorber 10 that is tunable. It comprises one or more energy absorbing modules 12. The energy absorbing modules 12 have means for coordinating 14 energy absorbing units 16 of the one or more modules. The means 14 for coordinating position and support the units 16 in relation to each other before and during relative motion between an incident object and the energy absorber. The units 16 are provided with an upper perimeter 22, a lower perimeter 24 and an intermediate wall 26 with stiffening male 36 or female 38 ribs. A method for configuring and for making the modular energy absorber are also disclosed.

Abstract: A multi-sectional, modular energy absorber 10 comprising one or more modules, which have one or more energy absorbing units 12. Some have a first section 14 and a second section 16 that are united like a clamshell to form the energy absorbing unit 12. There is a means for locating the sections 18 in relation to each other. First and second flange sections 20,22 extend from at least some of the first and second sections. There are means for coordinating energy absorbing units 24 in one of the one or more modules, the means for coordinating 24 having a topography including a number (n) of apertures 26 defined therein, where n is an integer ?0. At least some of the sections include an upper perimeter 28, a lower perimeter 30 and an intermediate wall 32 extending therebetween with a number (m) of breaches defined in the intermediate wall before impact, where m is an integer ?0.