Abstract: A modular energy absorber 10 that is tunable. It comprises one or more energy absorbing modules 12. The energy absorbing modules have means for coordinating energy absorbing units 16 of the one or more modules. The means 14 for coordinating position and support the units in relation to each other before, during and after relative motion between an incident object and the energy absorber. A crushable member is provided that has an upper perimeter, a lower perimeter and an intermediate section extending therebetween. It also includes a number (m) of breaches defined therein before impact. A method for configuring the modular energy absorber is also disclosed.

Abstract: A modular energy absorber 10 that is tunable. It comprises one or more energy absorbing modules 12. The energy absorbing modules have means for coordinating energy absorbing units 16 of the one or more modules. The means 14 for coordinating position and support the units in relation to each other before, during and after relative motion between an incident object and the energy absorber. A crushable member is provided that has an upper perimeter, a lower perimeter and an intermediate section extending therebetween. It also includes a number (m) of breaches defined therein before impact. A method for configuring the modular energy absorber is also disclosed.

Abstract: An energy absorber comprising a base and a plurality of recesses extending from the base. At least some of the plurality of recesses have a rim, a first wall extending between the base and the rim, a first floor, and a second wall extending between the rim and the first floor. At least some of the plurality of recesses are oriented such that their first and second walls are inclined respectively at angles alpha and beta to a major incident component of the impacting force, where alpha and beta lie between 1 and 45 degrees.

Abstract: A composite modular energy absorbing assembly with one or more gamma structures 100 that are interposed with one or more delta structures 200. The gamma structures have a base 12′ and a plurality of recesses 16′ defined therewithin. The recesses 16′ have at least one wall 20′ extending from the associated base 12′. At least some of the recesses 16′ are oriented such that their walls are substantially parallel to a major incident component of an impacting force. The walls 20′ collapse. The delta structures 200 have a lattice 210 of interconnected strands which intersect to define a plurality of cells 220. The plane of at least some of these cells are substantially parallel to the impacting force. The lattice collapses during energy absorption. The composite assembly serves to decelerate an object that impacts thereupon in order to maximize energy absorption over a given distance.

Abstract: A method is provided for making an energy-absorbing assembly for decelerating an object that impacts the assembly. The assembly comprises a base and at least energy-absorbing module associated therewith. To provide predetermined energy-absorption characteristics, the at least one energy-absorbing module is formed from a group consisting of a first structure (A) and a second structure (B). Structure (A) is a metal lattice which supported by the base. Structure (B) comprises a plurality of recesses, each having a floor and a wall. Together, structures (A) and (B) and combinations thereof afford a user-determinable resistance to impact.

Abstract: A modular energy absorbing assembly 10 comprising at base 12, and at least one energy absorbing module 14 associated with the base for accommodating deformation of the assembly. At least some of the energy absorbing modules have a plurality of recesses 16 defined within the base. Each of the plurality of recesses has a floor and at least one wall extending from the floor to the base. An intermediate segment extends between the floor and the at least one wall. The intermediate segment has an average radius (R). At least some of the recesses are oriented such that their floors are substantially orthogonal to a major incident component of the impacting force and their walls are inclined at an angle (&agr;) to the major incident component of the impacting force, where (0<&agr;<45 degrees), in order to maximize energy absorption by the wall over a given distance. The wall at least partially collapses and at least some of the recesses become at least partially compressed during energy absorption.

Abstract: An apparatus and method are provided for molding clusters of fibers, including at least some thermoplastic fibers, into products at a cost, quality, and performance level acceptable for commercial production. The clusters are dedensified 10 and then placed 12 into an empty mold 20. The mold 20 has apertures 28 to facilitate the transfer of thermal energy through the mold 20. A linear conveyor 32 is used to transport the mold through a plurality of process locations on a continuous or semi-continuous basis. Included is a heating location 48 wherein the mold 20 is heated 14, providing an influx of thermal energy sufficient to fuse the thermoplastic fibers to form a heated product. A cooling location 50 follows the heating location 48, wherein the mold 20 and the heated product contained therein are cooled 16 to produce a cooled product. The cooled product is then ejected 18 from the mold 520.

Abstract: An energy absorbing assembly is provided for decelerating an object that impacts the assembly. The assembly comprises at least one energy absorbing member for accommodating deformation of the assembly. The assembly comprises a base and at least energy absorbing module associated therewith. The at least one energy absorbing module is formed from a group consisting of structure (A) and structure (B). Structure (A) is a metal lattice which supported by the thermoformed base. Structure (B) comprises of plurality of recesses, each having a floor and a wall. Together, structures (A) and (B) and combinations thereof afford a user-determinable resistance to impact.

Abstract: An apparatus and method are provided for molding clusters of fibers, including at least some thermoplastic fibers, into products at a cost, quality, and performance level acceptable for commercial production. The clusters are dedensified 10 and then placed 12 into an empty mold 20. The mold 20 has apertures 28 to facilitate the transfer of thermal energy through the mold 20. A linear conveyor 32 is used to transport the mold through a plurality of process locations on a continuous or semi-continuous basis. Included is a heating location 48 wherein the mold 20 is heated 14, providing an influx of thermal energy sufficient to fuse the thermoplastic fibers to form a heated product. A cooling location 50 follows the heating location 48, wherein the mold 20 and the heated product contained therein are cooled 6 to produce a cooled product. The cooled product is then ejected 18 from the mold 20.

Abstract: An energy absorbing assembly 10 is provided for decelerating an object that impacts the assembly. The assembly comprises an incident member 12 having an incident surface 14 that meets the impacting object and at least one energy absorbing member 16 attached to an attachment region 17 of an opposing face 18 of the incident member 12 for accommodating deformation of the assembly 10. The energy absorbing member 16 comprises a lattice of interconnected strands 20, wherein the strands 20 intersect to define a plurality of cells 22. The energy absorbing member 16 is oriented such that the plane of each cell 22 is substantially perpendicular to the attachment region 17 in order to maximize energy absorption over a given distance. The lattice collapses and at least some of the cells 22 become at least partially closed during energy absorption.

Abstract: Disclosed is an energy absorbing structure (10) for decelerating an object that impacts the structure. The structure has at least one energy absorbing member (20). Each member includes a stranded structure such as expanded metal (22) which provides the energy absorbing structure (10) with the characteristic of energy absorption according to a near square wave characteristic.