PAD INCORPORATING SHEAR-THICKENING MATERIAL

• US 20140259326A1
• Filed: 03/14/2013
• Published: 09/18/2014
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Larry E. Carlson
• Original Assignee: Larry E. Carlson
• Inventors: Carlson, Larry E.
• Granted Patent: US 9,596,894 B2
• Time in Patent Office: Days
• US Class Current: 2/455
• CPC Class Codes: A41D 13/015 with shock-absorbing means A41D13/05 takes precedence
• CPC Class Codes: A41D 13/065 Knee protectors
• CPC Class Codes: A42B 3/121 with at least one layer or pad containing a fluid
• CPC Class Codes: F41H 1/02 Armoured or projectile- or missile-resistant garments; Composite protection fabrics F41H5/04 takes precedence

Abstract

A pad is disclosed that includes first and second outer layers. The outer layers include a plurality of channels at least partially filled with shear-thickening fluid. A shear layer is positioned between the first and second outer layers. The first and second outer layers may include first and second sheets that are bonded to one another in bonded portions and not bonded to one another in non-bonded portions such that the channels are defined by the non-bonded portions. The bonded portions may be perforated to facilitate air flow. The shear layer includes a lattice structure such as a plurality of rods extending between the first and second outer layers and oriented at a non-perpendicular angle to the outer layers. The rods themselves may be filled with shear-thickening fluid. The channels in the outer layers are criss-crossed to form a lattice or network in the plane of the outer layers.

Claims

1. A pad comprising:

first and second outer layers each including shear-thickening fluid; and

a shear layer positioned between the first and second outer layers.

4. The pad of claim 1, wherein the shear layer comprises a rigid polymer.

5. The pad of claim 1, wherein the shear layer defines a lattice structure defining straight shear paths between the first and second outer layers.

6. The pad of claim 1, wherein the shear layer defines a lattice structure of a plurality of rods extending between the first and second outer layers.

7. The pad of claim 6, wherein the plurality of rods are cylindrical.

8. The pad of claim 6, wherein the plurality of rods define a smallest included angle with respect to the first and second outer layers that is less than 85 degrees.

9. The pad of claim 6, wherein the plurality of rods contain shear-thickening fluid.

10. The pad of claim 6, wherein the plurality of rods have a buckling point effective to cause buckling of the rods at a first loading, the first loading being less than a second loading at which failure of either of the first and second outer layers occurs.

11. The pad of claim 6, wherein at least a portion of the rods of the plurality of rods each cross an adjacent rod of the plurality of rods and are joined to the adjacent rod at a crossing point.

12. The pad of claim 1, wherein the shear layer defines a plurality of openings permitting airflow between therethrough.

13. The pad of claim 1, wherein the shear layer has a hydrophilic coating effective to enable wicking of moisture between the first and second outer layers.

14. The pad of claim 1, wherein the first and second outer layers include a rigid polymer.

15. The pad of claim 1, wherein the first and second layers each define a plurality of channels, the shear thickening fluid being contained in the plurality of channels, the plurality of channels including first channels oriented at one of 45 degrees and −

45 degrees with respect to a common reference direction in a plane.

2. The pad of claim 1, wherein the first and second outer layers each comprise first and second sheets, the first and second sheets bonded to one another in bonded portions and not bonded to one another in non-bonded portions, the shear thickening fluid being contained in the non-bonded portions.

3. The pad of claim 2, wherein the bonded portions are perforated.

16. The pad of claim 15, wherein the plurality of channels include second channels oriented parallel to the reference direction in the plane and third channels oriented perpendicular to the reference direction in the plane.

17. The method of claim 15, wherein the first sheet defines a plurality of ridges at the unbonded areas, the ridges having concave inner surfaces at least partially defining the channels.

18. The method of claim 15, wherein placing shear-thickening fluid between the first and second sheets in the channels defined by the unbounded areas of the first sheet and the second sheet further comprises placing tubes containing shear-thickening fluid in the channels.

19. The method of claim 15, wherein the channels include:

first channels defining an angle of 45 degrees relative to a reference direction in a plane; and

second channels defining an angle of −

45 degrees relative to the reference direction in the plane.

20. The method of claim 19, wherein the channels include:

third channels parallel to the reference direction in the plane; and

fourth channels perpendicular to the reference direction in the plane.

15-1. A method for manufacturing a pad, the method comprising:

forming at least one outer layer by securing a first sheet to a second sheet at a plurality of bonded areas and leaving a plurality of unbonded areas of the first sheet that are not bonded to the second sheet;

placing shear-thickening fluid between the first and second sheets in channels defined by the unbonded areas of the first sheet and the second sheet; and

securing a shear layer to the at least one outer layer.

16-2. The method of claim 15, wherein placing the shear-thickening fluid between the first and second sheets further comprises pumping the shear-thickening fluid into the channels through a port defined by one or both of the first and second sheets.