Adhesive Threaded Helmet Mount for Ballistic Shell Integrity
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Solution Overview
Problem
Existing helmet mounting systems compromise the ballistic integrity of helmets by requiring holes to be drilled, which can lead to moisture infiltration and separation of ballistic plies, and pose challenges when different hole patterns are needed.
Innovation Solution
A modular helmet mount system using a threaded interface assembly with an adhesive attachment that does not penetrate the ballistic shell, featuring a threaded insert and outer portion with an inward-facing surface for bonding, allowing for the attachment of various devices without drilling holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If holes are drilled in the ballistic shell for mounting hardware, then mounting capability is improved, but ballistic integrity is compromised
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the mounting hardware and the ballistic shell, allowing force transfer without penetrating the shell. This mediator enables mounting capability while preserving the integrity of the ballistic structure by distributing stresses through adhesion rather than mechanical penetration.
Solution Approach 2:
The patent replaces the traditional mechanical fastening system (screws and holes penetrating the shell) with an adhesive bonding system. This substitution eliminates the need for holes in the ballistic shell while providing sufficient mounting strength through chemical adhesion and stress distribution across the adhesive layer.
2Adaptability or versatility
If holes are drilled by end user to accommodate mounting hardware, then adaptability is improved, but ballistic integrity and sealant finish are compromised
Solution Approach 1:
The patent applies adhesive to the mounting hardware or shell surface before attachment, creating a pre-prepared bonding interface that eliminates the need for user drilling. This preliminary action ensures proper positioning and maintains the sealant finish by avoiding any penetration of the ballistic shell during installation.
3Strength
If threaded inserts are bonded into holes by manufacturer, then mounting strength is improved, but ballistic structure is weakened
Solution Approach 1:
The adhesive layer serves as an intermediary that transfers mounting loads without requiring holes in the ballistic shell. This eliminates the structural weakening caused by hole drilling while maintaining mounting strength through distributed adhesive bonding across the mounting interface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Maintains the ballistic integrity of the helmet, enables adaptable and interchangeable mounting of various devices, reduces snag hazards, and standardizes the interface for increased modularity and compatibility.
Implementation Method 1
The outer portion has an inward facing surface configured to receive an adhesive layer for coupling the inward facing surface to a surface of the helmet
Data Source
AI summary
A helmet mount system for attaching a device to a helmet comprises a threaded interface assembly having an outer portion and a threaded insert received within a cavity formed in the outer portion. The outer portion has an inward facing surface configured to receive an adhesive layer for coupling the inward facing surface to a surface of the helmet. In a further aspect, a ballistic helmet having the helmet mount system herein is provided, wherein the helmet mount system does not penetrate a ballistic layer of the ballistic shell.