Baseball Cap Impact Layer Using Bursting Gas Cells
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Solution Overview
Problem
Current protective helmets fail to provide a complete cocoon of safety for the head, particularly in reducing concussion injuries, as they lack an outer layer of flexibility and energy dissipation, unlike the human scalp, which tears to increase deceleration distance and time, whereas existing foam-based solutions do not adequately burst or deform to dissipate force effectively.
Innovation Solution
A replaceable impact layer incorporating gas cells, which burst upon impact to increase deceleration distance and time, combined with a removable attachment system and an outer sheet material, is integrated into helmets and baseball caps to provide blunt force trauma protection, complementing the existing rigid structures with a flexible and lightweight layer that can absorb and dissipate impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid foam-based protective layers are used in helmets, then impact protection is provided, but the weight increases and rotational neck injuries may occur
Solution Approach 1:
The patent uses gas-filled cells (pneumatic structures) instead of solid foam to create a protective layer that is both lightweight and effective at dissipating impact forces. The gas cells can deform and burst to absorb energy while maintaining significantly lower weight compared to traditional foam materials.
Solution Approach 2:
The patent employs flexible gas cell structures that can deform under impact rather than rigid foam. These flexible cellular structures provide protection through controlled deformation and bursting, reducing the need for heavy rigid materials while maintaining protective functionality.
2Strength
If rigid helmet structures are used, then skull protection is provided, but deceleration time is insufficient leading to concussion injuries
Solution Approach 1:
The patent incorporates a pre-designed gas cell layer between the rigid helmet shell and the head that is specifically engineered to deform and burst during impact. This beforehand cushioning structure increases deceleration time by providing a progressive failure mode where cells collapse in sequence, extending the duration of force dissipation.
Solution Approach 2:
The gas cells undergo a phase transition from intact to burst state during impact, transforming from a contained gas structure to a collapsed configuration. This phase change absorbs energy over an extended period, increasing deceleration time while protecting the skull.
3Loss of energy
If traditional foam protective layers are used, then some cushioning is provided, but they do not burst or deform effectively to dissipate force
Solution Approach 1:
The gas cells are designed as single-use, disposable elements that burst upon impact. Rather than relying on reusable foam that deforms elastically, the patent uses inexpensive gas cells that permanently fail (burst) to dissipate energy, providing more effective force absorption through irreversible deformation.
Solution Approach 2:
The patent changes the physical parameters of the protective layer by using gas-filled cells with specific pressure thresholds. These cells are engineered to burst at predetermined pressure levels, creating a parameter-based failure mode that is more effective at energy dissipation than the elastic deformation of traditional foam.
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
The solution effectively reduces instantaneous G-force deceleration shock waves by increasing the deceleration distance and time, thereby minimizing the risk of concussion injuries and providing enhanced protection without the weight and rotational injuries associated with traditional foam-based solutions.
Implementation Method 1
The at least one gas cell layer includes a plurality of gas cells created between two plastic sheets. Each cell will burst upon a pre-determined impact.
Implementation Method 2
The physics of head injury is all focused on the distance over which deceleration occurs. The Holy Grail of injury prevention in deceleration injury is to increase the distance and therefore time during which deceleration occurs.
Data Source
AI summary
A baseball cap having impact protection includes a prior art baseball cap and an inner impact layer. The inner impact layer preferably includes at least two impact wedges. Each impact wedge matches the outer perimeter shape of one of the six wedges that make-up a cap portion of the baseball cap. Each impact wedge includes a plurality of non-bursting gas cells. Each gas cell preferably has a semi-spherical or a semi-tubular shape. The plurality of impact wedges may be permanently or removably secured to an inside surface of the baseball cap. The impact wedge includes a base sheet and an outside sheet. The outside sheet is attached to the base sheet to form the plurality of non-bursting gas cells. Alternatively, each wedge may be fabricated from closed cell foam that matches the outer perimeter shape of one of the six wedges that make-up a cap portion of the baseball cap.