Concentric Shell Helmet With Deforming Impact Structures
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Solution Overview
Problem
Current helmets are effective in preventing skull fractures but leave wearers vulnerable to concussions due to insufficient energy absorption from collisions, particularly in sports and activities that involve rapid changes in skull velocity relative to the brain.
Innovation Solution
A helmet design featuring two concentric shells with impact-absorbing structures between them, which deform under strong impact forces to reduce energy transmission to the wearer's skull, and modular rows that simplify manufacturing and allow for independent movement of the shells to mitigate rotational acceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-shell helmet design is used, then skull fracture prevention is achieved, but concussion protection is insufficient
Solution Approach 1:
The helmet is divided into two concentric shells with impact-absorbing structures positioned between them. The outer shell distributes impact forces over a wider area, while the inner shell provides rigid protection. The segmented structure allows independent optimization of each shell's function - the outer shell for force distribution and the inner shell for skull protection - while the impact-absorbing structures between them provide dedicated energy dissipation capability to prevent concussions.
2Strength
If rigid shell is used, then skull fracture protection is improved, but impact force transmission to brain increases
Solution Approach 1:
Impact-absorbing structures serve as intermediary elements positioned between the outer shell and inner shell. These structures receive distributed impact forces from the outer shell and transform them through deformation (buckling, crushing) before transmitting reduced forces to the inner shell. This intermediary layer prevents direct force transmission from the outer shell to the wearer's skull and brain, thereby reducing concussion risk while maintaining skull protection.
3Loss of energy
If impact absorbing structures are added between concentric shells, then concussion protection is improved, but manufacturing complexity increases
Solution Approach 1:
The impact-absorbing structures are positioned at specific locations between the concentric shells where impact forces are most likely to occur. Rather than making the entire helmet structure complex, the design concentrates energy-absorbing elements in strategic positions. The outer shell maintains a simple rounded shape for force distribution, while the inner shell remains relatively simple for skull protection, with complexity localized to the impact-absorbing structures between them.
4Area of stationary object
If outer shell is made flexible to deform locally, then impact force distribution is improved, but energy absorption capacity decreases
Solution Approach 1:
The design merges two distinct mechanisms into a unified system: the flexible outer shell provides force distribution over a wider area, while the impact-absorbing structures between the shells provide dedicated energy dissipation through controlled deformation. By combining these two functions in separate components rather than relying on a single mechanism, the helmet achieves both broad force distribution and sufficient energy absorption capacity.
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 design reduces the incidence and severity of concussions by effectively absorbing and dissipating impact forces, thereby enhancing head protection beyond traditional helmet capabilities.
Implementation Method 1
the impact absorbing structures undergo deformation (e.g., buckling) when subjected to forces from a sufficiently strong impact force. As a result of the deformation, the impact absorbing structures reduce energy transmitted from the outer shell to the inner shell
Implementation Method 2
the impact absorbing structures reduce energy transmitted from the outer shell to the inner shell, thereby reducing forces on the wearer's skull and brain
Implementation Method 3
the outer shell may also somewhat rigid to spread impact forces over a wider area of the impact absorbing structures positioned inside the outer shell
Data Source
AI summary
A garment worn by a wearer has an exterior shell and an interior shell with various impact absorbing material between the exterior shell and the interior shell. The impact absorbing material includes multiple structures, such as rods or filaments, capable of deforming when force is applied then returning to its state prior to application of the force. In various embodiments, the impact absorbing material is manufactured using injection molding to allow positioning of various structures in the impact absorbing material relative to each other during manufacture. During manufacturing, one or more living hinges are included in portions of the impact absorbing material to allow certain portions of the impact absorbing material to be accurately positioned relative to each other. Other manufacturing methods may be used, such as three-dimensional printing may be used to include structures in the impact absorbing material.