Custom Helmet Padding Assembly for Precise Head Contour Fit
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Solution Overview
Problem
Conventional protective sports helmets provide limited adjustment to fit a player's head size and contours, leading to inadequate fit and comfort, and susceptibility to movement during impacts.
Innovation Solution
A system and method for acquiring and processing a player's unique anatomical data to manufacture a bespoke helmet with a custom-formed internal padding assembly that matches the player's head topography and contours, using a scanning process and three-dimensional modeling to create customized padding inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional standard-sized helmets are used, then manufacturing cost and simplicity are maintained, but fit accuracy and comfort deteriorate due to limited adjustment options
Solution Approach 1:
The patent performs preliminary scanning and data collection of the player's head anatomy before helmet manufacturing. By capturing the head contour data in advance and creating a custom mold based on this data, the system prepares the personalized fitting parameters beforehand, enabling precise fit without requiring complex adjustments during assembly.
Solution Approach 2:
The patent creates a physical mold that is a direct copy of the player's head contour by scanning the head surface and transferring this digital model into a physical molding template. This copy serves as the basis for manufacturing custom-fitted padding and shell components, achieving precise anatomical matching without requiring the entire helmet to be custom-manufactured.
2Adaptability or versatility
If standard internal padding assemblies are used, then ease of manufacture is maintained, but adaptability to different head contours deteriorates
Solution Approach 1:
The patent applies local quality by creating padding assemblies with spatially varying properties. The mold captures the specific contour characteristics of the player's head at different locations, and the resulting padding has customized density, thickness, and shape at each local region to match the anatomical variations, rather than using uniform padding throughout.
Solution Approach 2:
The contour-matching padding is manufactured in advance by creating a physical mold from the player's head scan data. This preliminary action produces a custom-fitted padding assembly before the helmet is assembled, combining specialized manufacturing with standard assembly procedures.
3Manufacturing precision
If helmets are designed for standard head sizes, then production efficiency is maintained, but fit precision for individual players deteriorates
Solution Approach 1:
The system performs preliminary digital scanning and modeling of the player's head anatomy before physical manufacturing. By completing the design and mold creation in advance based on scanned data, the system streamlines the subsequent manufacturing process, reducing overall production time while achieving anatomical precision.
Solution Approach 2:
The patent uses digital copying of the head contour into a 3D model, then transfers this digital copy into a physical mold. This copying process enables precise reproduction of anatomical features without requiring manual measurement and fabrication, significantly reducing custom manufacturing time while maintaining high precision.
4Adaptability or versatility
If adjustable padding systems are added to standard helmets, then adaptability improves, but device complexity and cost increase
Solution Approach 1:
The patent incorporates dynamic elements into the padding assembly through inflatable or adjustable components that can change volume and shape. This allows the padding to adapt to different head sizes and contours dynamically, providing size adjustment functionality without requiring complex mechanical adjustment mechanisms throughout the entire helmet.
Data Source
AI summary
A partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.