Flexible Circuit Substrate for Helmet Power Distribution

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Solution Overview

Problem

The integration of accessory mounting and electrical interconnection devices on ballistic helmets poses challenges due to the need for complex wiring, which compromises the anti-ballistic properties of the helmet and complicates assembly.

Innovation Solution

A flexible circuit substrate with a conductive pattern is integrated into the helmet, providing a secure and non-penetrative means for electrical connections between power supplies and accessories, using terminal pads and mechanical fasteners for secure attachment without compromising the ballistic integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wiring assemblies are used to provide electrical connections between power supply and accessories on the helmet, then electrical power distribution is achieved, but the ballistic integrity of the helmet is compromised and device complexity increases

Engineering Contradiction:

Improveelectrical power distributionVSAvoidballistic integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent extracts the wiring assemblies from the helmet structure and replaces them with a flexible circuit substrate that provides electrical connections through printed conductive traces. This removal of traditional wiring eliminates the need for penetrating the helmet shell, thereby maintaining ballistic integrity while achieving the same electrical power distribution function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical wiring system with a flexible circuit substrate that uses printed conductive patterns. This substitution eliminates the need for physical cable routing and mechanical connections, reducing device complexity and preserving the helmet's structural integrity while maintaining electrical connectivity between power supply and accessories.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple openings and holes are provided in the helmet for mounting accessories and running cables, then accessory functionality is enhanced, but the anti-ballistic properties are compromised

Engineering Contradiction:

Improveaccessory mounting capabilityVSAvoidanti-ballistic properties

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The flexible circuit substrate serves multiple functions simultaneously: it provides electrical power distribution, data transmission, and structural support for accessory mounting. By integrating these functions into a single component that conforms to the helmet's inner surface, the patent eliminates the need for separate openings and holes, thereby maintaining accessory versatility while preserving ballistic protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent transitions from a three-dimensional wiring approach (cables running through the helmet volume) to a two-dimensional surface-based solution (flexible circuit substrate conforming to the inner helmet surface). This dimensional change allows electrical connections to be made without penetrating the helmet shell, maintaining anti-ballistic properties while enabling accessory functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Use of energy by moving object

If traditional wiring assemblies are used for electrical connections, then power distribution is achieved, but assembly complexity and installation difficulty increase

Engineering Contradiction:

Improveelectrical power transmissionVSAvoidwiring assembly complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent employs a flexible circuit substrate made of thin film material that can be easily conformed to the inner surface of the helmet. This flexible substrate carries printed conductive traces that provide electrical power transmission, eliminating the need for complex rigid wiring assemblies and simplifying both the device structure and installation process.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent replaces the mechanical wiring assembly system with a flexible circuit substrate system that uses printed conductive patterns for electrical connections. This substitution dramatically reduces assembly complexity, as the flexible substrate can be easily installed by conforming it to the helmet's inner surface without requiring complex cable routing, connectors, or sealing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8908389B2Power distribution system and helmet and method employing the same

Publication Date: 2014.12.09 WILCOX IND CORP CORP

AI summary

An integrated accessory mounting and electrical interconnection device are provided which can be embedded or attached to the surface of a ballistic or non-ballistic helmet. The helmet system herein includes a flexible circuit substrate that may be embedded between a ballistic shell and an outer skin or shell. The helmet system and method allow a secure connection of helmet mounted accessories to the helmet without the need to penetrate any one or more layers of the ballistic shell with mounting hardware, fasteners, wiring vias, and so forth.