Flexible EPU Helmet Shell for Foldable Impact Protection

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Solution Overview

Problem

Current cycle helmets are rigid, making them difficult to carry and store, poorly fit various head shapes, and provide inadequate protection for rotational accelerations and repeated impacts, while existing safety standards restrict the use of more flexible materials due to temperature testing requirements.

Innovation Solution

A helmet with a protective shell made from flexible expanded polyurethane (EPU) material, featuring different density and composition layers, allowing for foldability and improved impact absorption over a wide temperature range, along with a strap arrangement for secure fitting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid expanded polystyrene material is used for the helmet liner, then impact absorption is improved, but the helmet becomes difficult to carry and store

Engineering Contradiction:

Improveimpact absorptionVSAvoidportability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent changes the material parameter from rigid expanded polystyrene to flexible expanded polyurethane, which maintains impact absorption capabilities while adding flexibility for folding and compact storage

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure with multiple layers of EPU material having different densities, combining the benefits of rigidity for impact protection with flexibility for portability

Inventive Principle:

Principle #40Composite materials

2Strength

If rigid expanded polystyrene material is used for the helmet liner, then protection from straight on high speed impacts is improved, but protection against rotational accelerations is inadequate

Engineering Contradiction:

Improveprotection from straight on impactsVSAvoidprotection against rotational accelerations

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the material properties from rigid to flexible, allowing the helmet to deform and absorb rotational energies that rigid materials cannot handle, while maintaining straight-on impact protection through controlled deformation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs flexible EPU material that can deform under rotational forces, providing protection against oblique impacts and rotational accelerations that rigid materials fail to address

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If expanded polystyrene helmet is designed to be thick enough to absorb 12-15 mm of head movement, then deceleration force is reduced below 250 g, but the helmet becomes permanently crushed after one impact

Engineering Contradiction:

Improvedeceleration force reductionVSAvoidreusable protection

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent changes the material from expanded polystyrene to expanded polyurethane, which provides reversible compression and energy absorption, allowing the helmet to be compressed during impact and then return to its original shape for repeated use

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent allows greater compression (12-15 mm) during impact but designs the material to recover fully, providing excessive compression capacity that ensures complete energy absorption while maintaining structural integrity for reuse

Inventive Principle:

Principle #16Partial or excessive action

4Adaptability or versatility

If softer more flexible material is used for the helmet, then portability and fit adaptability are improved, but the material fails temperature extreme testing

Engineering Contradiction:

Improvefit adaptabilityVSAvoidtemperature extreme performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent selects expanded polyurethane with specific material parameters that maintain flexibility and adaptability across a wide temperature range while passing extreme temperature testing, unlike softer materials that fail at temperature extremes

Inventive Principle:

Principle #35Parameter changes

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 helmet is compact, adaptable to various head shapes, provides enhanced protection against rotational accelerations and repeated impacts, and maintains impact absorbency, while meeting safety standards.

Implementation Method 1

the deceleration force in a 20 kph impact will be less than 250 g if the head can travel at least 6.27 mm as it decelerates. Hence, known cycle helmets are designed to do exactly this, by deforming more than 6.27 mm under the force of the head decelerating

Methodology Applied

Scientific EffectImpact absorption: Deformation

Implementation Method 2

The material is resiliently flexible to allow the helmet to be folded into or out of shape yet is able to withstand repeated impacts

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

The material is resiliently flexible to allow the helmet to be folded into or out of shape yet is able to withstand repeated impacts

Methodology Applied

Scientific EffectResilience: Elasticity

Data Source

PatentUS10791789B2Helmet

Publication Date: 2020.10.06 HEADKAYSE

AI summary

A helmet is described, more specifically a helmet comprising a protective shell (10) formed of a flexible expanded polyurethane (EPU) material which defines a cavity for receiving the wearer's head, the shell being foldable, the helmet further comprising a strap (11) arrangement for fastening the shell to the wearer's head.