Flexible Protective Helmet Shells for Impact Energy Distribution
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Solution Overview
Problem
Current protective helmets with rigid shells and firm cushion layers fail to effectively distribute and absorb impact energy, leading to potential micro-concussions and concussions, which can contribute to long-term brain degeneration such as Chronic Traumatic Encephalopathy (CTE).
Innovation Solution
A protective helmet design featuring a flexible outer shell with a Flexural Modulus ranging from 50 MPa to 600 MPa and a cushion layer made of flexible, open-cell foams like crosslinked polyurethane, which spreads impact energy over a larger area and absorbs it effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid layer shell with high Flexural Modulus is used to protect the head, then the shell can resist impact forces, but the cushion layer cannot effectively spread and absorb the impact energy, leading to concentrated force on the head
Solution Approach 1:
The patent applies a flexible shell principle by using a cushion layer with specific flexibility characteristics (Flexural Modulus between 0.5 MPa to 500 MPa) that can deform and spread impact forces. This flexible cushion layer replaces the traditional rigid foam, allowing the shell system to absorb and distribute impact energy across a larger area rather than concentrating it on the head.
Solution Approach 2:
The patent changes the key parameter of the cushion layer from high rigidity (traditional firm foam) to controlled flexibility (Flexural Modulus 0.5-500 MPa). This parameter change enables the cushion layer to effectively spread impact energy while maintaining structural integrity, resolving the contradiction between shell strength and impact energy distribution.
2Stability of the object's composition
If a firm and hard cushion layer is used inside the rigid shell, then the cushion layer provides structural support, but it does not provide sufficient spreading of impact energy over a larger area to reduce force per square inch
Solution Approach 1:
The patent changes the Flexural Modulus parameter of the cushion layer to a specific range (0.5 MPa to 500 MPa) that balances stability and energy spreading. This parameter optimization allows the cushion layer to maintain its structural composition while simultaneously spreading impact energy over a larger area, reducing the force intensity on the head.
Solution Approach 2:
The patent creates a composite structure combining the rigid shell (Flexural Modulus > 600 MPa) with a flexible cushion layer (Flexural Modulus 0.5-500 MPa). This composite material approach allows each layer to perform its optimal function: the shell provides external protection while the cushion layer spreads and absorbs impact energy, resolving the contradiction between structural support and impact force reduction.
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 intensity of impact forces per square inch, minimizing the risk of brain trauma and potentially preventing conditions like CTE by distributing and absorbing energy more efficiently.
Implementation Method 1
spreads impact energy over a larger area and absorbs it effectively
Implementation Method 2
The rigid layer shell transfers the energy from an impact force to a cushion layer 2 of material in contact with the rigid layer shell that is intended to mitigate the energy to the wearer's head
Implementation Method 3
absorbs it effectively
Implementation Method 4
The rigid layer shell transfers the energy from an impact force to a cushion layer 2 of material in contact with the rigid layer shell that is intended to mitigate the energy to the wearer's head
Data Source
AI summary
A protective helmet comprising a helmet shell having at least two layers and the helmet shell having a flexural modulus from 50 MPa to 600 MPa as measured using ASTM D 790 B and a non-foamed specific gravity in the range of 0.916 g/cm3 up to 1.60 g/cm3. More than one helmet shell may be combined to provide greater protection to the wearer. The layers may be constructed of an open cell foam, a waterproof coating layer, a separator layer, a flexible layer, a slightly foamed layer, and a cushion layer. A protective facial barrier may be easily removed with use of a locking mechanism which removably secures the facial barrier to the helmet shell. The helmet shells may also be in parts and hinged so that the parts can separate for easy removal of the protective helmet. An adjustment locking mechanism may also tighten and adjust a second helmet shell.