Protective Helmet Epoxy Resin Layer for Oblique Impact Absorption

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Solution Overview

Problem

Existing helmets are ineffective in absorbing oblique impacts, leading to rotational acceleration of the brain, and do not significantly improve radial impact absorption compared to standard helmets, with complex and costly designs that are not compatible with pre-existing helmets.

Innovation Solution

A helmet design featuring an epoxy resin layer on the inner surface of the impact absorbing liner between the outer shell and comfort liner, which distributes impact force, reduces linear and rotational acceleration by allowing mutual displacement during impacts, and is applied using methods like spraying or brushing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an additional layer is positioned between the impact absorbing liner and the comfort liner to improve radial impact absorption, then radial impact absorption is improved, but oblique impact absorption remains ineffective and device complexity increases

Engineering Contradiction:

Improveradial impact absorptionVSAvoidhelmet structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies a low-friction coating specifically on the inner surface of the impact absorbing liner, creating a localized functional modification rather than adding a complete additional layer. This local quality change reduces friction between the liner and comfort liner, enabling relative movement that absorbs oblique impacts while maintaining the existing helmet structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent replaces the mechanical approach of adding rigid structural layers with a surface property modification (low-friction coating). This substitution changes the interaction mechanism from mechanical interlocking to reduced friction, allowing the comfort liner to slide relative to the impact absorbing liner during oblique impacts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If standard helmet layers are used without modification, then manufacturing is simple and cost-effective, but oblique impacts cause rotational acceleration of the brain

Engineering Contradiction:

Improvehelmet manufacturing simplicityVSAvoidrotational brain acceleration from oblique impacts

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The low-friction coating acts as an intermediary layer between the impact absorbing liner and the comfort liner. This intermediary reduces the frictional force that would otherwise prevent relative movement, enabling the comfort liner to slide and rotate independently during oblique impacts, thereby reducing rotational acceleration transmitted to the brain.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent introduces dynamic relative movement between previously static layers by reducing friction through the coating. During oblique impacts, the comfort liner can now move dynamically relative to the impact absorbing liner, allowing energy dissipation through sliding and rotation rather than rigid force transmission.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If friction between the impact absorbing liner and comfort liner is high, then layers remain stable, but oblique impact forces cannot be absorbed and rotational acceleration occurs

Engineering Contradiction:

Improvelayer stabilityVSAvoidoblique impact absorption

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent changes the friction parameter at the interface between the impact absorbing liner and comfort liner by applying a low-friction coating. This parameter change allows the system to maintain stability during normal use while enabling controlled relative movement during oblique impacts, resolving the contradiction between stability and impact absorption.

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 epoxy resin layer effectively reduces peak linear and rotational accelerations, enhancing impact absorption and compatibility with existing helmet structures while maintaining comfort and reducing the risk of brain damage from oblique impacts.

Implementation Method 1

the epoxy resin layer effectively reduces peak linear and rotational accelerations, enhancing impact absorption

Methodology Applied

Scientific EffectImpact force distribution: Impact Force

Implementation Method 2

allowing mutual displacement during impacts

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12022904B2Protective helmet

Publication Date: 2024.07.02 ALPINESTARS RES SRL

AI summary

Protective helmet (1) designed to be worn by a user and to protect the head (H) of the user during an impact. The protective helmet (1) comprises a rigid outer shell (6) and a comfort liner (10) having an inner surface (18), designed to be in contact with the user's head (H) when the helmet (1) is worn by the user, and an outer surface (20), opposite to the inner surface (18). The helmet (1) further comprises an impact absorbing liner (8) interposed between the rigid outer shell (6) and the comfort liner (10) and having an inner surface (22) facing the outer surface (20) of the comfort liner (10). The inner surface (22) of the impact absorbing liner (8) comprises at least one layer (36) made of an epoxy resin in contact with the comfort liner (10) in use.