3D-Printed Helmet Lattice Structure for Multi-Impact Protection
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Solution Overview
Problem
Helmets, particularly for sports like hockey and lacrosse, face challenges in balancing lightweight design with effective impact protection, breathability, comfort, and manufacturability, often requiring trade-offs due to material limitations and manufacturing constraints.
Innovation Solution
Incorporation of additively-manufactured components in helmets, such as adjustable shell members and liners with distinct zones for impact protection, to enhance fit, comfort, and adjustability, utilizing materials like polymeric foams and liquid crystal elastomers, and lattice structures for energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manufacturing methods are used for helmet components, then manufacturability is maintained, but impact protection and weight optimization are compromised
Solution Approach 1:
The patent applies parameter changes by utilizing additive manufacturing technology to create components with varying material densities and structural parameters. The lattice structures and cellular patterns allow for optimization of strength-to-weight ratio that cannot be achieved with traditional uniform manufacturing methods, enabling region-specific impact protection while reducing overall weight.
Solution Approach 2:
The patent employs composite materials by combining different materials with complementary properties in the additively manufactured components. This includes using materials with different stiffness, strength, and energy absorption characteristics in specific zones to achieve superior impact protection across multiple impact types while maintaining manufacturability through additive processes.
2Weight of moving object
If helmet weight is reduced for comfort, then breathability and comfort improve, but impact protection capability deteriorates
Solution Approach 1:
The patent applies local quality by creating non-uniform structures with varying material properties in different regions of the helmet. Critical impact zones have higher density and stronger lattice structures for maximum protection, while non-critical areas have lower density for weight reduction. This localized optimization achieves both weight reduction and maintained impact protection.
Solution Approach 2:
The patent segments the helmet structure into multiple functional zones with different structural characteristics. The shell is divided into regions with varying thickness and lattice density, allowing each segment to be optimized for its specific function - some areas prioritize impact resistance while others prioritize weight reduction and breathability.
3Device complexity
If fixed helmet structure is used for simplicity, then device complexity is reduced, but fit and comfort adjustability worsen
Solution Approach 1:
The patent applies dynamics by incorporating movable and adjustable components into the helmet structure. The shell members are designed to be repositionable relative to one another, allowing the helmet to adapt to different head sizes and shapes. This dynamic adjustability is achieved through integrated adjustment mechanisms that maintain structural integrity while enabling customization.
Solution Approach 2:
The patent achieves universality by designing a single helmet structure that can accommodate multiple users with different head dimensions. The additively manufactured components include integrated adjustment features that allow the same helmet to provide optimal fit and comfort across a range of users, eliminating the need for multiple fixed-size helmets.
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 additively-manufactured components provide improved impact protection, including multi-impact management, while maintaining a lightweight and comfortable fit, with adjustable features that enhance helmet performance and manufacturability.
Implementation Method 1
a first portion of the additively-manufactured component is configured to protect more against linear impact components than rotational impact components; and a second part of the additively-manufactured component is configured to protect more against rotational impact components than linear impact components
Implementation Method 2
utilizing materials like polymeric foams and liquid crystal elastomers
Implementation Method 3
lattice structures for energy absorption
Data Source
AI summary
A helmet comprising one or more additively-manufactured components designed to enhance performance and use of the helmet, such as: impact protection, including for managing different types of impacts; fit and comfort; adjustability; and/or other aspects of the helmet. Methods of additively-manufacturing components for such helmets are also provided, including methods involving expandable materials and the expansion of post-additively manufactured expandable components.