Monolithic Helmet Shell and Lattice Structure for Ventilation
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Solution Overview
Problem
Current helmets, particularly those for vehicles, face challenges with ventilation systems that limit air circulation, leading to increased head temperature and reduced comfort, while also having limited durability due to the use of materials like Styrofoam that degrade over time and are not suitable for high-impact resistance.
Innovation Solution
A helmet design featuring a monolithic connection between the shell and lattice structure with interconnected air channels for improved air circulation and a three-dimensional lattice structure made from fibers that provides enhanced mechanical resistance, lightness, and ventilation, along with a manufacturing method using three-dimensional printing to create a single piece without complex molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Styrofoam protective padding is used, then the helmet can absorb impact energy, but the validity period is limited to 5 years due to temperature and humidity degradation
Solution Approach 1:
The patent changes the material parameter from traditional Styrofoam to a lattice structure made of thermoplastic material with optimized geometric parameters. The lattice structure maintains impact energy absorption capability while being resistant to temperature and humidity degradation, thus extending the validity period beyond 5 years.
Solution Approach 2:
The patent creates a composite structure combining the shell, lattice protective padding, and comfort padding as a single integrated component through 3D printing. This composite approach allows the lattice structure to provide both protective function and environmental stability, resolving the contradiction between impact absorption and durability.
2Ease of operation
If bigger channels are realized in the protective padding for ventilation, then air circulation is improved, but the padding is too weakened making the helmet unsafe
Solution Approach 1:
The patent employs a porous lattice structure that inherently provides ventilation channels while maintaining structural strength. The interconnected pores allow air circulation without requiring large channels that would compromise padding integrity, thus resolving the contradiction between ventilation and strength.
Solution Approach 2:
The lattice structure distributes ventilation pathways across three dimensions, creating numerous small interconnected channels rather than a few large channels. This dimensional approach allows sufficient air circulation while maintaining the structural integrity of the protective padding.
3Ease of operation
If bigger holes are made in the shell for ventilation, then air entry is improved, but the shell becomes potential trigger points for fractures during impact
Solution Approach 1:
The patent uses a porous lattice structure integrated with the shell that provides numerous small ventilation openings distributed across the shell surface. This approach allows air entry while avoiding large holes that would create stress concentration points and potential fracture triggers during impact.
4Strength
If the helmet structure is made more robust for high-impact resistance, then protection is improved, but the weight increases
Solution Approach 1:
The patent segments the protective function into the shell and the lattice structure, where the lattice provides the primary impact absorption through its geometric design. This segmentation allows the shell to be lighter while the lattice structure, positioned strategically, provides the necessary impact resistance without excessive weight.
Solution Approach 2:
The lattice structure utilizes curved and optimized geometric forms that efficiently distribute impact forces throughout the structure. The curved lattice elements provide superior strength-to-weight ratio compared to straight structural members, enabling high impact resistance with reduced weight.
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 enhances air exchange and internal air recirculation, providing better comfort and extended durability while maintaining mechanical resistance, and the three-dimensional printing method simplifies production, avoiding costly and complex manufacturing techniques.
Implementation Method 1
The material of the protective padding, making itself smaller and compact, allows to absorb the energy of a big impact
Implementation Method 2
a continuous network of interconnected air channels runs through the shell and the lattice structure to enable the passage of air from the external to the internal of the helmet
Data Source
Figure 1~2
Figure 3~4
Figure 5~6E
AI summary
Protective helmet (1) comprising a shell (10) and a lattice structure (11), wherein said shell and said lattice structure are monolithically connected each other and configured so that a continuous network of interconnected air channels runs through the shell and the lattice structure to enable the passage of air from the external to the internal of the helmet.