Helmet Liner Assembly Interlocking Segments

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Solution Overview

Problem

Existing helmet liner assemblies often result in gaps between the liner and the helmet shell due to trimming processes, increasing manufacturing time and labor costs, and requiring complex assembly methods.

Innovation Solution

A helmet liner assembly with complementary shaped left and right liner portions and a central liner portion that interlock via projections and recesses, rabbeted edges, and engagement surfaces to reduce relative movement and secure the assembly within the helmet shell without adhesives or fasteners, using expanded polystyrene (EPS) material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a foam piece is trimmed to fit the liner into the cavity, then the liner can be manufactured, but gaps are left between the liner and the shell inner surface, reducing efficiency

Engineering Contradiction:

Improveliner manufacturingVSAvoidliner fit to shell

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The liner assembly is divided into multiple segments: a first liner portion with a first engagement surface, a second liner portion with a second engagement surface, and a bridging portion connecting them. This segmentation allows each portion to be optimized for specific engagement zones, eliminating gaps while maintaining manufacturability through modular construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a bridging portion that extends in a third dimension between the first and second liner portions. This vertical bridging element fills the gap between lateral portions, transforming a two-dimensional trimming problem into a three-dimensional engagement solution that eliminates gaps without compromising manufacturing ease.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If multiple liner pieces are used to reduce gaps, then the liner fit improves, but the assembly process becomes more complex and manufacturing time increases

Engineering Contradiction:

Improveliner fit to shellVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The first and second liner portions are merged with a bridging portion that integrates them into a unified assembly. The engagement surfaces are designed to work together as a cohesive system, reducing the number of separate assembly steps while maintaining the gap-reducing benefits of multiple portions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The liner assembly is designed with self-aligning engagement surfaces that guide the pieces into proper positioning during assembly. The bridging portion automatically finds its position between the first and second portions, reducing the need for complex alignment procedures and minimizing assembly time.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If multiple liner pieces are connected via adhesive or fasteners, then the liner structure is secured, but labor costs and manufacturing complexity increase

Engineering Contradiction:

Improveliner structure securityVSAvoidassembly process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The invention replaces adhesive or fastener-based mechanical connection systems with a geometric interlocking system. The engagement surfaces are shaped to create inherent mechanical retention through form-fit, eliminating the need for additional bonding materials or fasteners and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The engagement surfaces are designed with specific geometric parameters including angled surfaces and interlocking features that create inherent mechanical retention. By optimizing these geometric parameters, the liner portions achieve secure connection through shape alone, eliminating the need for adhesives or fasteners.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20230255298A1Helmet liner assembly

Publication Date: 2023.08.17 KIMPEX

AI summary

A helmet having a helmet shell with an inner surface defining a cavity and a frontal opening is provided. The helmet includes a liner assembly for engagement with the helmet shell within the cavity, and which has a lateral liner portion including left and a right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively. The left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, with the chin segments being configured to engage one another proximate a front section of the helmet. The liner assembly also includes a central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central portion of the inner surface portion for engagement therewith.