Helmet Liner Studs for Damping and Weight Reduction
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Solution Overview
Problem
Conventional sports helmets face challenges in balancing damping properties with weight and manufacturing complexity, particularly in the critical top zone, which affects comfort and certification standards.
Innovation Solution
A helmet design featuring a monolithic cap with a first layer and studs that project from the cap, where the height of the studs is greater than the thickness of the first layer, allowing for improved anchoring and deformation-based damping, reducing the number of parts and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the cap is increased to improve damping properties, then the damping performance is improved, but the weight of the helmet increases
Solution Approach 1:
The cap is segmented into a first layer and multiple studs that are integrally formed. The studs are distributed across the cap surface, with varying heights to provide localized damping zones. This segmentation allows the damping function to be distributed throughout the cap structure rather than requiring uniform thickness increase, thereby maintaining lightweight properties while achieving effective damping.
Solution Approach 2:
The studs have different heights (first studs, second studs, third studs) arranged in specific patterns across the cap. This creates local variations in damping characteristics - higher studs in critical impact zones provide enhanced damping where needed, while lower studs in less critical areas reduce overall weight. This local quality approach optimizes damping performance without uniformly increasing cap thickness.
2Reliability
If independent studs are added to the helmet to improve damping, then the damping properties are improved, but the manufacturing complexity and production cost increase
Solution Approach 1:
The studs and the cap's first layer are merged into a single integral structure formed by one molding operation. The studs are not separate components that need to be attached separately; rather, they are formed as an integral part of the cap during the molding process. This merging eliminates the complexity of separate stud attachment processes and reduces production steps while maintaining the damping benefits of multiple studs.
3Ease of manufacture
If the number of assembled parts is reduced to simplify production, then the manufacturing process is simplified, but the damping performance may be compromised
Solution Approach 1:
The cap and multiple studs are combined into a single molded part, eliminating the need for separate assembly operations. This integral construction simplifies manufacturing while preserving the damping performance that would otherwise require multiple separate studs to be precisely positioned and attached. The single-mold approach ensures proper stud positioning and eliminates assembly complexity.
Solution Approach 2:
Within the single molded cap structure, the segmentation into first layer and multiple studs of varying heights is maintained. This internal segmentation provides the necessary damping zones without requiring external assembly. The studs are distributed with different heights to create effective damping zones while being formed as one piece, thus simplifying production while maintaining performance.
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 results in a lightweight, ventilated helmet with enhanced damping properties, improved anchoring, and reduced manufacturing complexity, while maintaining safety and comfort standards.
Implementation Method 1
the height of the studs allows deformation by bending and/or buckling, which improves the damping properties of the helmet
Implementation Method 2
the height of the studs allows deformation by bending and/or buckling, which improves the damping properties of the helmet
Data Source
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AI summary
The invention relates to a helmet (10) comprising: - an outer shell (11), - a liner (13), made of a material such as EPS or EPP, the liner being located inside the shell and having an upper part (131) intended to cover at least the top of the skull, the liner comprising a first layer (132) of thickness "e" covering substantially the upper part and several studs (133) projecting from the first layer towards the head, of a height "h", the first layer and the studs forming a single piece (13). The height of the studs is greater than the thickness of the first layer.