Helmet Load Distribution Plate with Adjustable Nesting Pods
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Solution Overview
Problem
Existing helmets do not adequately address the issue of high pressure points created by open or less dense impact absorption structures, leading to discomfort and inadequate impact mitigation, and fail to provide a customizable fit for different head sizes and dimensions.
Innovation Solution
The helmet system incorporates an impact mitigation layer with load distribution plates and a fit-adjustable liner featuring protrusions and nesting pods, which distribute impact forces uniformly and allow for customizable fitting through interchangeable nesting pods of varying heights and thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If open or less dense impact absorption structures are used, then impact absorption capacity is improved, but high pressure points are created causing discomfort
Solution Approach 1:
The liner is divided into multiple regions with different densities - denser material in high-pressure areas and less dense material in lower pressure areas. This local variation in density allows the liner to distribute impact forces more evenly across the head, eliminating high pressure points while maintaining effective impact absorption capacity.
2Ease of manufacture
If fixed liner design is used, then manufacturing simplicity is improved, but adaptability to different head sizes is reduced
Solution Approach 1:
The liner is segmented into multiple removable regions that can be independently adjusted or removed. This segmentation allows the helmet to be customized for different head sizes and shapes while maintaining a relatively simple manufacturing process, as each region can be produced separately and then assembled.
Solution Approach 2:
The liner transitions from a fixed, static design to a dynamic, adjustable system where regions can be added, removed, or repositioned. This dynamic approach enables the same helmet base to adapt to various head sizes and preferences, significantly improving versatility without complicating the core manufacturing process.
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 system effectively mitigates high pressure points and provides a comfortable, customizable fit by distributing impact forces uniformly and accommodating varying head sizes, enhancing both comfort and protection.
Implementation Method 1
impact absorbing structures
Implementation Method 2
impact mitigation
Implementation Method 3
customizable fit
Data Source
AI summary
A helmet system includes an outer shell, an absorption layer coupled to the outer shell, a load distribution plate coupled to the absorption layer, and a liner coupled to the inner load distribution plate. The absorption layer can include multiple absorption structures extending from an outer end adjacent to the outer shell to an inner end, where the inner ends of the absorption structures define an inner surface of the absorption layer. Each absorption structure can include a tapered shape profile between its outer end and its inner end, and the load distribution plate is coupled to the inner surface of the absorption layer. The liner can be positioned adjacent to a head of a wearer of the helmet system.