Helmet Locking Liner with Rotatable Foam Mechanism
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Solution Overview
Problem
Existing helmets lack an effective and adhesive-free mechanism for securely coupling the liner to the outer shell, which can compromise energy management and ease of replacement during impacts.
Innovation Solution
A helmet design featuring a locking liner with a rotatable foam locking piece that engages with an integrally formed locking mechanism on the outer shell, using a mechanical connection without hook and loop fasteners or adhesive, allowing for secure coupling and easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hook and loop fasteners or adhesive are used to couple the liner to the outer shell, then the liner can be securely attached, but the coupling mechanism becomes complex and difficult to replace during impacts
Solution Approach 1:
The coupling mechanism is divided into separate modular components: a locking piece with protrusions that engage with corresponding recesses in the outer shell, and a locking liner with matching features. This segmentation allows the liner to be securely coupled through interlocking geometry while maintaining simplicity and ease of replacement, as the modular design enables quick disengagement without complex adhesive removal or fastener manipulation.
2Reliability
If adhesive is used to attach the liner to the outer shell, then secure coupling is achieved, but the liner cannot be easily replaced and the outer shell lifespan is reduced
Solution Approach 1:
The adhesive is completely extracted from the coupling system and replaced with a mechanical interlocking mechanism featuring locking pieces with protrusions and recesses. This extraction enables the liner to be easily removed and replaced by simply disengaging the locking pieces, while the outer shell retains its full lifespan without adhesive degradation or damage, as no chemical bonding occurs between the liner and shell.
3Ease of repair
If a mechanical locking mechanism is used without adhesive, then ease of replacement is improved, but coupling security may be compromised during impacts
Solution Approach 1:
The locking mechanism employs asymmetric interlocking geometry where the locking piece features specifically shaped protrusions that engage with corresponding asymmetric recesses in the outer shell. This asymmetric design creates a mechanically secure connection that resists disengagement during impact forces from any direction, while maintaining ease of replacement through a simple rotational or linear disengagement motion that does not require adhesive breakdown.
Data Source
AI summary
A helmet can comprise an outer shell comprising an outer surface and an inner surface opposite the outer surface, wherein the inner surface of the outer shell comprises an integrally formed locking mechanism. The helmet can also comprise a locking liner formed of a foam material and disposed within the outer shell adjacent the inner surface of the outer shell. The locking liner can further comprise at least one side piece sized to fit between a lower edge of the outer shell and top portion of the outer shell, a top piece disposed at the top portion of the outer shell and comprising a central opening, and a rotatable foam locking piece sized to fit within the central opening and comprising a tab that is sized to mateably couple with the integrally formed locking mechanism of the outer shell to releasably couple the locking liner to the outer shell.