Custom Helmet Mesostructure With Thickness Gradient for Impact Fit
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Solution Overview
Problem
Existing helmets do not conform to the anthropometric aspects of individuals' heads, leading to issues with fit, comfort, and stability, which compromises their protective effectiveness during impacts.
Innovation Solution
A custom-designed mesostructure helmet that conforms to the user's head shape, featuring a thickness gradient and can be combined with an outer shell, formed using additive manufacturing, to enhance fit, comfort, and stability, thereby improving impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standardized helmet design is used, then manufacturing cost and complexity are reduced, but fit and comfort for individual users deteriorate
Solution Approach 1:
The patent applies local quality by creating a helmet with spatially varying thickness - the shell is thinner in some regions and thicker in others, optimized for each specific location's impact protection needs while maintaining overall lightweight design. This localized optimization enables both manufacturing efficiency and superior individualized fit
Solution Approach 2:
The patent utilizes parameter changes by varying the thickness parameter of the helmet shell across different spatial locations. The thickness transitions smoothly between regions, allowing the same manufacturing process to produce customized fit characteristics for individual users while maintaining structural integrity
2Ease of manufacture
If a uniform thickness helmet shell is used, then manufacturing is simpler, but impact protection effectiveness deteriorates due to inability to optimize for different impact zones
Solution Approach 1:
The helmet shell features local quality through spatially varying thickness, where critical impact zones have greater thickness for enhanced protection while non-critical areas are thinner to reduce overall weight. This localized optimization improves impact protection effectiveness without complicating the manufacturing process
Solution Approach 2:
The patent introduces thickness variation as an additional design dimension, transitioning from a uniform 2D shell to a 3D variable-thickness structure. This dimensional enhancement allows optimization of impact protection across different zones while maintaining manufacturing simplicity through continuous surface geometry
3Reliability
If a thicker helmet shell is used throughout, then impact protection is improved, but weight and comfort deteriorate
Solution Approach 1:
The helmet implements local quality by providing greater thickness only where impact protection is most needed, while maintaining thinner sections in areas with lower impact risk. This localized thickening achieves superior protection at critical zones without proportionally increasing overall helmet weight
Solution Approach 2:
The patent applies partial action by providing enhanced thickness only in specific regions rather than uniformly throughout the entire shell. This selective thickening delivers adequate protection where required while minimizing unnecessary material and weight in non-critical areas
4Ease of operation
If a customized helmet design is used, then fit and comfort are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent achieves universality by creating a single customized shell design that serves multiple functions: it provides personalized fit through contoured geometry, delivers optimized impact protection through variable thickness, and maintains manufacturing efficiency through continuous surface formation. This multi-functional design reduces the need for additional components or assembly steps
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 mesostructure provides improved fit and comfort, increasing the likelihood of proper helmet wear and enhancing impact protection by distributing load and reducing peak linear and rotational acceleration.
Implementation Method 1
The mesostructure can be designed to include a thickness gradient extending from an inner periphery to an outer periphery of the mesostructure, to reduce peak linear acceleration during an impact
Implementation Method 2
forming the mesostructure using an additive manufacturing technique such as, for instance, three-dimensional (3D) printing
Data Source
AI summary
A custom-formed mesostructure for a helmet and process for designing the mesostructure are described. In one example, a process for designing a helmet for an individual can include generating a model of anthropometric aspects of a head of the individual using a scanning technique. The process can further include editing the model to generate a refined model of the anthropometric aspects of the head. The process can further include designing a mesostructure based on the refined model. The process can also include designing the mesostructure as a latticed structure having a thickness gradient that is relatively thinner along an inner periphery of the mesostructure and thicker along an outer periphery of the mesostructure, to reduce peak linear acceleration during an impact. The process can also include forming the mesostructure using an additive manufacturing technique. The mesostructure can be used independently as a helmet or combined with an outer shell.