Helmet Impact Reduction Layer Using Microgear Energy Dissipation

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Solution Overview

Problem

Current head protection devices for sports and physical activities lack an impact-proof, shock-absorbing, lightweight, and reusable design that effectively mitigates high-speed impacts without being destroyed during collisions.

Innovation Solution

A head protection device comprising an outer shell, a flexible elastomeric seal, an impact reduction layer with embedded hemi-spherical impact-absorbers, penta-pieces, and gear units on an elastic net, secured to a base helmet with fastener pins and impact absorber members, which absorbs and dissipates impact energy through rotational motion of microgears.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional head protection devices are used, then basic protection is provided, but they lack impact-proof and shock-absorbing capabilities for high-speed impacts

Engineering Contradiction:

Improveimpact protection reliabilityVSAvoidimpact energy

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The impact reduction layer is divided into multiple independent impact absorbers distributed across the helmet surface. Each absorber independently absorbs impact energy, preventing energy concentration at single points and ensuring reliable protection across various impact scenarios

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The impact absorbers are pre-positioned within the impact reduction layer in a compressed state, ready to immediately absorb impact energy when subjected to high-speed impacts, thereby providing beforehand cushioning before the impact reaches the head

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If traditional head protection devices are used, then protection is provided, but they are not lightweight and reusable

Engineering Contradiction:

Improveprotection reliabilityVSAvoidhelmet weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The impact absorbers utilize flexible elastomeric materials that can be formed into thin, lightweight structures while maintaining high impact absorption capability. The flexible nature allows the materials to be thin yet effective, reducing overall weight while preserving protection reliability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The impact absorbers are designed to change their physical parameters (compression, expansion, density) dynamically during impact events, allowing them to provide maximum protection with minimal material usage, thereby reducing the overall weight of the helmet

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional head protection devices are used, then protection is provided, but the components are destroyed during collisions

Engineering Contradiction:

Improveprotection functionalityVSAvoidreusability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The impact absorbers are designed as dynamic components that can compress and expand during impact events, allowing them to absorb energy repeatedly without permanent deformation. This dynamic behavior enables the same components to be reused across multiple impact events without destruction

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The impact absorbers are designed to recover their original shape and position after each impact event, effectively discarding the impact energy and preparing themselves for the next impact. This recovery capability ensures long-term reusability without degradation of protection functionality

Inventive Principle:

Principle #34Discarding and recovering

4Object-affected harmful factors

If traditional head protection devices are used, then protection is provided, but they do not effectively dissipate impact energy

Engineering Contradiction:

Improveimpact energy dissipationVSAvoidimpact energy

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The impact absorbers convert the harmful impact energy into beneficial elastic deformation and heat, dissipating the energy through controlled compression and expansion cycles. This energy conversion process transforms the harmful impact into useful work, effectively reducing the energy that reaches the head

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 device provides reliable, lightweight, and reusable protection by effectively absorbing and dissipating impact energy, allowing the components to revert to their original position after each impact, maintaining functionality post-collision.

Implementation Method 1

The hemi-spherical impact-absorbers with slits, expand in diameter as a result of the impact (hit), and in the process they push against the penta-pieces

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the elastic net may be made of any resilient material, such as rubber... all the components of the impact reduction sub-assemblies once again revert to their original position on the elastic net

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Implementation Method 3

The piston lever which is pivotally mounted on the piston base, engages with the cam disc such that the pivotal movement of the piston lever induces rotational movement of the microgears

Methodology Applied

Scientific EffectMechanical energy conversion: Mechanical Force

Data Source

PatentUS10321730B2Impactproof head protection device

Publication Date: 2019.06.18 SAFAR SAMIR HANNA

AI summary

The present invention relates to an impactproof head protection device. The device comprises of an outer shell, a flexible ring shaped elastomeric seal, an impact reduction layer and a base helmet. The impact reduction layer further comprises of an elastic net, on to which a plurality of impact reduction sub-assemblies are embedded. When the outer shell is subjected to an impact, the impact is conveyed to the impact reduction layer. The impact reduction sub-assemblies absorb the impact, and dissipate the same in the form of rotational motion of the microgears. The microgears stop rotating once all the absorbed energy is dissipated, and all the components of the impact reduction sub-assemblies once again revert to their original position on the elastic net.