Helmet Impact-Mitigation Structure with Rolling Reactive Layer

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Solution Overview

Problem

Conventional helmets and body armor often fail to provide adequate protection against both linear and tangential forces during impacts, particularly oblique impacts, which can result in rotational acceleration of the brain and neck injuries.

Innovation Solution

A helmet design featuring a reactive layer sandwiched between inner and outer layers, where elements in the reactive layer roll to facilitate movement of the layers relative to each other, converting impact energy into linear and rotational movement and isolating the inner layer from rotational forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional helmets use impact absorbing layers to reduce linear forces, then linear impact protection is improved, but protection against rotational forces and oblique impacts remains inadequate

Engineering Contradiction:
Improvelinear impact protectionVSAvoidrotational force protection
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent introduces a reactive layer with movable elements that dynamically respond to impact forces. During oblique impacts, these elements roll or translate to facilitate relative movement between the outer shell and inner liner, converting rotational energy into beneficial motion that reduces brain injury risks while maintaining linear impact protection

Inventive Principle:
Principle #15Dynamics

2Strength

If the helmet structure is made rigid to protect against impact, then structural strength is improved, but the ability to reduce rotational acceleration and facilitate layer movement deteriorates

Engineering Contradiction:
Improvestructural strengthVSAvoidlayer movement capability
Core Design Contradiction:
StrengthVSEase of operation

Solution Approach 1:

The patent employs a flexible reactive layer positioned between the rigid outer shell and inner liner. This layer can deform and move relative to adjacent layers during impact, allowing the helmet to maintain overall structural integrity while enabling necessary layer movement to reduce rotational forces

Inventive Principle:
Principle #30Flexible shells and thin films

3Loss of energy

If energy is dissipated within the helmet structure during impact, then impact absorption is improved, but the transfer of rotational forces to the head is reduced less effectively

Engineering Contradiction:
Improveimpact energy absorptionVSAvoidrotational force transfer to head
Core Design Contradiction:
Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The reactive layer acts as an intermediary between the outer shell and inner liner. During oblique impacts, it facilitates controlled movement between these layers, converting harmful rotational energy into motion of the reactive layer itself, thereby preventing direct transfer of rotational forces to the head while still absorbing impact energy

Inventive Principle:
Principle #24Intermediary (Mediator)

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 effectively reduces the transfer of rotational and linear forces to the head, minimizing the risk of brain and neck injuries by transferring energy into the movement of the layers rather than dissipating it within the helmet.

Implementation Method 1

the plurality of elements of the reactive layer are configured to roll to facilitate movement of the first inner layer and the second outer layer with respect to each other

Methodology Applied
Scientific EffectRolling motion: Roller

Data Source

PatentUS12458096B2Impact mitigating structure
Publication Date: 2025.11.04 HEXR LTD
  • US12458096B2 patent drawing
  • US12458096B2 patent drawing
  • US12458096B2 patent drawing

AI summary

A helmet includes an impact mitigating structure (100). The impact mitigating structure includes a first inner layer (102), a second outer layer (104) and a reactive layer (105) positioned between the first inner layer and the second outer layer. The reactive layer includes multiple elements (106) held between the first inner layer and second outer layer. The reactive layer is arranged such that, when the second layer is subject to an impact, the multiple elements of the reactive layer are configured to roll to facilitate movement of the first inner layer and the second outer layer with respect to each other.