Helmet Shell Attachment Pockets for Secure Accessory Mounting
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Solution Overview
Problem
Existing protective helmets lack a simple and stable method for attaching add-on parts, such as ear muffs and visors, which can detach but may not securely hold during impacts.
Innovation Solution
The helmet features oval-shaped pockets on the outside of the shell with protruding edges forming an inner and outer wall, designed to be stable and unbreakable, with a reinforcement lug for added security, allowing for secure attachment of accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If add-on parts are releasably attached to the helmet from the outside, then the helmet can accommodate accessories like ear muffs and visors, but the attachment stability during impact is insufficient
Solution Approach 1:
The helmet is divided into functional zones with specifically designed attachment pockets integrated into the shell structure. These pockets are positioned at locations optimized for accessory placement (ear muffs, visors) and are structurally separated from the main shell to provide focused reinforcement where needed.
Solution Approach 2:
The attachment pockets are merged with the helmet shell as an integrated structure rather than separate add-on components. The pockets are formed directly from the thermoplastic material during the injection molding process, creating a unified structure that combines the protective shell function with the accessory attachment function.
2Strength
If the helmet shell is made with sufficient thickness for protection, then impact resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The helmet shell and attachment pockets utilize curved, oval-shaped geometries that distribute impact forces more effectively than flat surfaces. The rounded contours of the pockets and shell work together to deflect and disperse impact energy, enhancing protective performance while maintaining structural efficiency.
Solution Approach 2:
The wall thickness of the helmet shell and attachment pockets is optimized within specific ranges (1.5-3.0 mm for pocket edges, 2.0-2.5 mm preferred) to achieve the necessary balance between impact resistance and manufacturing feasibility. These parameter specifications allow for consistent production using standard injection molding processes.
Data Source
Figure 1~3
AI summary
The helmet (10) has a projecting portion (16) that is provided at edge (27). An upwardly open pocket (14) is provided at the inner side of the projecting portion on outside of a convex shell (12). The convex shell is oval in shape in plan view. The distance between the projecting portion and the pocket is 2mm. The projecting portion is formed of a side wall (22), a front wall (24) and a rear wall (26).