Multi-Component Helmet With Sliding Ventilation Shutter
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Solution Overview
Problem
Helmets for outdoor activities face a trade-off between providing adequate protection, being lightweight, offering sufficient ventilation, being affordable, and having a design that balances manufacturability and aesthetics, as these criteria often compete with each other.
Innovation Solution
A helmet design featuring a ventilation shutter assembly with a seamless shock-absorbing liner and overlapping shell components that provide structural integrity and adjustable ventilation, using materials like polycarbonate and expanded polystyrene, and incorporating features like goggle strap retainers and brim guards for enhanced functionality and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a helmet is designed with a harder shell material to provide greater impact protection, then the protection capability is improved, but the weight of the helmet increases
Solution Approach 1:
The helmet shell is constructed using composite materials, specifically a polycarbonate outer shell combined with an expanded polystyrene (EPS) foam liner. This composite structure provides high impact protection through the hard polycarbonate shell while the EPS liner absorbs impact energy, achieving superior protection without the excessive weight of solid harder materials throughout the entire helmet structure.
2Ease of operation
If a helmet is designed with more ventilation openings to improve airflow, then the ventilation capability is improved, but the protection capability deteriorates due to reduced coverage
Solution Approach 1:
The helmet incorporates multiple ventilation openings strategically positioned in specific regions of the shell where they do not compromise the overall structural integrity or impact protection. The openings are localized to areas that allow airflow while maintaining adequate coverage and protection in critical impact zones, achieving both ventilation and protection simultaneously.
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 helmet design achieves a balance between protection, weight, ventilation, and manufacturability, offering improved structural strength, adjustable ventilation, and aesthetic appeal while maintaining affordability.
Implementation Method 1
a seamless shock-absorbing liner... using materials like polycarbonate and expanded polystyrene
Data Source
AI summary
Helmets and methods for manufacturing a helmet are described. An example helmet includes an upper helmet component having a shell and a shock absorbing liner and further having a lower helmet component having a shell and a shock absorbing liner. The shock absorbing liner of the lower helmet component has an angled interface portion to which the upper helmet component is attached. A vent sill is attached to the shock absorbing liner of the upper helmet component and a vent shutter is slidably attached to the vent sill. An example method include forming a first in-mold component having a shell and shock absorbing liner and forming a second in-mold component having a shell and shock absorbing liner, the shock absorbing liner having a seamless headform. After a vent shutter assembly is attached to the first in-mold component the second in-mold component is attached to the first in-mold component.