Helmet Suspension Keyed Connections for Correct Installation
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Solution Overview
Problem
Existing helmet assembly mechanisms are cumbersome and time-consuming, leading to inefficient cleaning, inspection, and potential incorrect installation, which compromises safety and maintenance compliance.
Innovation Solution
A helmet design featuring connection tabs and receptacles with distinct shapes and colors, along with a biased member mechanism, ensures easy and proper assembly and disassembly, promoting regular maintenance by requiring disconnection of the outer shell for suspension web removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing helmet assembly mechanisms are used, then the helmet can be assembled and disassembled, but the process is cumbersome and time-consuming
Solution Approach 1:
The helmet is divided into separate modular components: an outer shell, an inner liner, and a suspension web system. Each component can be independently assembled and disassembled through simple connection interfaces, eliminating cumbersome integrated assembly mechanisms while maintaining structural integrity.
Solution Approach 2:
The suspension web connection mechanism is extracted as a separate, simplified system with connection tabs that interface directly with the inner liner. This extraction allows the suspension web to be easily removed for cleaning and inspection without disassembling the entire helmet structure.
2Reliability
If existing helmet assembly mechanisms are used, then the helmet can be assembled, but incorrect installation may occur
Solution Approach 1:
Connection tabs and receptacles are designed with asymmetric shapes that provide mechanical keying. Each connection tab has a specific orientation and geometry that only fits into its corresponding receptacle in the correct orientation, preventing incorrect installation while maintaining simple operation.
Solution Approach 2:
Connection tabs are color-coded to correspond with specific receptacles on the inner liner. This visual indication system guides users to the correct connection points and orientations, ensuring proper installation while simplifying the assembly process through intuitive color matching.
3Ease of repair
If the suspension web is easily accessible for removal, then maintenance is simplified, but the release mechanism may be accessible during normal wear
Solution Approach 1:
The connection tabs are nested within the inner liner structure during normal helmet assembly. The release mechanisms are positioned inside the helmet cavity, making them inaccessible from the outside during normal wear. For maintenance, the entire inner liner can be removed from the outer shell, providing access to the nested connection points for suspension web replacement.
Data Source
AI summary
Systems and methods are provided a helmet that includes shell comprising a plurality of connection receptacles, a first connection receptacle having a shape that is different from a shape of a second connection receptacle. A flexible suspension web includes a plurality of straps for supporting the shell on a head of a wearer, each of the straps including a connection tab, where a first connection tab, which is associated with a first strap, has a shape corresponding to the shape of the first connection receptacle, and where a second connection tab, which is associated with a second strap, has a shape corresponding to the shape of the second connection receptacle.