Helmet Wire Guard Spacer Adjustment System
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Solution Overview
Problem
Existing helmet and faceguard systems require multiple sizes of wire guards to fit different helmet shells, increasing production costs and complexity, as a single larger shell size with varying padding is costly and inefficient for accommodating smaller head sizes.
Innovation Solution
A helmet system that uses a uniformly sized wire guard with spacers and fasteners to accommodate different shell sizes, allowing a single wire guard to fit various shell sizes by adjusting the spacers, eliminating the need for multiple wire guard sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different wire guard sizes are manufactured for each helmet shell size, then proper fit for each helmet size is achieved, but the number of SKUs and manufacturing complexity increases
Solution Approach 1:
A single wire guard design is created that can universally fit multiple helmet shell sizes through the use of interchangeable spacers. The wire guard serves multiple functions by accommodating different shell sizes without requiring different wire guard models, thereby reducing SKU complexity while maintaining proper fit.
Solution Approach 2:
Spacers are introduced as intermediary components between the wire guard and the helmet shell. These spacers act as mediators that adjust the distance and positioning, allowing a single wire guard to properly fit different shell sizes without requiring custom wire guards for each size.
2Ease of manufacture
If a single larger shell size is used for all helmets with varying padding, then wire guard manufacturing is simplified, but the cost of smaller size helmets increases due to excessive material
Solution Approach 1:
The system segments the adjustment mechanism into separate components: the wire guard remains a standard size while spacers of different thicknesses are used to accommodate different shell sizes. This segmentation allows the wire guard to be manufactured once in a standard size while still fitting smaller shells that use additional padding.
3Manufacturing precision
If multiple wire guard sizes are produced to match different shell sizes, then exact fit is achieved, but production costs and inventory complexity increase
Solution Approach 1:
The system introduces dynamic adjustability through interchangeable spacers that can be added or removed based on the shell size. This allows the wire guard assembly to be dynamically adjusted to fit different shell sizes without requiring multiple wire guard designs, thereby maintaining manufacturing precision while improving production efficiency.
Data Source
AI summary
A helmet comprising a shell, a wire guard, at least one spacer, and at least one fastener. The shell has at least one attachment portion which includes an outer surface. The wire guard has at least one attachment portion corresponding to the at least one attachment portion of the shell. The attachment portion of the wire guard includes an inner surface. Each spacer has an outer surface corresponding to the inner surface of a the attachment portion of the wire guard. Each spacer also has an inner surface corresponding to the outer surface of the attachment portion of the shell. The at least one fastener engages each spacer with the corresponding attachment portions of the shell and wire guard.