Hinged Modular Cooling Fan for Safety Helmets
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Solution Overview
Problem
Existing safety helmets with integrated cooling fans face challenges such as unnecessary weight and bulk when not needed, complex adjustment mechanisms, and difficulty in accommodating different brim configurations for removable fan systems.
Innovation Solution
A modular safety helmet fan system featuring a hinged mount that allows the fan enclosure to rotate between a cooling position and a stowed position, with a battery pack and adjustable louvres for customizable airflow, and a two-piece mount adapter for wide brim helmets, enabling easy attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fans are integrated into the shell of the hard hat, then cooling function is provided, but the fan unit and its weight and bulk must always be worn by the user even in conditions that do not require fan cooling
Solution Approach 1:
The cooling fan system is segmented into a separate removable housing that can be detached from the helmet shell. This allows the fan unit to be worn only when cooling is needed, separating the cooling function from the permanent helmet structure and eliminating the burden of carrying unnecessary weight and bulk.
Solution Approach 2:
The fan housing is made dynamically adjustable through a hinge mechanism that allows it to rotate between a cooling position (where the fan directs airflow to the user) and a stowed position (where it is minimized). This dynamic positioning enables the user to activate or deactivate the cooling function as needed, rather than having it permanently fixed.
2Ease of operation
If bands or brackets or fasteners are used to mount a fan unit to the hard hat shell, then the fan can be removably mounted, but the user must make multiple adjustments or manipulate multiple threaded fasteners
Solution Approach 1:
The complex mounting mechanism (bands, brackets, threaded fasteners) is extracted and replaced with a simplified snap-fit engagement system. The housing contains mounting features that directly engage with corresponding features on the helmet shell, eliminating the need for separate adjustment components and reducing the number of parts the user must manipulate.
Solution Approach 2:
The mounting function is merged into the housing structure itself through integrated snap-fit features. Rather than using separate bands, brackets, and fasteners, the housing incorporates mounting elements that combine attachment and positioning functions into a single simplified engagement action.
3Device complexity
If a fixed fan housing is used, then the fan structure is simple, but it cannot accommodate different brim configurations or be easily stored
Solution Approach 1:
The fan housing incorporates a hinge mechanism that enables dynamic rotation between a cooling position and a stowed position. This dynamic capability allows the housing to adapt to different brim configurations by rotating away from obstructions and provides a compact stowed position for easy storage, while maintaining a simple overall structure.
4Ease of operation
If the fan housing is made removable, then it can be easily stored, but the mounting mechanism becomes more complex
Solution Approach 1:
The complex mounting mechanisms (bands, brackets, threaded fasteners) are extracted and replaced with a simplified snap-fit engagement system. The housing contains mounting features that directly engage with corresponding features on the helmet shell, eliminating the need for separate adjustment components and reducing the number of parts the user must manipulate.
Solution Approach 2:
The mounting function is merged into the housing structure itself through integrated snap-fit features. Rather than using separate bands, brackets, and fasteners, the housing incorporates mounting elements that combine attachment and positioning functions into a single simplified engagement action.
Data Source
AI summary
A safety helmet fan system includes a safety helmet comprising a mount slot and a housing comprising a body having a fan enclosure, a mount configured to engage the mount slot to removably attach the housing to the safety helmet, and a hinge connecting the body to the mount, wherein the mount is engaged to the mount slot and the hinge is configured to allow the body to rotate, relative to the mount, between a cooling position and a stowed position wherein in the cooling position a rotational axis of the fan is below an axis of rotation of the hinge, and in the stowed position the rotational axis of the fan is above the axis of rotation of the hinge.