Integrally-Formed Multi-Layer Helmet for Impact Energy Management
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Solution Overview
Problem
Commercially available helmets often provide suboptimal protection and comfort due to standard sizes and shapes, uncomfortable foam linings, and failure-prone fasteners, which can lead to discomfort and reduced effectiveness in energy dissipation during impacts.
Innovation Solution
The development of helmets utilizing additive manufacturing techniques to create integrated hardware and multi-density layers, reducing the need for separate fasteners and optimizing energy absorption, while also incorporating features like low-profile cages and sweat gutters for improved fit and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional injection molded outer shells with foam lining are used, then manufacturing process is established, but comfort and energy dissipation performance are suboptimal
Solution Approach 1:
The patent uses a multi-layer composite structure consisting of an outer shell layer, energy management layer, and comfort layer, where each layer is made of different materials optimized for its specific function. This composite approach allows the helmet to achieve both high energy dissipation performance and comfort simultaneously, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The energy management layer features variable density foam with different densities at different locations - higher density near the impact surface for energy absorption and lower density near the comfort layer for comfort. This local variation in material properties allows the same structure to provide both protection and comfort, resolving the contradiction between energy dissipation and comfort.
2Reliability
If standard sizes and shapes are used for helmets, then manufacturing is simplified, but fit and protection effectiveness are reduced
Solution Approach 1:
The helmet incorporates an adjustable retention system with dial mechanisms that allow the shell and liner to be adjusted to different positions and orientations. This dynamic adjustment capability enables a single shell design to fit multiple head sizes and shapes, achieving both protection effectiveness and manufacturing simplicity.
Solution Approach 2:
The helmet is divided into separate adjustable components including the outer shell, energy management layer, and retention system. This segmentation allows each component to be optimized independently while maintaining overall protection effectiveness across different head sizes and shapes.
3Reliability
If separate fasteners are used for accessory attachment, then ease of attachment is improved, but reliability and weight are compromised
Solution Approach 1:
The patent integrates accessory attachment features directly into the shell structure, eliminating the need for separate fasteners. The shell includes built-in mounting points and attachment mechanisms that are part of the shell itself, providing reliable accessory attachment while reducing overall weight by eliminating redundant fastening components.
4Ease of operation
If foam lining is used for comfort, then comfort is improved, but energy dissipation performance deteriorates
Solution Approach 1:
The energy management layer uses variable density foam with higher density near the impact surface for energy absorption and lower density near the comfort layer for comfort. This local variation in material properties allows the same structure to provide both protection and comfort, resolving the contradiction between energy dissipation and comfort.
Solution Approach 2:
The multi-layer composite structure separates the energy management function (outer layers with higher density materials) from the comfort function (inner layers with softer, lower density materials). This functional separation allows each layer to optimize for its specific purpose without compromising the other.
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 solution results in helmets that are lighter, more comfortable, and provide enhanced energy absorption and protection, reducing the risk of concussions and improving visibility, while minimizing material usage and manufacturing costs.
Implementation Method 1
an energy management layer configured to absorb and dissipate energy received by the helmet during an impact
Implementation Method 2
an outer shell layer disposed over the energy management layer, wherein the outer shell layer is configured to disperse and dissipate impact energy
Data Source
AI summary
A helmet may be worn on a head of a wearer having a shape and a contour. The helmet may have a plurality of layers coupled together including an energy management layer and an outer shell layer disposed over the energy management layer. The plurality of layers are integrally formed with one another, and the energy management layer is configured to absorb and dissipate energy received by the helmet during an impact by an external force. The outer shell layer is configured to disperse and dissipate impact energy from the external force. Each of the plurality of layers has a density and a geometry, and the density or geometry of at least one layer differs from the density or geometry of at least another layer.