Malleable Protective Insert for Headgear Using Composite Foam

Solution Overview

Problem

There is a need for protective headgear that is both aesthetically pleasing and comfortable, as many adolescents refuse to wear traditional helmets due to their appearance and discomfort, leading to increased head injuries from wheeled conveyance accidents.

Innovation Solution

A malleable protective insert for headgear, featuring a dome-shaped main body with impact-resistant polyurethane foam and polyborodimethylsiloxane, air vents, and connectors for secure attachment to any hat, providing both protection and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional helmets are used to provide head protection, then safety and impact resistance are improved, but comfort and aesthetics deteriorate

Engineering Contradiction:

Improvehead protectionVSAvoidcomfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The protective function is extracted from the traditional helmet structure and placed into a separate removable insert that fits inside regular hats. This allows the protection to be obtained without wearing the bulky, uncomfortable traditional helmet exterior.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The protective insert is nested within the hat structure, with the foam insert fitting inside the hat's interior space. This nesting approach allows the protective element to be contained within the aesthetic outer layer of regular headwear.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If traditional helmets are used to provide head protection, then safety and impact resistance are improved, but aesthetics deteriorate

Engineering Contradiction:

Improvehead protectionVSAvoidaesthetics

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The protective function is extracted from the traditional helmet structure and placed into a separate removable insert that fits inside regular hats. This allows the protection to be obtained without wearing the bulky, uncomfortable traditional helmet exterior.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The protective insert is nested within the hat structure, with the foam insert fitting inside the hat's interior space. This nesting approach allows the protective element to be contained within the aesthetic outer layer of regular headwear.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of operation

If protective headgear is designed to be comfortable and aesthetic like a hat, then ease of wear and appearance are improved, but impact protection capability deteriorates

Engineering Contradiction:

Improveease of wearVSAvoidimpact protection

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The insert utilizes composite materials including polyurethane foam combined with polyborodimethylsiloxane to achieve both comfort and impact protection. This material combination provides the necessary protective properties while maintaining a comfortable, hat-like form factor.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The material properties change based on compression state - the foam is soft and comfortable during normal wear but becomes rigid and protective upon impact. This parameter change allows the same structure to provide both comfort and protection.

Inventive Principle:

Principle #35Parameter changes

4Shape

If protective headgear is designed to be comfortable and aesthetic like a hat, then ease of wear and appearance are improved, but impact protection capability deteriorates

Engineering Contradiction:

ImproveappearanceVSAvoidimpact protection

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The insert utilizes composite materials including polyurethane foam combined with polyborodimethylsiloxane to achieve both comfort and impact protection. This material combination provides the necessary protective properties while maintaining a comfortable, hat-like form factor.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The material properties change based on compression state - the foam is soft and comfortable during normal wear but becomes rigid and protective upon impact. This parameter change allows the same structure to provide both comfort and protection.

Inventive Principle:

Principle #35Parameter changes

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 insert absorbs and disperses impact energy, reducing the risk of serious head injuries while maintaining the aesthetics and comfort of a hat, ensuring protection without the bulk of a traditional helmet.

Implementation Method 1

impact resistant material that is disposed between the inside and outside facing surfaces... the impact resistant material includes polyurethane foam and polyborodimethylsiloxanea, which is malleable in a non-compressed state, and becomes firm and rigid when receiving an impact force

Methodology Applied

Scientific EffectImpact force absorption and energy dispersion: Damping

Data Source

PatentUS10624403B2Malleable protective insert for headgear

Publication Date: 2020.04.21 SEELA RITHVIK

AI summary

A protective insert for headgear includes a malleable main body member having an inside facing surface, an outside facing surface and an impact resistant material that is disposed between the inside and outside facing surfaces. A plurality of connectors are disposed along the insert, and removably engage complementary connectors positionable inside a traditional hat. A plurality of air vents are disposed throughout the main body, and the impact resistant material includes polyurethane foam and polyborodimethylsiloxanea, which is malleable in a non-compressed state, and becomes firm and rigid when receiving an impact force.