Modular Helmet Liner Segmentation for Custom Fit and Impact Control
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Solution Overview
Problem
Conventional helmet sizing and fitting methods are cumbersome, inaccurate, and often result in improperly fitted helmets that fail to account for the unique shape and size of a wearer's head, leading to increased risk of head injuries due to improper force transmission during impacts.
Innovation Solution
A modular impact liner system with customizable segments and layers, including deformable materials, that can be mixed and matched to fit the wearer's head shape and size, reducing angular motion and enhancing comfort and impact force absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional helmet sizing and fitting methods are used, then the helmet can be manufactured in standard sizes, but the fit is inaccurate and fails to account for unique head shapes, leading to improper force transmission during impacts
Solution Approach 1:
The liner is divided into multiple detachable segments that can be independently sized and configured. Each segment can be adjusted to fit different head shapes and sizes, allowing for precise customization without requiring entirely different helmet designs. This segmentation enables accurate fitting while maintaining manufacturing efficiency through modular production.
Solution Approach 2:
The liner incorporates adjustable and reconfigurable elements that can be modified based on the wearer's head shape and impact requirements. The dynamic adjustment capability allows the liner to adapt to different users while maintaining a standardized base design, improving fit precision without proportionally increasing manufacturing complexity.
2Reliability
If a custom-fitted liner is made for each wearer, then impact force transmission is optimized, but the cost and complexity of production increases significantly
Solution Approach 1:
The liner system uses standardized segments that can be combination to create custom fits. Instead of manufacturing entirely unique liners for each wearer, the system combines a limited set of standardized segments in different configurations, maintaining production efficiency while achieving customized fit and impact protection.
Solution Approach 2:
The standardized liner segments are designed to be universal components that can be used across multiple different head shapes and sizes. These segments serve multiple functions (impact absorption, fit customization, comfort) and can be combined in various ways, reducing the total number of unique products needed while maintaining high reliability of impact protection.
3Strength
If the liner is made from rigid materials for impact protection, then structural strength is improved, but comfort and ability to conform to head shape deteriorates
Solution Approach 1:
The liner incorporates composite material structures that combine rigid impact-absorbing materials with flexible conforming materials. This allows different regions of the liner to have different properties - rigid where impact protection is needed and flexible where comfort and head conformity are important, achieving both strength and comfort simultaneously.
Solution Approach 2:
Different portions of the liner are made from materials with different mechanical properties tailored to their specific functions. Impact-absorbing regions use rigid materials while contact regions use flexible materials, allowing the liner to provide both structural strength and wearer comfort in the same integrated design.
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 modular system optimizes helmet fit, reducing peak impact and rotational forces by up to 50%, thereby enhancing protection and comfort, and can be retrofitted into existing helmets.
Implementation Method 1
the deformable material may be coupled to regions of the flexible layer so the deformable material uniformly distributes force around the circumference of wearer's head when force is applied to the helmet
Implementation Method 2
reducing peak impact and rotational forces by up to 50%, thereby enhancing protection
Implementation Method 3
the deformable material may have a threshold recovery time, so the deformable material returns to its original shape after compression in at least the threshold recovery time
Implementation Method 4
the deformable material may be coupled to regions of the flexible layer so the deformable material uniformly distributes force around the circumference of wearer's head when force is applied to the helmet
Implementation Method 5
reducing peak impact and rotational forces by up to 50%
Data Source
AI summary
Disclosed are methods, devices, and systems for improved protective clothing such as helmets and protective headgear, including improvements in modular, semi-custom or customized helmet liners and/or inserts to enhance wearer comfort and reduce the deleterious effects of impacts between the wearer and other players and/or objects in all types of wearer activities (i.e., sports, military, equestrian, etc.).