Oblique Impact Protection Foam Layer for Helmet Rotational Force Reduction
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Solution Overview
Problem
Current helmet technologies fail to adequately address oblique impacts, leading to increased risk of injury from torque and rotational forces, and suffer from issues such as high cost, complexity, weight, reduced ventilation, and discomfort.
Innovation Solution
A closed cell foam layer with square-shaped apertures and wells is integrated into the helmet design, allowing for side and lateral flexing to reduce rotational forces during oblique impacts, while maintaining comfort and reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional helmet technologies are used, then manufacturing simplicity and cost-effectiveness are maintained, but protection against oblique impacts is inadequate
Solution Approach 1:
The helmet shell is segmented into a rigid outer shell and a separate oblique-impact protection layer with a cellular structure. This segmentation allows each layer to perform its specific function: the rigid shell handles traditional impacts while the cellular layer specifically addresses oblique impacts through its ability to deform and dissipate rotational energy.
Solution Approach 2:
The oblique-impact protection layer utilizes a porous cellular structure that allows controlled deformation during oblique impacts. The cellular geometry enables the material to absorb and dissipate rotational energy through cell wall bending and collapse, providing protection without significantly increasing overall helmet complexity.
2Reliability
If oblique impact protection layers are added, then protection effectiveness is improved, but weight increases
Solution Approach 1:
The porous cellular structure provides high protection-to-weight ratio by utilizing the geometry of the cells rather than adding substantial material mass. The cellular walls are designed to deform in a controlled manner during oblique impacts, absorbing energy through structural deformation rather than relying on material strength alone, thus minimizing weight addition.
Solution Approach 2:
The helmet combines the rigid outer shell material with a cellular material having different mechanical properties. This composite structure allows each material to contribute its strengths: the rigid shell provides impact resistance while the cellular material provides rotational energy dissipation, achieving effective oblique impact protection without excessive weight gain.
3Reliability
If complex multi-layer structures are implemented, then oblique impact protection is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The oblique-impact protection layer is integrated with the existing helmet shell structure rather than being implemented as a completely separate component. This merging approach allows the protective function to be incorporated into the manufacturing process of the helmet shell itself, reducing the number of discrete assembly steps and lowering manufacturing complexity despite the enhanced protective functionality.
4Reliability
If dense material structures are used, then impact absorption is improved, but ventilation is reduced
Solution Approach 1:
The cellular structure inherently provides porosity that allows air circulation while maintaining impact absorption capabilities. The cell walls are designed with appropriate thickness and geometry to absorb impact energy while the spaces between cells facilitate ventilation, resolving the contradiction between dense material structures and airflow requirements.
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 closed cell foam layer effectively reduces oblique and traditional impact forces by up to 50% and 40%, respectively, while minimizing material usage, manufacturing complexity, and enhancing ventilation.
Implementation Method 1
The layer allows side and lateral flexing to reduce rotational forces during oblique impacts
Implementation Method 2
A closed cell foam layer with square-shaped apertures and wells is integrated into the helmet design, allowing for side and lateral flexing
Data Source
Figure 1
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AI summary
An oblique-impact protection technology member (20) contains a layer (50) of closed cell foam containing a first surface (52), a second surface (54), and a plurality of wells (56) on the first surface (52). The first surface (52) contains a plurality of first surface apertures (58) and the first surface apertures (58) have a square shape. The second surface (54) is opposite the first surface (52) and optionally contains a plurality of second surface apertures (62). Each well (56) corresponds to a first surface aperture (58) and the second surface (54) is substantially parallel; or parallel, to the first surface (52). A helmet (10) and/or a piece of sporting equipment (12) may contain this technology, and a process may manufacture this technology.