Segmented Ballistic Helmet Shell for Ventilation and Formability
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Solution Overview
Problem
Ballistic armor helmets face challenges of high cost, heat retention, and limited head coverage due to the use of expensive composite materials and complex manufacturing processes, which affect weight, comfort, and protection levels.
Innovation Solution
A ballistic combat helmet is designed with multiple shell pieces that allow for air vents, reducing material waste and complexity in forming compound curves, enabling efficient use of materials and enhanced cooling while providing greater head coverage and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece helmet shell is used to provide continuous head coverage, then protection against projectiles is improved, but heat retention and discomfort increase
Solution Approach 1:
The helmet shell is divided into multiple separate pieces (front portion, rear portion, and side portions) that can be assembled together. This segmentation allows incorporation of vent gaps between pieces for cooling while maintaining coverage, resolving the contradiction between continuous protection and heat management
2Area of stationary object
If deep compound curves are formed in the helmet shell to match head shape, then head coverage and protection are improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The helmet is divided into multiple pieces with shallower individual curves that can be more easily manufactured. The pieces are then assembled to achieve the overall deep compound curve shape needed for head coverage, reducing manufacturing complexity while maintaining protection
Solution Approach 2:
Instead of forming deep curves in a single piece, the design uses multiple pieces with moderate curves assembled in three-dimensional space. The vent gaps between pieces allow the assembly to achieve complex head-form coverage without requiring each individual piece to have deep compound curves
3Shape
If overlapping gores are used to form non-developable surfaces, then helmet shape conforming to head is achieved, but material waste increases
Solution Approach 1:
The helmet shell is segmented into multiple pieces that can be manufactured with simpler, more efficient material layouts. This reduces the need for extensive overlapping gores while still achieving the necessary non-developable surface shape for head coverage
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 multi-part helmet design results in a lighter, cooler, and more cost-effective solution that offers improved comfort and protection by efficiently using materials and promoting transpirational cooling, while maintaining ballistic integrity.
Implementation Method 1
air vents which allow movement of air through the helmet which provides transpirational cooling, especially in hot and dry climates where sweat evaporates from the soldier's head and is readily absorbed by the dry air
Data Source
AI summary
A ballistic armor helmet has two or more shell elements which are fixed to one another to define one or more ventilation gaps. The shell elements preferably overlap to keep projectiles from entering the helmet. By dividing the helmet into two or more parts, the depth and extent of the compound curvature of the shells being formed can be reduced, reducing or eliminating the need for gores, by bringing the depth of the compound curves within the inherent formability of polymer coated ballistic fabrics. The helmet more efficiently uses materials, and promotes cooling when in use, resulting in a helmet which covers a greater percentage of the head which is more comfortable and less costly.