Segmented Helmet Shell with Elastomer Splines
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Solution Overview
Problem
Current helmets for contact sports fail to adequately distribute and absorb repeated impact forces, leading to potential concussions and traumatic brain injuries due to inadequate design in managing both direct and rotational forces.
Innovation Solution
A pressure attenuating helmet design featuring a segmented shell made of separate plates joined by energy dissipating sutures and elastomer splines, with foam layers of varying durometer ratings and air-filled cavities to dissipate and absorb impact forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional single-piece helmet shell is used, then the helmet structure is simple and easy to manufacture, but it cannot effectively distribute and absorb repeated impact forces leading to concussions and brain injuries
Solution Approach 1:
The helmet shell is divided into multiple separate plates that can move independently relative to each other. These plates are connected through elastomer splines and sutures, allowing each plate to absorb and dissipate impact forces independently, thereby preventing force concentration that would occur in a single-piece shell.
Solution Approach 2:
The helmet combines multiple materials with different properties: rigid plates for structural integrity, elastomer splines for flexible connection and energy absorption, and foam layers for additional cushioning. This composite structure allows the helmet to both withstand and dissipate impact forces effectively.
2Strength
If foam layers with high durometer rating are used throughout, then impact resistance is improved, but comfort and rotational force management deteriorate
Solution Approach 1:
The foam padding is divided into multiple layers with different durometer ratings positioned at specific locations. Higher durometer foam is used where impact resistance is prioritized, while lower durometer foam is used where comfort and rotational force absorption are more important, creating locally optimized protection.
Solution Approach 2:
The foam layers are designed to deform dynamically under different types of forces. The varying durometer ratings allow the foam to respond differently to direct impacts versus rotational forces, providing adaptive protection that maintains comfort while managing both types of mechanical stress.
3Strength
If plates are joined rigidly, then structural strength is improved, but force distribution and absorption capability deteriorates
Solution Approach 1:
The plates are connected through flexible elastomer splines and sutures rather than rigid joints. These flexible connections allow the plates to move independently during impact, distributing forces across multiple plates and preventing force concentration, while still maintaining overall structural integrity of the helmet shell.
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 helmet effectively reduces the transfer of forces to the head and neck by distributing and absorbing impact energies, minimizing the risk of concussions and traumatic brain injuries through enhanced force dissipation and rotational force management.
Implementation Method 1
A network of elastomer splines may be shaped and positioned to separate adjacent plates both along the adjacent edges and the perforated flanges
Implementation Method 2
The plates are enabled to be joined along the adjacent edges to the other ones of the plurality of plates, forming a helmet shell
Implementation Method 3
at least one foam layer is formed to the undersurface of each plate
Implementation Method 4
A third foam layer may be formed to engage a user's head, and a second foam layer may be formed between the first and third foam layers
Implementation Method 5
In this embodiment, the foam layers are adhered to each other forming a single foam insert which may be removably attached to the plates
Data Source
AI summary
A pressure attenuating helmet is provided including separate plates having a plate thickness, an outer surface, under surface, and adjacent edges. The plates joined along the adjacent edges to the other ones of the plurality of plates, forming a helmet shell. Perforated flanges formed along the under surface at the adjacent edges of the plates, the flanges formed inwardly along a line from the adjacent edge of each of the plates extending in the direction of the thickness of the plates. Perforation in the flanges spaced equidistantly in an array along a long direction of the flanges, enabled to accept sutures and aligned flange-to-flange. A network of elastomer splines shaped and positioned to separate the adjacent plates both along the adjacent edges and the perforated flanges. Sutures through the perforations securing the plates together along the adjacent edges and foam cushions are provided between the plates and a wearers head.