Software for designing, configuring and providing manufacturing specifications for biomechanically aware protective gear

Abstract

Software for designing, configuring, and manufacturing a smart, biomechanically aware helmet is described. The software has numerous modules. One module creates instructions on designing and configuring a baseline helmet where number of shell layers, air vents, sensors, lining layer, and other features are provided. Another module is used for creating instructions on the number of energy and impact transformer layers and the mechanical and non-mechanical means used in each to absorb energy from mechanical impacts to the helmet. These dampers can include ball bearings, elastic devices, conical structures, liquids, gels, foams, and other structures that function in the transformer layers which are between the hard shell layers.

1 . A method of manufacturing a helmet, comprising:
 accepting initial configuration data;   accepting a number of energy and impact transformer layers;   accepting an energy and impact transformer layer type;   accepting damper specifications and configuration; and   providing instructions to a manufacturing system.   
     
     
         2 . A method as recited in  claim 1  wherein said instructions are based on said damper specifications and configuration. 
     
     
         3 . A method as recited in  claim 1  wherein initial configuration data includes a number of shell layers. 
     
     
         4 . A method as recited in  claim 1  further comprising configuring instructions for a ball bearing-based damper in the energy and impact transformer layer. 
     
     
         5 . A method as recited in  claim 1  further comprising configuring instructions for a concertinaed structure damper in the energy and impact transformer layer. 
     
     
         6 . A method as recited in  claim 1  further comprising configuring instructions for an elastic shear protection damper in the energy and impact transformer layer. 
     
     
         7 . A method as recited in  claim 6  further comprising configuring instructions for a fixed elastic shear protection damper or an adjustable elastic shear protection damper. 
     
     
         8 . A method as recited in  claim 1  further comprising configuring instructions for a conical structure type damper in the energy and impact transformer layer. 
     
     
         9 . A method as recited in  claim 1  wherein initial configuration data includes a separate lining layer and a neck brace mechanism. 
     
     
         10 . A method as recited in  claim 1  further comprising configuring instructions for inserting a liquid, gel, or foam into the energy and impact transformer layer. 
     
     
         11 . A method as recited in  claim 1  further comprising configuring instructions for inserting a magnetic suspension element or an electro-rheological element in the energy and impact transformer layer. 
     
     
         12 . A method as recited in  claim 4  further comprising configuring instructions for creating a perforation in an outer shell to enable a ball bearing housing. 
     
     
         13 . A method as recited in  claim 8  further comprising configuring instructions for creating aligned or non-aligned pyramidal, parabolic, or cylindrical structures. 
     
     
         14 . A system for manufacturing a smart, biomechanically aware helmet comprising:
 a helmet configuration module wherein a concentric geodesic dome having multiple shell layers is configured;   an energy and impact transformer layer module wherein mechanical and non-mechanical means are selected to function as dampers to protect against rotational, shear, tension/compression and penetrating forces on the helmet; and   a manufacturing process module wherein computer-readable instructions are created based on specifications and configuration data from said helmet configuration module and energy and impact transformer layer module.   
     
     
         15 . A system as recited in  claim 14  wherein the energy and impact transformer layer module further comprises options for selecting a ball bearing type damper, a concertinaed structure damper, an elastic shear protection damper, or a conical structure.