A shock-reducing protective neck brace and its manufacturing process

Abstract

This invention relates to the field of racing safety accessories technology, and in particular to a shock-reducing protective neck brace and its manufacturing process. The brace includes a chest and shoulder support, a head and neck movement section, a sliding rope, and a damping device. One end of the head and neck movement section is rotatably connected to the chest and shoulder support. One end of the damping device is movably connected to the chest and shoulder support, and the other end is movably connected to the end of the head and neck movement section away from the chest and shoulder support. The damping device absorbs the kinetic energy generated by the rotation of the head and neck movement section relative to the chest and shoulder support. The middle end of the sliding rope is connected to the head and neck movement section, and both ends of the rope are detachably fixed to the outer helmet, transferring the forward kinetic energy of the helmet to the head and neck movement section. In conclusion, this invention, based on the use of HANS (Hansen International Motors) driver protective neck braces, further reduces the impact force on the driver's head during impacts, mitigates the impact on the driver's brain, protects the driver's physical and mental health, and improves the driver's comfort during races.

Description

Technical Field

[0001] This invention relates to the field of racing safety accessories technology, and in particular to a shock-reducing protective neck brace and its manufacturing process. Background Technology

[0002] HANS (Head and Neck Support) is a system that protects the driver's neck and head during a collision, forming a crucial part of passive safety. The HANS system is relatively simple, consisting primarily of a U-shaped device that wraps around the neck, supplemented by shoulder pads, straps, and buckles. While four-point racing harnesses can secure the driver's body, they cannot protect the vulnerable head and neck. In a collision, the head violently impacts the steering wheel. The combined inertia of the head and helmet causes significant tearing of the neck. Since racing steering wheels do not have airbags, the impact can severely injure the driver's head.

[0003] The Hans system protects the rider's head and neck when used in conjunction with a helmet and a dual shoulder strap system. The dual shoulder strap system has two straps on each shoulder: one to secure the rider's body and the other to secure the Hans system. In the event of a collision, the Hans system provides a rearward pull to the sides of the helmet to prevent forward head movement, thus protecting the rider's head and neck.

[0004] A driver's neck brace (HANS) is a safety device used in motorsports. Wearing a driver's neck brace is mandatory in most major motorsports events. This brace reduces the likelihood of serious head or neck injuries in the event of a collision, including a reduced risk of fatal skull base fractures. The HANS device maintains the head's position relative to the body and transfers energy to the stronger chest, torso, shoulders, seatbelt, and seat during head deceleration.

[0005] Most HANS (Head and Neck Braces) on the market are one-piece designs. Upon impact, the head and helmet accelerate forward due to inertia, and then the lanyard pulls the helmet to a stop, preventing it from directly impacting the steering wheel at high speed and reducing the likelihood of serious head and neck injuries. However, the head impacting the stopped inner wall of the helmet can still cause injury. While existing HANS can use elastic lanyards, the lanyard's length limits its elasticity, resulting in limited deceleration. Furthermore, if the lanyard's elasticity is too strong, the helmet may be pulled backward after stopping forward, impacting the HANS again. This is equivalent to repeated front-and-back impacts. Although this repeated impact reduces the impact energy and thus the possibility of fatal injury, it can still easily damage the rider's brain, even causing concussions. While the injury may not be fatal, it affects the rider's physical and mental health and reduces their comfort during races.

[0006] Therefore, based on the use of HANS driver protection neck braces, how to further reduce the impact of impacts, mitigate the impact on the driver's brain, and improve the driver's racing comfort is a technical problem that needs to be solved. Summary of the Invention

[0007] To overcome the shortcomings mentioned above, the present invention aims to provide a technical solution that can solve the above problems.

[0008] This invention provides a protective neck brace to reduce impact, comprising a chest and shoulder support, a head and neck movement section, and a damping device. One end of the head and neck movement section is rotatably connected to the chest and shoulder support and can rotate relative to the chest and shoulder support. One end of the damping device is rotatably connected to the chest and shoulder support, and the other end is rotatably connected to the end of the head and neck movement section away from the chest and shoulder support. The damping device is used to absorb the kinetic energy generated by the rotation of the head and neck movement section relative to the chest and shoulder support.

[0009] As a further aspect of the present invention, it also includes a sliding rope, wherein a limiting hole is provided on the back of the head and neck movable part connected to the damping device, and the sliding rope passes through the limiting hole, thereby forming a limiting connection between the limiting hole and the sliding rope.

[0010] As a further aspect of the present invention, it also includes an end cap and a plate cap. The end cap is fixedly connected to the chest and shoulder support and provides protection for the connection between the damping device and the chest and shoulder support. The plate cap is fixedly connected to the head and neck movement part and provides protection for the damping device.

[0011] The present invention also provides a manufacturing process for a protective neck brace, comprising the following steps:

[0012] S1. The head and neck movement section of the neck brace is manufactured using a hot-press molding process, and after finishing, the head and neck movement section is obtained. S2. The chest and shoulder support section of the neck brace is manufactured using a hot-press molding process, and after finishing, the chest and shoulder support section is obtained. S3. The head and neck movement section is installed on the chest and shoulder support section, allowing it to rotate at a certain angle relative to the chest and shoulder support section. S4. A damping device is prepared, with one end installed on the chest and shoulder support section and the other end installed on the head and neck movement section, thus limiting the rotation of the head and neck movement section. S5. A sliding rope is prepared and installed in the limiting hole of the head and neck movement section, restricting the direction of the sliding rope's movement. S6. The relevant components are inspected to ensure correct installation, thus completing the manufacturing of the entire neck brace.

[0013] As a further aspect of the present invention: the process for manufacturing the movable head and neck portion described in step S1 includes the following steps:

[0014] S1.1 Prepare a first carbon cloth thick layer, a second carbon cloth thick layer, a U-shaped carbon fiber woven cloth, a limiting carbon cloth strip and a limiting woven cloth, prepare a prefabricated head and neck mold, and apply a release agent to the mold cavity of the prefabricated head and neck mold.

[0015] S1.2 After the release agent dries, attach a piece of limiting woven cloth to both sides of the corresponding part of the mold cavity of the prefabricated head and neck mold, at the position of the limiting hole, then place the limiting carbon cloth strip on the limiting woven cloth, and then place the limiting hole slider on the limiting carbon cloth strip.

[0016] S1.3, attach a U-shaped carbon fiber woven fabric to the corresponding part of the U-shaped frame in the mold cavity, and then attach the first carbon cloth thick layer and the second carbon cloth thick layer to the U-shaped carbon fiber woven fabric in sequence.

[0017] S1.4, attach a piece of carbon fiber woven fabric of the corresponding size to the entire cavity area, and then attach two pieces of unidirectional carbon fiber fabric, the layup angles of the two pieces of unidirectional carbon fiber fabric are 0 degrees and 90 degrees respectively.

[0018] S1.5, A piece of carbon fiber woven fabric of the corresponding size is vertically attached to the outer surface of the arc ring of the U-shaped frame part inside the mold cavity.

[0019] S1.6, attach a piece of carbon fiber woven fabric of the corresponding size to the area enclosed by the vertically attached carbon fiber woven fabric, and then bend the protruding part of the vertically attached carbon fiber woven fabric above the middle part of the mold cavity toward the middle part of the mold cavity so that it wraps around the edge of the carbon fiber woven fabric in the middle part.

[0020] S1.7, perform mold closing operation on the head and neck mold, and then place the closed head and neck mold on the hot press table of the hot press machine for hot pressing molding treatment. The molding temperature is 140℃~160℃, and the heat preservation and curing is carried out for 25 minutes~45 minutes to cure the carbon fiber prepreg in the head and neck mold.

[0021] S1.8, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished head and neck movable part.

[0022] As a further aspect of the present invention: the process for preparing the first and second carbon cloth thick layers in step S1.1 includes the following steps: according to the shape and size of the U-shaped frame of the head and neck movement part, a U-shaped cutting die is made; the U-shaped cutting die is installed on a stamping machine to cut the carbon fiber prepreg; 14 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut; the U-shaped cutting die is used to cut the cloth to be cut to obtain a U-shaped carbon cloth thin layer; three U-shaped carbon cloth thin layers are overlapped and attached to each other to form the first carbon cloth thick layer; two U-shaped carbon cloth thin layers are overlapped and attached to each other to form the second carbon cloth thick layer.

[0023] As a further aspect of the present invention, the process for preparing U-shaped carbon fiber woven fabric in step S1.1 includes the following steps: using the U-shaped cutting die to cut the raw material of carbon fiber woven fabric to obtain U-shaped carbon fiber woven fabric.

[0024] As a further aspect of the present invention: the process for manufacturing the chest and shoulder support portion described in step S2 includes the following steps:

[0025] S2.1, Prepare a prefabricated core mold. Attach a unidirectional carbon fiber cloth to the prefabricated core mold at a layup angle of 45 degrees. Then attach four unidirectional carbon fiber cloths at a layup angle of 0 degrees. Attach one unidirectional carbon fiber cloth at a layup angle of 90 degrees. Finally, attach a carbon fiber woven cloth to the outermost layer to obtain the part to be formed for the chest and shoulder support.

[0026] S2.2, Prepare a prefabricated chest and shoulder mold, and apply a release agent to the mold cavity area of ​​the prefabricated chest and shoulder mold;

[0027] S2.3 After the release agent dries, place the part to be molded after being attached in step S2.1 into the cavity of the prefabricated chest and shoulder mold;

[0028] S2.4, Prepare round hole fillers and non-hole fillers. Insert one round hole filler, three non-hole fillers and one round hole filler into each bolt hole of the part to be formed in sequence.

[0029] S2.5, attach a piece of carbon fiber woven fabric to the surface of the bolt hole area of ​​the part to be formed after the filler is inserted, and make its texture roughly aligned with the texture of the outermost carbon fiber woven fabric attached in step S2.1.

[0030] S2.6, perform mold closing operation on the chest and shoulder mold, and then place the closed chest and shoulder mold on the hot press table of the hot press machine for hot pressing molding. The molding temperature is 140℃~160℃, and the mold is kept warm and cured for 25 minutes to 45 minutes to cure the carbon fiber prepreg in the chest and shoulder mold.

[0031] S2.7, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished product of the chest and shoulder support part.

[0032] As a further aspect of the present invention, the process of preparing the round hole filling part and the non-perforated filling part in step S2.4 includes the following manufacturing steps: According to the shape and size of the bolt holes in the chest and shoulder support, a round hole cutting die and a non-perforated cutting die are respectively made; the round hole cutting die is installed on a stamping machine to cut the carbon fiber prepreg; 10 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut; the round hole cutting die is used to cut the cloth to be cut to obtain the round hole filling part; the non-perforated cutting die is installed on a stamping machine to cut the carbon fiber prepreg; 40 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut; the non-perforated cutting die is used to cut the cloth to be cut to obtain the non-perforated filling part.

[0033] As a further aspect of the present invention: before installing one end of the damping device on the chest and shoulder support in step S4, the following steps are also included: preparing a prefabricated end cap and installing the end cap on the bolt hole of the chest and shoulder support connecting the damping device.

[0034] As a further aspect of the present invention, the preparation of the prefabricated end cap includes the following steps: according to the shape and size of the end cap, an end cap cutting die and an end cap mold are made; the end cap cutting die is installed on a stamping machine to cut the carbon fiber prepreg; three pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of +45 degrees and -45 degrees respectively, and cut using the end cap cutting die to obtain the cut cloth; a piece of carbon fiber woven cloth is attached to the outermost layer of the cut cloth to obtain the end cap to be hot-pressed; the end cap to be hot-pressed is placed into the cavity of the end cap mold, and then the mold is closed; the closed mold is placed on the hot press table of a hot press for hot pressing and forming; then the mold is removed for demolding; after trimming the burrs, the manufactured prefabricated end cap is obtained.

[0035] As a further aspect of the present invention: after installing one end of the damping device on the head and neck movable part in step S4, the invention further includes the following steps: preparing a prefabricated cover plate and installing the cover plate on the head and neck movable part to protect the damping device.

[0036] As a further aspect of the present invention, the preparation of the prefabricated cover includes the following steps: According to the shape and size of the cover, a cover cutting die and a cover mold are made; the cover cutting die is installed on a stamping machine to cut the carbon fiber prepreg; six pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of +45 degrees and -45 degrees, and cut using the cover cutting die to obtain the cut cover fabric; a piece of carbon fiber woven cloth is attached to the outermost layer of the cut cover fabric to obtain the cover to be hot-pressed; the cover to be hot-pressed is placed into the cavity of the cover mold, and then a mold closing operation is performed; the closed mold is placed on the hot press table of a hot press for hot pressing and forming; then the mold is removed for demolding; after trimming the burrs, the manufactured prefabricated cover is obtained.

[0037] Compared with the prior art, the beneficial effects of the present invention are:

[0038] 1. By setting the head and neck section of the neck brace as a movable part of the head and neck, and installing a damping device between the movable part of the head and neck and the chest and shoulder support, the kinetic energy generated by the rotation of the movable part of the head and neck relative to the chest and shoulder support during the impact can be absorbed.

[0039] 2. A limiting hole is also provided on the head and neck movement section, and a sliding rope is set in the limiting hole. The forward impact force of the helmet is transmitted to the head and neck movement section through the sliding rope. The impact force is then absorbed by the damping device provided on the head and neck movement section, so that the helmet can linearly reduce the forward speed under the damping effect, further reducing the inertia and impact force on the head.

[0040] 3. In addition, when the helmet is pulled backward by the rope, when the helmet hits the head and neck movement area, the head and neck movement area rotates backward, and the damping device can also absorb the backward impact force, further reducing the impact force on the rider's head.

[0041] Therefore, with the above improvements, this invention can further reduce the impact force on the rider's head when using the HANS driver protection neck brace, reduce the impact on the rider's brain, maintain the rider's physical and mental health, and improve the rider's racing comfort.

[0042] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0045] Figure 2 This is a schematic diagram of the ply angles of the present invention;

[0046] Figure 3 This is a schematic diagram of the limiting hole structure of the present invention;

[0047] Figure 4 This is a schematic diagram of the damping device of the present invention;

[0048] Figure 5 This is a schematic diagram of the bolt hole structure of the present invention;

[0049] Figure 6 This is a schematic diagram of the rotating hole structure of the present invention;

[0050] Figure 7 This is a schematic diagram of the head and neck mold of the present invention;

[0051] Figure 8 This is a schematic diagram of the manufacturing process of the present invention;

[0052] Figure 9 This is a flowchart illustrating step S1 of the present invention;

[0053] Figure 10 This is a flowchart illustrating step S2 of the present invention.

[0054] The reference numerals and names in the figure are as follows:

[0055] 10. Chest and shoulder support; 11. Bolt hole; 12. Shoulder pad end; 13. Support leg end; 14. Rotating seat; 15. Rotating shaft; 16. Fixing bolt; 20. Head and neck movable part; 21. U-shaped frame; 22. Rotating hole; 23. Rotating rod; 24. Limiting hole; 25. Buffer pad; 26. Outer facade; 30. Damping device; 31. Head joint bearing; 32. Piston rod; 33. Hydraulic cylinder; 34. Tail joint bearing; 40. Sliding rope; 41. Fixing buckle; 51. End cap; 52. Plate cap; 60. Head and neck mold; 61. Limiting hole slider. Detailed Implementation

[0056] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0057] First, it should be noted that the unidirectional carbon fiber cloth mentioned in this invention refers to a type of carbon fiber cloth with a large amount of carbon fiber yarn in one direction and only a small amount of carbon fiber yarn in the other direction, so that all the strength of the unidirectional carbon fiber cloth is concentrated in one direction. Carbon fiber woven cloth refers to carbon fiber cloth with a certain pattern formed by plain weave or twill weave methods in existing technologies, and its structural strength is relatively uniform in both the radial and weft directions. Carbon fiber prepreg refers to an intermediate material formed by composite treatment of epoxy resin onto carbon fiber yarn using high pressure and high temperature technology. It is a composite material made of carbon fiber yarn, epoxy resin, release paper, etc., processed through existing processes such as coating, hot pressing, cooling, lamination, and winding. All unidirectional carbon fiber cloth, carbon fiber woven cloth, or other carbon fiber intermediate materials mentioned in this invention are carbon fiber prepregs processed using the above-mentioned existing processes.

[0058] Secondly, each piece of carbon fiber prepreg described in this invention is formed by bonding two layers of woven carbon fiber fabric or two layers of unidirectional carbon fiber fabric using the above-mentioned process. Both sides are covered with release paper. During production, workers peel off the release paper to attach the two layers of carbon fiber prepreg, which have a certain degree of adhesion, to the corresponding positions. For example... Figure 2 As shown, in the specific application process of carbon fiber prepreg, the angle between the arrangement direction of the main carbon fiber yarns of the unidirectional carbon fiber cloth and the parallel line of the shoulder pad end 12 of the chest and shoulder support 10 is defined as the layup angle. Specifically, the layup angle of the unidirectional carbon fiber cloth applied approximately parallel to the shoulder pad end 12 is 0 degrees, and the layup angle of the unidirectional carbon fiber cloth applied approximately perpendicular to the shoulder pad end 12 is 90 degrees. The layup angle between 0 degrees and 90 degrees is ±45 degrees, and the layup angle between 90 degrees and 180 degrees is ±45 degrees. It is understandable that the layup angles of 0 degrees, ±45 degrees, 90 degrees, and ±45 degrees can have a certain degree of error. For example, an error within ±5 degrees is within the normal range and has no impact on the overall strength and structure of the neck brace, nor on the entire manufacturing process.

[0059] Please see Figures 1 to 10In one embodiment of the present invention, a shock-reducing protective neck brace includes a chest and shoulder support portion 10, a head and neck movement portion 20, and a damping device 30. One end of the head and neck movement portion 20 is rotatably connected to the chest and shoulder support portion 10 and can rotate relative to the chest and shoulder support portion 10 at a certain angle. One end of the damping device 30 is movably connected to the chest and shoulder support portion 10, and the other end is movably connected to the end of the head and neck movement portion 20 away from the chest and shoulder support portion 10. The damping device 30 is used to absorb the kinetic energy generated by the rotation of the head and neck movement portion 20 relative to the chest and shoulder support portion 10.

[0060] Specifically, since most HANS (Head and Neck Braces) on the market are one-piece designs, while they can prevent riders' heads and necks from being subjected to violent impacts, they still bear a relatively large impact force. This is mainly because the sliding rope 40 can easily generate a large impact force when pulling the helmet from a high-speed forward motion to a stop. Although this impact force will not cause fatal injuries, it can still easily lead to concussions and other adverse conditions for the rider's brain, affecting the rider's health. Therefore, this invention improves the original one-piece HANS into a two-piece HANS, allowing the head and neck movement part 20 to rotate relative to the chest and shoulder support part 10. At the same time, by setting up a damping device 30, the rotation speed of the head and neck movement part 20 can be linearly reduced. That is, the damping device 30 absorbs the kinetic energy of the forward rotation of the head and neck movement part 20, thereby allowing the high-speed forward motion of the helmet to be stopped relatively linearly, reducing the impact force on the helmet and preventing the rider's brain from being impacted and suffering concussions or other adverse conditions.

[0061] Secondly, the damping device 30 can be an existing hydraulic damper or spring damper. Preferably, a hydraulic damper is used, which can provide both tensile and compressive damping. This allows for damping even when the head and neck movement section 20 rotates backward. Most importantly, it maintains greater damping on the forward movement of the head and neck movement section 20. The damping device 30 also has a greater capacity to absorb the forward kinetic energy of the head and neck movement section 20, resulting in a more linear deceleration effect when pulled forward by the helmet and rope 40. This provides better cushioning for the rider's head, reduces the impact force on the rider's head, lessens head sway, reduces the impact on the rider's brain, protects the rider's physical and mental health, and improves the rider's comfort during the race.

[0062] like Figures 1 to 3 As shown, preferably, the neck support device further includes a sliding rope 40. The back of the head and neck movement part 20 is connected to the damping device 30 and a limiting hole 24 is provided. The sliding rope 40 passes through the limiting hole 24, thereby forming a limiting connection between the limiting hole 24 and the sliding rope 40.

[0063] Specifically, by setting a limiting hole 24, the sliding rope 40 can only move left and right within the limiting hole 24, allowing the rider's head to rotate left and right at a certain angle, thus facilitating observation. The middle end of the sliding rope 40 is connected to the head and neck movement part 20, and the two ends of the sliding rope 40 are detachably fixed to the external helmet, transmitting the forward impulse energy of the helmet to the head and neck movement part 20. The rope strap of the sliding rope 40 is preferably made of a relatively non-stretchable fibrous strip material. When the rider fastens the seat belt inside the vehicle, the chest and shoulder support part 10 is stably fixed to the rider's chest and shoulder area by the shoulder strap of the shoulder harness (not shown in the figure). The shoulder strap of the shoulder harness extends along the shoulder pad end 12 and the support leg end 13 of the chest and shoulder support portion 10, such that the shoulder pad end 12 and the support leg end 13 are located between the shoulder strap and the driver, while the head and neck movement portion 20 is located above the driver's shoulder. The shoulder strap of the shoulder harness ensures that the chest and shoulder support portion 10 is in stable contact with the front of the driver's chest and shoulder during normal driving. In the event of a car accident, the connection between the sliding rope 40 and the helmet (not shown in the figure) can pull the entire head and neck movement section 20 forward, while the chest and shoulder support section 10 is fixed by the shoulder strap of the seat belt. This causes the head and neck movement section 20 to accelerate forward relative to the chest and shoulder support section 10. At this time, the damping device 30 resists the rotation of the head and neck movement section 20, slowing down the rotation speed of the head and neck movement section 20. At the same time, it can also absorb the kinetic energy of the head and neck movement section 20, so that the forward impulse energy of the helmet can be reduced relatively linearly. This avoids the rider's head being subjected to strong shock under the action of strong forward impulse energy, further reducing the possibility of head injury to the rider, reducing the impact of the impact on the rider's brain, maintaining the rider's physical and mental health, and improving the rider's racing comfort.

[0064] Additionally, it is understood that both ends of the sliding rope 40 are provided with fixing buckles 41, which can be detachably and securely connected to the rider's helmet, thereby forming a traction connection between the head and neck movement part 20 and the rider's helmet. In another specific embodiment, the sliding rope 40 can slide a certain length within the limiting hole 24, thereby allowing the rider's head to rotate from one side to the other after wearing the helmet. Preferably, the sliding rope 40 has a fixed length, enabling the rider to rotate their head to increase the lateral field of vision.

[0065] like Figures 1 to 4 As shown, preferably, the neck support device further includes an end cap 51 and a plate cap 52. The end cap 51 is fixedly connected to the chest and shoulder support 10 and protects the connection between the damping device 30 and the chest and shoulder support 10. The plate cap 52 is fixedly connected to the head and neck movement part 20 and protects the damping device 30.

[0066] Specifically, to further enhance safety, end caps 51 and plate caps 52 can be provided. End cap 51 is fixedly connected to the bolt hole 11 via the engagement of the bolt and fixing bolt 16, thus protecting the tail joint bearing 34 and rotating seat 14 of the damping device 30. Plate cap 52 is preferably fixed to the head and neck movement part 20 using Velcro, thus protecting the head joint bearing 31, piston rod 32, and hydraulic cylinder 33 of the entire damping device 30. Furthermore, after passing through the limiting hole 24, the sliding rope 40 preferably passes through the surface of plate cap 52, allowing it to slide relatively easily left and right, enabling the rider to rotate the helmet left and right and improve visibility.

[0067] like Figure 8 As shown, the present invention also provides a manufacturing process for a protective neck brace, comprising the following steps:

[0068] S1, the head and neck movable part 20 of the neck brace is manufactured by hot pressing molding process, and the head and neck movable part 20 is obtained after trimming.

[0069] S2, the semi-finished product of the chest and shoulder support part 10 of the neck brace is manufactured by hot pressing molding process, and the chest and shoulder support part 10 is obtained after trimming.

[0070] S3, install the head and neck movable part 20 on the chest and shoulder support part 10, so that it can rotate a certain angle relative to the chest and shoulder support part 10;

[0071] S4, prepare the damping device 30, install one end of the damping device 30 on the chest and shoulder support part 10, and install the other end on the head and neck movement part 20, so that the damping device 30 can restrict the rotation of the head and neck movement part 20.

[0072] S5, prepare the sliding rope 40, install the sliding rope 40 on the head and neck movement part 20, so that the head and neck movement part 20 restricts the movement direction of the sliding rope 40;

[0073] S6. Inspect the relevant components to ensure they are installed correctly, thus completing the manufacturing of the entire neck brace.

[0074] Specifically, the head and neck movable part 20 is mounted on the chest and shoulder support part 10, mainly by fixing the rotating seat 14 through the bolt holes 11 and fixing bolts 16 on the chest and shoulder support part 10. Preferably, the rotating seat 14 is a conventional rotating seat 14 with a rotating shaft 15, the mounting end of which can be inserted into the bolt hole 11 and then fixed by the fixing bolt 16. Additionally, the two ends of the U-shaped frame 21 of the head and neck movable part 20 are preferably provided with rotating holes 22, which can be fitted onto the rotating shaft 15, thereby allowing rotation around the rotating shaft 15.

[0075] Secondly, the tail joint bearing 34 of the damping device 30 can also be sleeved on the rotating shaft 15 of the rotating seat 14, thereby forming a rotatable connection with the chest and shoulder support 10. In addition, the middle part of the U-shaped frame 21 of the head and neck movement part 20 is preferably also provided with a rotating hole 22 and a rotating rod 23, and the head joint bearing 31 of the damping device 30 can be sleeved on the rotating rod 23, thereby forming a rotatable connection with the head and neck movement part 20.

[0076] like Figure 9 As shown, in another embodiment, the process of manufacturing the head and neck movable part 20 described in step S1 includes the following steps:

[0077] S1.1 Prepare a first carbon cloth thick layer, a second carbon cloth thick layer, a U-shaped carbon fiber woven cloth, a limiting carbon cloth strip and a limiting woven cloth, prepare a prefabricated head and neck mold 60, and apply a release agent to the mold cavity of the prefabricated head and neck mold 60.

[0078] Specifically, the process of preparing the limiting carbon fiber strip and the limiting woven fabric described in step S1.1 includes the following steps: according to the approximate shape and size of the limiting hole 24, the carbon fiber woven fabric is cut by hand to obtain the corresponding limiting woven fabric; according to the approximate shape and size of the limiting hole 24, the unidirectional carbon fiber fabric is cut by hand, and two pieces of the cut unidirectional carbon fiber fabric are attached at layup angles of 0 degrees and 90 degrees, and then the two attached unidirectional carbon fiber fabrics are wound into an approximate strip by hand to obtain the corresponding limiting carbon fiber strip.

[0079] Additionally, the preparation of the prefabricated head and neck mold 60 described in step S1.1 involves fabricating a corresponding prefabricated head and neck mold 60 based on the shape and size of the movable head and neck part 20. This includes an upper head and neck mold (not shown in the figure) and a lower head and neck mold (not shown in the figure). A cavity with dimensions and shape consistent with the movable head and neck part 20 is provided in the internal space formed between the upper and lower head and neck molds. A limiting hole slider 61 corresponding to the limiting hole 24 is also provided. It is understood that the head and neck mold 60 may also be equipped with other devices required in the hot pressing process, such as a stop device, a mold closing device, and a mold opening device, to help complete the hot pressing molding process. These devices are existing products in the prior art and will not be described in detail here.

[0080] S1.2 After the release agent dries, attach a piece of limiting woven cloth to both sides of the corresponding part of the mold cavity of the prefabricated head and neck mold 60, at the position relative to the limiting hole 24, then place the limiting carbon cloth strip on the limiting woven cloth, and then place the limiting hole slider 61 on the limiting carbon cloth strip.

[0081] Understandably, a release agent can also be applied to the surface of components such as the limiting hole slider 61 or other abutment devices to facilitate demolding after hot pressing.

[0082] S1.3, attach a U-shaped carbon fiber woven fabric to the corresponding part of the U-shaped frame 21 in the mold cavity, and then attach the first carbon cloth thick layer and the second carbon cloth thick layer to the U-shaped carbon fiber woven fabric in sequence.

[0083] Specifically, during the hot pressing process, the epoxy resin inside the carbon fiber prepreg melts, thus better and more uniformly bonding the numerous carbon fiber yarns to form a dense molded structure and enhance the structural strength of the carbon fiber product. Therefore, to better facilitate the melting and bonding of the internal epoxy resin, it is preferable to apply the first and second carbon cloth layers separately, rather than directly applying the same number of unidirectional carbon fiber cloth sheets in one go. Specifically, the two applications create a gap between the first and second carbon cloth layers, allowing the epoxy resin to melt and penetrate better during hot pressing, thus enabling the carbon fiber yarns to bond together better and enhance the structural strength of the final product. Furthermore, separate application ensures a better fit between the carbon fiber prepreg and the mold, preventing gaps that could affect the shape and quality of the final product.

[0084] S1.4, attach a piece of carbon fiber woven fabric of the corresponding size to the entire cavity area, and then attach two pieces of unidirectional carbon fiber fabric, the layup angles of the two pieces of unidirectional carbon fiber fabric are 0 degrees and 90 degrees respectively.

[0085] S1.5, A piece of carbon fiber woven fabric of the corresponding size is vertically attached to the outer facade 26 of the arc ring of the U-shaped frame 21 in the mold cavity.

[0086] Specifically, such as Figure 7 As shown, in order to ensure that the entire exterior of the head and neck movable part 20 has a similar carbon fiber woven fabric pattern, a piece of carbon fiber woven fabric also needs to be attached to the outer facade 26. Its length is approximately equal to the outer perimeter of the U-shaped frame 21, and its width is approximately slightly wider than the thickness of the U-shaped frame 21.

[0087] S1.6, attach a piece of carbon fiber woven fabric of the corresponding size to the area enclosed by the vertically attached carbon fiber woven fabric, and then bend the protruding part of the vertically attached carbon fiber woven fabric above the middle part of the mold cavity toward the middle part of the mold cavity so that it wraps around the edge of the carbon fiber woven fabric in the middle part.

[0088] Specifically, in order to create a unified pattern effect, a piece of carbon fiber woven fabric can be attached to the area enclosed by the U-shaped frame 21, and then the protruding parts around it can be bent towards the center to wrap the carbon fiber woven fabric in the middle and form a whole.

[0089] S1.7, perform mold closing operation on head and neck mold 60, and then place the closed head and neck mold 60 into the hot press table of hot press machine for hot pressing molding process, wherein the molding temperature is 140℃~160℃, and heat preservation and curing is performed for 25 minutes~45 minutes to cure the carbon fiber prepreg in head and neck mold 60.

[0090] S1.8, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished head and neck movable part 20.

[0091] Specifically, steps S1.7 and S1.8 can be part of a hot-press molding process. After appropriate hot-press molding and cooling treatments, a semi-finished product is obtained after demolding. After trimming the burrs, the corresponding head and neck movement part 20 is obtained. Considering the above process, the U-shaped frame 21 of the head and neck movement part 20 has very high structural strength. It mainly works in conjunction with the sliding rope 40 to provide tension for the helmet. The middle part of the U-shaped frame 21 can be relatively thin, and a cushioning pad 25 can be provided on the side facing the helmet. This makes the contact between the helmet and the head and neck movement part 20 softer, preventing the head from hitting relatively hard parts during normal riding and improving the rider's experience.

[0092] In another embodiment, the process of preparing the first carbon cloth thick layer and the second carbon cloth thick layer described in step S1.1 includes the following steps:

[0093] Based on the shape and size of the U-shaped frame 21 of the head and neck movement section 20, a U-shaped cutting die is made. The U-shaped cutting die is installed on a stamping machine to cut the carbon fiber prepreg. Fourteen pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut. The U-shaped cutting die is used to cut the cloth to be cut to obtain a U-shaped carbon cloth thin layer. Three U-shaped carbon cloth thin layers are overlapped and attached to each other to form a first carbon cloth thick layer. Two U-shaped carbon cloth thin layers are overlapped and attached to form a second carbon cloth thick layer.

[0094] Specifically, the U-shaped cutting die can be manufactured according to existing processes in the prior art, and then the carbon fiber prepreg is cut using a stamping machine tool in conjunction with the die.

[0095] In another embodiment, the process of preparing U-shaped carbon fiber woven fabric in step S1.1 includes the following steps: using the cutting die to cut the raw material of carbon fiber woven fabric to obtain U-shaped carbon fiber woven fabric.

[0096] like Figure 10 As shown, in another embodiment, the process of manufacturing the chest and shoulder support portion 10 described in step S2 includes the following steps:

[0097] S2.1, Prepare a prefabricated core mold, attach a unidirectional carbon fiber cloth to the prefabricated core mold at a layup angle of 45 degrees, then attach 4 unidirectional carbon fiber cloths at a layup angle of 0 degrees, then attach 1 unidirectional carbon fiber cloth at a layup angle of 90 degrees, and finally attach a carbon fiber woven cloth to the outermost layer to obtain the to-be-formed part of the chest and shoulder support 10.

[0098] Specifically, the layup angle on the precast core mold can be positive 45 degrees or negative 45 degrees, and there is no limitation here. The process of preparing the precast core mold includes the following manufacturing steps: according to the size and shape of the chest and shoulder support 10 to be manufactured, a corresponding core mold shell is made, then polyurethane solution is poured into the core mold shell, and after the polyurethane solution cools and solidifies, the core mold shell is removed to obtain the corresponding precast core mold.

[0099] S2.2, Prepare a prefabricated chest and shoulder mold, and apply a release agent to the mold cavity area of ​​the prefabricated chest and shoulder mold;

[0100] S2.3 After the release agent dries, place the part to be molded after being attached in step S2.1 into the cavity of the prefabricated chest and shoulder mold;

[0101] S2.4, Prepare round hole fillers and non-hole fillers. Insert one round hole filler, three non-hole fillers and one round hole filler into each bolt hole 11 of the part to be formed in sequence.

[0102] S2.5, attach a piece of carbon fiber woven fabric to the surface of the area where the bolt hole 11 of the part to be formed is located after the filler is inserted, and make its texture roughly aligned with the texture of the outermost carbon fiber woven fabric attached in step S2.1.

[0103] S2.6, perform mold closing operation on the chest and shoulder mold, and then place the closed chest and shoulder mold on the hot press table of the hot press machine for hot pressing molding. The molding temperature is 140℃~160℃, and the mold is kept warm and cured for 25 minutes to 45 minutes to cure the carbon fiber prepreg in the chest and shoulder mold.

[0104] S2.7, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished product of the chest and shoulder support part 10.

[0105] Specifically, the process of preparing the prefabricated chest and shoulder mold described in step S2.2 includes the following manufacturing steps: Based on the size and shape of the chest and shoulder support 10 to be manufactured, a corresponding prefabricated chest and shoulder mold (not shown in the figure) is manufactured, including an upper chest and shoulder mold and a lower chest and shoulder mold. A cavity with the same size and shape as the chest and shoulder support 10 is provided in the internal space formed between the upper and lower chest and shoulder molds. It is understood that the chest and shoulder mold may also be equipped with other devices required in the hot pressing process, such as a stop device, a mold closing device, or a mold opening device, to help complete the hot pressing molding process. These devices are existing products in the prior art and will not be described in detail here.

[0106] In another embodiment of the present invention, preferably, the process of preparing the round hole filling part and the non-perforated filling part described in step S2.4 includes the following manufacturing steps: according to the shape and size of the bolt holes 11 of the chest and shoulder support part 10, a round hole cutting die and a non-perforated cutting die are respectively made; the round hole cutting die is installed on a stamping machine to cut the carbon fiber prepreg, 10 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut, and the round hole cutting die is used to cut the cloth to be cut to obtain the round hole filling part; the non-perforated cutting die is installed on a stamping machine to cut the carbon fiber prepreg, 40 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut, and the non-perforated cutting die is used to cut the cloth to be cut to obtain the non-perforated filling part.

[0107] Specifically, since the main stress points of the head and neck movable part 20 and the damping device 30 are fixed by bolts connecting the rotating seat 14 and the bolt hole 11, the structural strength of the bolt hole 11 must be relatively high to withstand the corresponding impact force. However, if the bolt hole 11 is manufactured directly on the head and neck mold 60, its dimensions will not be accurate enough, and it will be inconvenient to demold the mold. Therefore, the bolt hole 11 is preferably formed by drilling later. Thus, a relatively thick non-perforated filler can be used to fill the holes on the core mold. At the same time, to facilitate drilling later, a round hole filler can be placed at each end of the hole. When drilling later, the tool can be placed in the round hole for drilling, which is more convenient and faster.

[0108] In another embodiment of the present invention, preferably, before installing one end of the damping device 30 onto the chest and shoulder support 10 in step S4, the following steps are also included: preparing a prefabricated end cap 51, and installing the end cap 51 onto the bolt hole 11 connecting the damping device 30 to the chest and shoulder support 10. The preparation of the prefabricated end cap 51 includes the following steps: according to the shape and size of the end cap 51, making an end cap 51 cutting die and an end cap 51 mold; installing the end cap 51 cutting die on a stamping machine to cut the carbon fiber prepreg; alternately attaching three pieces of unidirectional carbon fiber cloth at layup angles of +45 degrees and -45 degrees respectively, and cutting them using the end cap 51 cutting die to obtain the cut fabric; attaching one piece of carbon fiber woven fabric to the outermost layer of the cut fabric to obtain the end cap 51 to be heat-pressed; and then... The end cap 51 to be hot-pressed is placed into the mold cavity of the end cap 51 mold, and then the mold is closed. The closed mold is placed on the hot press table of the hot press machine for hot pressing and forming. The forming temperature is 140℃~160℃, and the heat preservation is carried out for 25 minutes to 45 minutes to solidify the carbon fiber prepreg in the mold. The hot-pressed mold is transported to the cooling table for cooling for 5 minutes to 15 minutes. Then the mold is removed for demolding. After the burrs are trimmed, the prefabricated end cap 51 is obtained.

[0109] In another embodiment of the present invention, preferably, after installing one end of the damping device 30 onto the head and neck movable part 20 in step S4, the following steps are also included: preparing a prefabricated cover 52, and installing the cover 52 onto the head and neck movable part 20 to protect the damping device 30. The preparation of the prefabricated cover 52 includes the following steps: according to the shape and size of the cover 52, fabricating a cover 52 cutting die and a cover 52 mold; installing the cover 52 cutting die on a stamping machine to cut the carbon fiber prepreg; alternately attaching six pieces of unidirectional carbon fiber cloth at layup angles of +45 degrees and -45 degrees respectively, and cutting them using the cover 52 cutting die to obtain the cut fabric; attaching one piece of carbon fiber woven fabric to the outermost layer of the cut fabric to obtain the cover 52 to be heat-pressed; and then... The cover plate 52 to be hot-pressed is placed into the mold cavity of the cover plate 52 mold, and then the mold is closed. The closed mold is placed on the hot press table of the hot press machine for hot pressing and forming. The forming temperature is 140℃~160℃, and the heat preservation is carried out for 25 minutes to 45 minutes to solidify the carbon fiber prepreg in the mold. The hot-pressed mold is then transported to the cooling table for cooling for 5 minutes to 15 minutes. Then the mold is removed for demolding. After the burrs are trimmed, the prefabricated cover plate 52 is obtained.

[0110] When in use, before entering the race car, the driver can put on the protective neck brace on both shoulders, with the shoulder pad end 12 placed on both shoulders and the support leg end 13 placed in front of the chest. Then, the fixing buckle 41 of the sliding rope 40 is connected to the corresponding device on the helmet, thereby forming a pulling effect on the helmet.

[0111] After the driver enters the race car, they first use one shoulder strap of the dual shoulder strap system to secure their body, and the other shoulder strap to secure the chest and shoulder support 10 of the neck brace, thus firmly fixing the neck brace between the shoulder strap and the body. Subsequently, during normal riding, a sliding rope 40 of a certain length allows the driver's head and helmet to have a certain amount of room to move, and the sliding rope 40 can also slide left and right in the limiting hole 24, allowing the driver's head to turn to a certain angle to the left and right, thereby enhancing the driver's lateral field of vision.

[0112] In the event of an unexpected collision, particularly a frontal collision, the rider's head and helmet, propelled forward by inertia, experience a rapid and intense impact. After a certain distance, the helmet's sliding cord 40 pulls on the helmet, transferring its forward kinetic energy to the head and neck movement unit 20. This pull causes the head and neck movement unit 20 to rotate forward, simultaneously engaging the damping device 30. The damping device 30 generates resistance during this pull, reducing the forward rotational energy of the head and neck movement unit 20 and thus decreasing the helmet's forward kinetic energy. This gradually brings the helmet's forward motion to a relatively linear stop. Therefore, this further reduces the impact on the rider's head, lessens the impact on the brain, protects the rider's physical and mental health, and improves the rider's comfort during the race.

[0113] When a collision occurs at the rear of the vehicle, the helmet moves backward and impacts the head and neck movement part 20, causing the head and neck movement part 20 to rotate backward at a certain angle. Similarly, the damping device 30 can also provide a certain amount of resistance to reduce the speed at which the head and neck movement part 20 rotates backward. Therefore, it can further reduce the impact force on the rider's head, reduce the impact on the rider's brain, maintain the rider's physical and mental health, and improve the rider's comfort during the race.

[0114] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A manufacturing process for a protective neck brace, characterized in that, Includes the following steps: S1, the head and neck movable part (20) of the neck brace is manufactured by hot pressing molding process, and the head and neck movable part (20) is obtained after trimming. S2, the chest and shoulder support part (10) of the neck brace is manufactured by hot pressing molding process, and the chest and shoulder support part (10) is obtained after trimming. S3, install the head and neck movable part (20) on the chest and shoulder support part (10) so that it can rotate a certain angle relative to the chest and shoulder support part (10); S4, prepare the damping device (30), install one end of the damping device (30) on the chest and shoulder support (10) and the other end on the head and neck movement part (20), so that the damping device (30) can restrict the rotation of the head and neck movement part (20). S5, prepare the sliding rope (40), install the sliding rope (40) in the limiting hole (24) of the head and neck moving part (20) so that the head and neck moving part (20) restricts the movement direction of the sliding rope (40); S6. Inspect the relevant components to ensure they are installed correctly, thus completing the manufacturing of the entire neck brace; The process for manufacturing the head and neck movable part (20) described in step S1 includes the following steps: S1.1, prepare a first carbon cloth thick layer, a second carbon cloth thick layer, a U-shaped carbon fiber woven cloth, a limiting carbon cloth strip and a limiting woven cloth, prepare a prefabricated head and neck mold (60), and apply a release agent to the mold cavity of the prefabricated head and neck mold (60). S1.2 After the release agent dries, attach a piece of limiting woven cloth to both sides of the corresponding part of the mold cavity of the prefabricated head and neck mold (60) at the position relative to the limiting hole (24), then place the limiting carbon cloth strip on the limiting woven cloth, and then place the limiting hole slider (61) on the limiting carbon cloth strip. S1.3, attach a U-shaped carbon fiber woven fabric to the corresponding part of the U-shaped frame (21) in the mold cavity, and then attach the first carbon cloth thick layer and the second carbon cloth thick layer to the U-shaped carbon fiber woven fabric in sequence. S1.4, attach a piece of carbon fiber woven fabric of the corresponding size to the entire cavity area, and then attach two pieces of unidirectional carbon fiber fabric, the layup angles of the two pieces of unidirectional carbon fiber fabric are 0 degrees and 90 degrees respectively. S1.5, a piece of carbon fiber woven fabric of the corresponding size is vertically attached to the outer facade (26) of the arc ring of the U-shaped frame (21) in the mold cavity; S1.6, attach a piece of carbon fiber woven fabric of the corresponding size to the area enclosed by the vertically attached carbon fiber woven fabric, and then bend the protruding part of the vertically attached carbon fiber woven fabric above the middle part of the mold cavity toward the middle part of the mold cavity so that it wraps around the edge of the carbon fiber woven fabric in the middle part. S1.7, perform mold closing operation on the head and neck mold (60), and then place the closed head and neck mold (60) on the hot press table of the hot press machine for hot pressing molding treatment, wherein the molding temperature is 140℃~160℃, and heat preservation and curing is performed for 25 minutes~45 minutes to cure the carbon fiber prepreg in the head and neck mold (60). S1.8, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished head and neck movable part (20) that has been initially manufactured; The process of preparing the first carbon cloth thick layer and the second carbon cloth thick layer as described in step S1.1 includes the following steps: according to the shape and size of the U-shaped frame (21) of the head and neck movable part (20), a U-shaped cutting die is made, and the U-shaped cutting die is installed on a stamping machine to cut the carbon fiber prepreg; 14 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut, and the cloth to be cut is cut using the U-shaped cutting die to obtain a U-shaped carbon cloth thin layer; 3 U-shaped carbon cloth thin layers are overlapped and attached to each other to form the first carbon cloth thick layer; 2 U-shaped carbon cloth thin layers are overlapped and attached to form the second carbon cloth thick layer.

2. The manufacturing process of a protective neck brace according to claim 1, characterized in that, The process of preparing U-shaped carbon fiber woven fabric in step S1.1 includes the following steps: using the U-shaped cutting die to cut the raw material of carbon fiber woven fabric to obtain U-shaped carbon fiber woven fabric.

3. The manufacturing process of a protective neck brace according to claim 1, characterized in that, The process for manufacturing the chest and shoulder support (10) described in step S2 includes the following steps: S2.1, prepare a prefabricated core mold, attach a unidirectional carbon fiber cloth on the prefabricated core mold at a layup angle of 45 degrees, then attach 4 unidirectional carbon fiber cloths at a layup angle of 0 degrees, then attach 1 unidirectional carbon fiber cloth at a layup angle of 90 degrees, and then attach a carbon fiber woven cloth on the outermost layer to obtain the chest and shoulder support part (10) to be formed. S2.2, Prepare a prefabricated chest and shoulder mold, and apply a release agent to the mold cavity area of ​​the prefabricated chest and shoulder mold; S2.3 After the release agent dries, place the part to be molded after being attached in step S2.1 into the cavity of the prefabricated chest and shoulder mold; S2.4, Prepare round hole fillers and non-hole fillers. Insert one round hole filler, three non-hole fillers and one round hole filler into each bolt hole (11) of the part to be formed in sequence. S2.5, attach a piece of carbon fiber woven fabric to the surface of the area where the bolt hole (11) of the part to be formed is after the filler is inserted, and make its texture roughly aligned with the texture of the outermost carbon fiber woven fabric attached in step S2.

1. S2.6, perform mold closing operation on the chest and shoulder mold, and then place the closed chest and shoulder mold on the hot press table of the hot press machine for hot pressing molding. The molding temperature is 140℃~160℃, and the mold is kept warm and cured for 25 minutes to 45 minutes to cure the carbon fiber prepreg in the chest and shoulder mold. S2.7, after hot pressing, the mold is transported to the cooling table for cooling for 5 to 15 minutes, and then the mold is removed for demolding to obtain the semi-finished product of the chest and shoulder support part (10).

4. The manufacturing process of a protective neck brace according to claim 3, characterized in that, The process of preparing the round hole filling part and the non-hole filling part described in step S2.4 includes the following manufacturing steps: according to the shape and size of the bolt hole (11) of the chest and shoulder support part (10), a round hole cutting die and a non-hole cutting die are made respectively; the round hole cutting die is installed on a stamping machine to cut the carbon fiber prepreg, 10 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut, and the round hole cutting die is used to cut the cloth to be cut to obtain the round hole filling part; the non-hole cutting die is installed on a stamping machine to cut the carbon fiber prepreg, 40 pieces of unidirectional carbon fiber cloth are alternately attached at layup angles of 0 degrees and 90 degrees to form a cloth to be cut, and the non-hole cutting die is used to cut the cloth to be cut to obtain the non-hole filling part.

5. The manufacturing process of a protective neck brace according to claim 1, characterized in that, Before installing one end of the damping device (30) on the chest and shoulder support (10) in step S4, the following steps are also included: preparing a prefabricated end cap (51) and installing the end cap (51) on the bolt hole (11) of the chest and shoulder support (10) connecting the damping device (30).

6. The manufacturing process of a protective neck brace according to claim 5, characterized in that, The preparation of the prefabricated end cap (51) includes the following steps: according to the shape and size of the end cap (51), make the end cap (51) cutting die and the end cap (51) mold, install the end cap (51) cutting die on the stamping machine to cut the carbon fiber prepreg; attach three pieces of unidirectional carbon fiber cloth alternately at a layup angle of positive 45 degrees and negative 45 degrees respectively, and cut them using the end cap (51) cutting die to obtain the cut cloth; attach one piece of carbon fiber woven cloth to the outermost layer of the cut cloth to obtain the end cap (51) to be hot-pressed; The end cap (51) to be hot-pressed is placed into the mold cavity of the end cap (51) mold, and then the mold is closed. The mold after the mold is closed is placed on the hot press table of the hot press machine for hot pressing and forming. Then the mold is removed and demolded. After the burrs are trimmed, the prefabricated end cap (51) is obtained.

7. The manufacturing process of a protective neck brace according to claim 1, characterized in that, After installing one end of the damping device (30) on the head and neck movable part (20) in step S4, the following steps are also included: preparing a prefabricated cover (52) and installing the cover (52) on the head and neck movable part (20) to protect the damping device (30).

8. The manufacturing process of a protective neck brace according to claim 7, characterized in that, The preparation of the prefabricated cover (52) includes the following steps: according to the shape and size of the cover (52), make a cover (52) cutting die and a cover (52) mold; install the cover (52) cutting die on a press to cut the carbon fiber prepreg; attach 6 pieces of unidirectional carbon fiber cloth alternately at a layup angle of positive 45 degrees and negative 45 degrees respectively, and cut them with the cover (52) cutting die to obtain the cut cover (52) cloth; attach a piece of carbon fiber woven cloth to the outermost layer of the cut cover (52) cloth to obtain the cover (52) to be hot-pressed; put the cover (52) to be hot-pressed into the cavity of the cover (52) mold, and then perform a mold closing operation; put the mold after mold closing into the hot press table of the hot press machine for hot pressing and forming; then take out the mold for demolding; after trimming the burrs, the prefabricated cover (52) is obtained.

9. A shock-reducing protective neck brace, characterized in that, The protective neck brace is manufactured using the manufacturing process described in any one of claims 1-8, and includes a chest and shoulder support (10), a head and neck movement part (20), and a damping device (30). The head and neck movement part (20) is a U-shaped frame component independent of the helmet and the chest and shoulder support part (10). One end of the head and neck movement part (20) is rotatably connected to the chest and shoulder support part (10) via a rotating shaft (15), and can rotate relative to the chest and shoulder support part (10) around the rotating shaft (15). The damping device... One end of (30) is movably connected to the chest and shoulder support (10) via a tail joint bearing (34), and the other end is movably connected to the free end of the head and neck movement part (20) away from the chest and shoulder support part (10) via a head joint bearing (31), forming a lever structure with the rotation shaft (15) as the fulcrum and the connection point of the damping device (30) as the end of the lever arm. The damping device (30) is used to absorb the kinetic energy generated by the rotation of the head and neck movement part (20) relative to the chest and shoulder support part (10) through the lever structure.

10. A shock-reducing protective neck brace according to claim 9, characterized in that, It also includes a sliding rope (40). The back of the head and neck movement part (20) connected to the damping device (30) is provided with a limiting hole (24). The sliding rope (40) passes through the limiting hole (24), so that the limiting hole (24) forms a limiting connection with the sliding rope (40). The diameter of the limiting hole (24) matches the sliding rope (40) to limit the vertical displacement of the sliding rope (40) and allow it to slide left and right. The two ends of the sliding rope (40) can be detachably connected to the external helmet to transfer the forward impulse energy of the helmet to the head and neck movement part (20) and cooperate with the lever structure to achieve linear deceleration of the helmet.

11. A shock-reducing protective neck brace according to claim 9, characterized in that, It also includes an end cap (51) and a plate cap (52). The end cap (51) is fixedly connected to the bolt hole (11) of the chest and shoulder support (10) and protects the connection between the damping device (30) and the chest and shoulder support (10), while also enhancing the structural strength of the bolt hole (11). The plate cap (52) is fixedly connected to the head and neck movement part (20) and protects the damping device (30), while also preventing the damping device (30) from interfering with the helmet and clothing.

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