A lightweight multifunctional helmet and a preparation method thereof

Abstract

This invention belongs to the field of helmet manufacturing technology, and relates to a lightweight multifunctional helmet and its manufacturing method. It includes a helmet shell, with a buffer layer and a padding layer sequentially disposed inside the shell, and a suspension assembly disposed outside the shell. The helmet shell is equipped with integrated functional modules and an interactive system. The integrated functional modules include: an optical sensing unit, an acoustic sensing unit, an environmental sensing unit, a bio-monitoring unit, a protective unit, and an energy management unit. The integrated functional modules interact with the interactive system. Using ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcement materials, the helmet's weight is effectively reduced while ensuring protective performance, thus improving the wearer's mobility.

Description

Technical Field

[0001] This invention belongs to the field of helmet manufacturing technology, and relates to a lightweight multifunctional helmet and its manufacturing method. Background Technology

[0002] Riot helmets are primarily made of ultra-high molecular weight polyethylene (UHMWPE) or aramid composite materials, weighing ≤1.35kg, and can withstand direct impact from high-strength objects and hard projectiles. Non-metallic protective technology is mature, and the non-porous design enhances protective integrity. Night vision devices, recording equipment, and bone conduction headphones are standard equipment; some high-end models integrate AR displays and environmental sensors (such as toxic gas detection) to support visualization of work scene information. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and to propose a lightweight multifunctional helmet and its manufacturing method.

[0004] A lightweight, multi-functional helmet, such as Figure 2 As shown, the helmet includes a helmet shell, inside which a buffer layer and a pad are sequentially arranged, and outside of which a suspension assembly is arranged; The helmet shell is equipped with an integrated functional module, which includes: an optical sensing unit, an acoustic sensing unit, an environmental sensing unit, a biological monitoring unit, a protection unit, and an energy management unit. The integrated functional module interacts with the interactive system, and the information processing module CPU is located in the interactive system.

[0005] Material weight reduction: The helmet shell uses T800 grade unidirectional prepreg (density 1.6g / cm³); 3D printing titanium alloy topology optimization (weight reduction of 35%).

[0006] Information interaction with the interaction center is achieved through integrated functional modules on the helmet. For example, the camera of the optical sensing unit records the surrounding scene and transmits it to the interaction system. The interaction system displays the information in the interaction center. The microphone of the acoustic sensing unit transmits sound information to the interaction system in real time. The interaction system displays the information in the interaction center. The interaction center releases sound signals and transmits them to the helmet wearer through bone conduction headphones. And so on.

[0007] Furthermore, the helmet shell is made of ultra-high molecular weight polyethylene fiber (UHMWPE, 80%) and poly(p-phenylene terephthalamide) (PPTA, 20%) laminated in a 4:1 ratio. The lamination process is as follows: lay-up (alternating lay-up of UHMWPE and PPTA fiber fabrics in a designed ratio (e.g., [0° / 90°])), impregnation (coating with thermosetting epoxy resin or thermoplastic resin such as polyethylene), and hot-press curing (curing at high temperature (120-160°C) and high pressure (5-20 MPa) to form a dense shell); the buffer layer is made of ethylene-vinyl acetate copolymer foamed plastic, and the suspension assembly is made of polycarbonate material.

[0008] Specifically, such as Figure 2 As shown, the helmet shell can be made in different colors depending on the requirements. The helmet shell is made of ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) to provide NIJ IIIA level protection. The buffer layer is a non-Newtonian fluid used to absorb impact kinetic energy with an attenuation rate of more than 60%. The surface of the helmet shell is coated with a radar-absorbing coating, which can reduce radar reflection (RCS reduction > 8dB).

[0009] Furthermore, the optical sensing unit includes multiple cameras arranged around the outside of the helmet shell, the acoustic sensing unit includes a microphone arranged outside the helmet shell, the environmental sensing unit includes a compass, a barometric altimeter, and a toxic gas detection sensor arranged outside the helmet shell, and the biological monitoring unit includes a temperature sensor arranged inside the liner. The information data detected by the sensors is transmitted to the interactive system.

[0010] Specifically, the optical sensing module consists of four low-light / infrared dual-mode cameras arranged in a ring around the outside of the helmet shell, with a resolution of 1280×1024, providing a panoramic view; a laser ranging module with an accuracy of ±0.3m / 1km; a ring arrangement of four SWIR low-light cameras (900-1700nm); a MEMS microphone array (beamforming, noise reduction ratio >30dB); and an acoustic sensing module including bone conduction headphones (frequency response 100Hz-8kHz), with a signal-to-noise ratio greater than 70dB, used for voice communication and alarms.

[0011] Environmental perception: The compass is a three-axis digital compass, and the barometric altimeter is used for navigation and positioning; the toxic gas detection sensor can detect CO / NO2, etc., with a detection limit of ≤1ppm.

[0012] Active noise reduction control; Algorithm: FxLMS adaptive filtering (convergence time ≤50ms); Actuator: Neodymium magnet moving coil unit (frequency response 20Hz-20kHz±3dB); Noise reduction depth: Low frequency (<500Hz): 25dB; Gunshot pulse noise: instantaneous attenuation 40dB.

[0013] Biomonitoring: A temperature sensor is placed inside the forehead pad, a forehead EEG electrode monitors brain waves, and an infrared body temperature sensor monitors body temperature (accuracy ±0.2℃).

[0014] Integrated design: The sensor PCB conformally fits the helmet's curved surface; Furthermore, the protective unit includes a directional acoustic emitter located inside the helmet, either on top of or in front of the head.

[0015] Specifically, acoustic countermeasures include: directional sound wave emitters (maximum sound pressure level 140dB / 1m) for non-lethal countermeasures; and active noise cancellation (low-frequency noise attenuation >25dB) to improve comfort. Electromagnetic protection: Transient voltage suppressors (response time < 1 ns) and Faraday cage braided layers (shielding effectiveness > 60 dB) protect electronic equipment.

[0016] Furthermore, the energy management unit includes a curved solar cell located on the outer surface of the helmet shell.

[0017] Specifically, kinetic energy recovery: a piezoelectric ceramic cantilever beam array can generate 0.5W of electricity, with the solar cells and protective layer integrally molded.

[0018] Solar Energy: Curved GaAs thin-film solar cell with a conversion efficiency of 29%, providing 8W of power under standard illumination conditions (AM1.5).

[0019] Main power source: Lithium-sulfur battery pack with an energy density of up to 450Wh / kg, ensuring long-term battery life (72 hours).

[0020] Connections between parts: Physical Connections: The sensor array is connected to the main processor (NVIDIA Jetson Orin) via an LVDS interface. The main processor drives the optical waveguide display via a MIPI-DSI interface, connects to the bone conduction headphones via an I2S interface, and the communication unit communicates with the main processor via a CAN bus. The battery management system exchanges data with the main processor via the PMBus protocol and supports wireless charging.

[0021] Data flow: Sensor data first enters the edge computing layer (main processor), and then the processed information can be uploaded to the cloud platform or downloaded to update the AI ​​model. Real-time processing (such as object detection) is completed at the edge computing layer, ensuring low latency (<50ms).

[0022] This lightweight, multi-functional helmet system achieves integrated functionality, including sensing, communication, display, and active protection, while ensuring protective performance through a highly integrated design. It also enables long-duration combat capability through advanced energy management.

[0023] Furthermore, the padding includes a top head pad, a forehead pad, a side head pad, and a back head pad, and the padding is detachably connected to the buffer layer; the padding is a titanium alloy honeycomb structure.

[0024] Specifically, a titanium alloy honeycomb structure forced convection channel (thermal resistance <0.5K / W); and a phase change material patch (melting point 37℃) absorbs the processor's heat.

[0025] Furthermore, the surface paint of the helmet shell has a hardness ≥ H, an afterflame time ≤ 2S, and a volatile organic compound content ≤ 400g / L.

[0026] Furthermore, the suspension assembly includes a suspension base, on which a guide rail assembly is provided. The guide rail assembly includes a slider that slides inside the guide rail. The equipment is connected to the slider, and the equipment slides up and down through the slider.

[0027] This invention also discloses a method for manufacturing a lightweight, multifunctional helmet, such as... Figure 1 As shown, the specific steps include: Step 1, Helmet shell preparation: Ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material are compounded in a ratio of (4~6.8):1, and the helmet shell is prepared by compression molding process; Step 2: Buffer layer preparation: A foaming agent is added to the ethylene-vinyl acetate copolymer foamed plastic, wherein the mass ratio of the foamed plastic to the foaming agent is 100:(3~7), and a buffer layer is prepared by compression molding foaming process; the foaming ratio can reach 5~8 times; In the preparation of ethylene vinyl acetate copolymer (EVA) foamed plastic for helmet cushioning layer, the ratio of foaming agent to EVA needs to be determined comprehensively based on the foaming ratio, material density, and mechanical performance requirements.

[0028] 1. Conventional foaming system EVA : Blowing agent (AC type) = 100 : 3.0~5.0; In patent literature, the mass ratio of EVA matrix to blowing agent is often 100 parts EVA to 3.0~5.0 parts AC blowing agent. In high-resilience EVA formulations, adding 4.0 kg of AC blowing agent to 100 kg of EVA can achieve a foaming ratio of 5~8 times. 2. Demand for high-ratio foaming EVA : foaming agent = 100 : 5.0~7.0; simultaneously adjust the amount of crosslinking agent (such as DCP) to 0.8~1.0Phr, and control the foaming temperature at 160~180℃ (to avoid excessive decomposition).

[0029] Key influencing factors and adjustment strategies 1. Type of foaming agent AC foaming agent: decomposition temperature 160~200℃, preferably, ratio 3.5~4.5 parts / 100 parts EVA. Low-temperature foaming agents (such as AD-300): decomposition temperature 140~150℃, the ratio needs to be increased to 5.0~6.0 parts, and zinc oxide (1~2 parts) should be added to reduce the decomposition temperature. 2. Target density and buffering performance Low-density buffer layer (0.15~0.25g / cm³): The proportion of foaming agent is increased to 5.0~6.0 parts, and 20~40 parts of modified lignocellulose powder are added to enhance the uniformity of the foam cells. High energy absorption requirements: A gradient foaming structure is adopted, with a surface layer ratio of 4.0 parts / 100 parts EVA (density 0.3g / cm³) and an inner layer ratio of 6.0 parts / 100 parts EVA (density 0.18g / cm³).

[0030] III. Collaborative Optimization of Process Parameters 1. Temperature control Intensive mixing stage: 100~120℃ (to avoid premature decomposition of foaming agent). Foaming stage: 160~180℃ (optimal decomposition range of AC foaming agent). 2. Crosslinking agent matching DCP dosage: 0.5~0.6Phr (flat-sheet foaming) or 0.8~1.0Phr (injection foaming) to ensure a balance between crosslinking degree and foaming rate.

[0031] The helmet cushioning layer formulation can be: 100 parts EVA + 4.2 parts AC foaming agent + 1.5 parts zinc oxide + 50 parts modified lignocellulose powder. Performance: density 0.21 g / cm³, compression resilience >85%, meeting NIJ Level III impact resistance standards. Alternatively, gradient bubble optimization can be used, where: Surface layer (penetration-resistant layer): 100 parts EVA + 3.5 parts AC, density 0.28 g / cm³. Intermediate layer (energy absorption layer): 100 parts EVA + 5.0 parts AC, density 0.18 g / cm³.

[0032] Bottom layer (adhesive layer): 100 parts EVA + 4.0 parts AC + 15 parts carbon nanotube onion, conductivity 1×10-5 S / cm.

[0033] Foaming agent residue control: The residue of AC foaming agent is about 30%. It is necessary to add 1 to 3 parts of zinc stearate to reduce surface blooming. Environmental adaptability: In high temperature and high humidity environments, it is recommended to use a composite foaming agent system of AC:OBSH=3:1 to reduce the heat of decomposition.

[0034] Recommended initial mixing ratio: EVA : foaming agent = 100 : 4.0~4.5, combined with 1.0~1.5 parts zinc oxide and 0.6 Phr DCP. Actual production requires verification of cushioning performance through foaming ratio test (ASTM D3575) and drop hammer impact test (MIL-STD-662F).

[0035] Step 3: Component assembly: Bond the helmet shell to the buffer layer, attach the top pad, forehead pad, side pad, and back pad to the inside of the buffer layer using Velcro, and attach the suspension assembly and goggles to the helmet shell.

[0036] Furthermore, in step two, the foaming temperature and pressure in the compression molding foaming process are recommended to be initially set at a temperature of 165±5℃ and a pressure of 100~120 kg / cm² for EVA system compression molding foaming, and then finely adjusted according to the expansion ratio test (ASTM D3575) and drop hammer impact test (MIL-STD-662F). Other materials need to be matched with specific process windows according to their thermodynamic properties.

[0037] I. Typical Composite Ratio Range Mass ratio range 4:1 ~ 6.8:1 (UHMWPE : PPTA) The blending ratio of ultra-high molecular weight polyethylene fiber to reinforcing fiber (including aramid) is 4:1 to 6.8:1 to balance lightweight and performance.

[0038] Layered application: Outer layer: Primarily UHMWPE (over 85%), utilizing its high toughness and energy absorption properties. Middle layer: A blend of UHMWPE and PPTA (e.g., 6:1) to enhance overall impact resistance. Inner layer: Slightly higher proportion of PPTA (e.g., 1:3) to improve resistance to collapse.

[0039] II. The Impact of Key Performance on Proportion For lightweight applications, a higher UHMWPE ratio results in a lighter helmet (density of only 0.97g / cm³), but this reduces its high-temperature resistance. Commonly used helmets typically employ a 6:1 ratio to balance weight and protection.

[0040] Impact resistance. Academic research shows that the UHMWPE layer sandwiched with a PPTA layer (e.g., K:U=1:3) exhibits the best impact resistance. Vacuum hot pressing (110~130℃) can optimize fiber bond strength.

[0041] For environmental adaptability, the proportion of PPTA (inherent flame retardancy) needs to be increased in high-temperature environments, such as 3:1; in conventional environments, the proportion of UHMWPE can be increased.

[0042] III. Recommended Process Parameters Hot pressing composite conditions: temperature: 110~130℃ (vacuum hot pressing) or pressure: 5~15MPa (non-vacuum); holding time: 15~30 minutes.

[0043] Pre-compression and molding: Pre-compression stage: 128~133℃, 15MPa pressure; Reinforcing fiber layer molding: 135~155℃, 3~7MPa pressure.

[0044] Conclusion: Recommended initial ratio: UHMWPE to PPTA at 5:1 to 6:1, with subsequent adjustments based on protection level (e.g., NIJ III), environmental tolerance (high temperature, humidity), and cost. Actual performance needs to be verified in conjunction with hot pressing process parameters.

[0045] Compared with the prior art, the present invention has the following beneficial effects: (1) Lightweight: The helmet is made of ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material, which effectively reduces the weight of the helmet and improves the mobility of the wearer while ensuring the protective performance.

[0046] (2) High protection performance: It can effectively resist the threat of explosive fragments and protect the head.

[0047] (3) Multifunctionality: The equipment suspension base and guide rail assembly can be equipped with visual detection modules, transmitting and receiving modules and other equipment to realize information interconnection and meet the needs of modern informatization.

[0048] (4) Comfort: The buffer layer is made of ethylene-vinyl acetate copolymer foamed plastic, the padding is made of Velcro for easy detachment, and the wearing device is made of Wendy suspension system, which improves the wearing comfort and stability of the helmet.

[0049] (5) Strong environmental adaptability: The helmet surface paint has good hardness, flame retardant properties and low volatile organic compound content, and can adapt to various complex environments. Attached Figure Description

[0050] The accompanying drawings are incorporated in and form part of this specification, and together with the description serve to explain the principles of the invention.

[0051] 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, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 This is a flowchart of the helmet manufacturing method in this invention. Figure 2 This is a schematic diagram of the helmet in this invention; Figure 3 This is a top view of the helmet in this invention.

[0053] Wherein: 1 is the helmet shell; 2 is the suspension assembly; 2-1 is the suspension base; 2-2 is the guide rail assembly. Detailed Implementation

[0054] Exemplary embodiments will now be described in detail. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples consistent with some aspects of the invention as detailed in the appended claims.

[0055] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0056] Example 1 This embodiment provides a method for manufacturing a lightweight multifunctional helmet, specifically including the following steps: Step 1, preparation of helmet shell 1: Ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material are compounded in a ratio of 4:1, and helmet shell 1 is prepared by compression molding process; Step 2: Buffer layer preparation: A foaming agent is added to the ethylene-vinyl acetate copolymer foamed plastic, wherein the mass ratio of the foamed plastic to the foaming agent is 100:3, and a buffer layer is prepared by compression molding foaming process; Step 3: Component assembly: Bond the helmet shell 1 to the buffer layer with epoxy resin adhesive. Install the top pad, forehead pad, side pad, and back pad on the inside of the buffer layer with Velcro. Install the suspension assembly 2 on the helmet shell 1.

[0057] Example 2 This embodiment provides a method for manufacturing a lightweight multifunctional helmet, specifically including the following steps: Step 1, preparation of helmet shell 1: Ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material are compounded in a ratio of 5:1 and prepared by compression molding process; Step 2: Buffer layer preparation: A foaming agent is added to the ethylene-vinyl acetate copolymer foamed plastic, wherein the mass ratio of the foamed plastic to the foaming agent is 100:5, and a buffer layer is prepared by compression molding foaming process; Step 3: Component assembly: Bond the helmet shell 1 to the buffer layer with epoxy resin adhesive. Install the top pad, forehead pad, side pad, and back pad on the inside of the buffer layer with Velcro. Install the suspension assembly 2 on the helmet shell 1.

[0058] Example 3 This embodiment provides a method for manufacturing a lightweight multifunctional helmet, specifically including the following steps: Step 1, preparation of helmet shell 1: Ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material are compounded in a ratio of 6.8:1, and helmet shell 1 is prepared by compression molding process; Step 2: Buffer layer preparation: A foaming agent is added to the ethylene-vinyl acetate copolymer foamed plastic, wherein the mass ratio of the foamed plastic to the foaming agent is 100:7, and a buffer layer is prepared by compression molding foaming process; Step 3: Component assembly: Bond the helmet shell 1 to the buffer layer with epoxy resin adhesive. Install the top pad, forehead pad, side pad, and back pad on the inside of the buffer layer with Velcro. Install the suspension assembly 2 on the helmet shell 1.

[0059] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention.

[0060] It should be understood that the present invention is not limited to the content already described above, and various modifications and changes can be made without departing from its scope. The scope of the present invention is limited only by the appended claims.

Claims

1. A lightweight, multi-functional helmet, characterized in that, The helmet shell (1) includes a buffer layer and a padding layer arranged in sequence inside the helmet shell (1), and a suspension assembly (2) arranged outside the helmet shell (1). The helmet shell (1) is provided with an integrated functional module and an interactive system. The integrated functional module includes: an optical sensing unit, an acoustic sensing unit, an environmental sensing unit, a biological monitoring unit, a protective unit, and an energy management unit. The integrated functional module interacts with the interactive system.

2. The lightweight multi-functional helmet according to claim 1, characterized in that, The buffer layer is made of ethylene-vinyl acetate copolymer foamed plastic, and the suspension component (2) is made of polycarbonate material.

3. A lightweight multi-functional helmet according to claim 1, characterized in that, The optical sensing unit includes multiple cameras surrounding the outside of the helmet shell (1), the acoustic sensing unit includes a microphone disposed outside the helmet shell (1), the environmental sensing unit includes a compass, barometric altimeter and toxic gas detection sensor disposed outside the helmet shell (1), and the biological monitoring unit includes a temperature sensor disposed inside the liner.

4. A lightweight multi-functional helmet according to claim 1, characterized in that, The protective unit includes a directional acoustic emitter located inside the helmet, either on top of or in front of the head.

5. A lightweight multi-functional helmet according to claim 1, characterized in that, The energy management unit includes a curved solar cell located on the outer surface of the helmet shell (1).

6. A lightweight multi-functional helmet according to claim 1, characterized in that, The padding includes a top head pad, a forehead pad, a side head pad, and a back head pad, and the padding is detachably connected to the buffer layer; the padding is a titanium alloy honeycomb structure.

7. A lightweight multi-functional helmet according to claim 1, characterized in that, The surface paint of the helmet shell (1) has a hardness ≥ H, an afterflame time ≤ 2S, and a volatile organic compound content ≤ 400g / L.

8. A lightweight multi-functional helmet according to claim 1, characterized in that, The suspension assembly (2) includes a suspension base (2-1), on which a guide rail assembly (2-2) is provided. The guide rail assembly (2-2) includes a slider that slides inside the guide rail. The equipment is connected to the slider, and the equipment slides up and down through the slider.

9. A method for manufacturing a lightweight multifunctional helmet, characterized in that, The lightweight multi-functional helmet is the helmet described in any one of claims 1 to 8, and specifically includes the following steps: Step 1, preparation of helmet shell (1): Ultra-high molecular weight polyethylene fiber and poly(p-phenylene terephthalamide) reinforcing material are compounded in a ratio of (4~6.8):1, and the helmet shell (1) is prepared by compression molding process. Step 2: Preparation of buffer layer: Add a foaming agent to the ethylene-vinyl acetate copolymer foamed plastic, wherein the mass ratio of the foamed plastic to the foaming agent is 100:(3~7), and prepare the buffer layer by compression molding foaming process; Step 3: Component assembly: Bond the helmet shell (1) to the buffer layer with epoxy resin adhesive, install the top pad, forehead pad, side pad and back pad on the inside of the buffer layer with Velcro, and install the suspension assembly (2) on the helmet shell.

10. The method for manufacturing a lightweight multifunctional helmet according to claim 9, characterized in that, In step two, the foaming temperature in the compression molding foaming process is 160~180℃ and the pressure is 10~15MPa.

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