Chin Strap Buckle Assembly with Non-Marring Plastic Tray
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Solution Overview
Problem
Metal buckles in sports helmets pose a risk of causing injury due to sharp edges and potential damage to equipment, especially in contact sports, as they can catch on clothing or scratch the helmet surface.
Innovation Solution
A buckle assembly comprising a metal part securely connected to a non-marring plastic part, where the metal plate is locked within a polycarbonate tray using locking tabs, preventing easy disconnection and minimizing exposure of metal edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal buckles are used for chin straps, then strength and durability are improved, but the risk of injury and equipment damage increases due to sharp edges
Solution Approach 1:
The buckle is divided into two separate components: a metal part providing strength and a plastic part providing protection. The metal part contains the internal structure and strength-critical elements, while the plastic part forms an outer shell that shields users from sharp edges. This segmentation allows each component to fulfill its specific function without compromise.
Solution Approach 2:
The invention uses a composite structure combining metal and plastic materials. The metal provides the necessary mechanical strength for the buckle function, while the plastic material provides a soft, non-marring exterior that prevents injury and equipment damage. The composite design leverages the advantages of both materials while mitigating their individual disadvantages.
2Ease of manufacture
If metal parts are exposed in the buckle, then manufacturing simplicity is improved, but the risk of scratching helmet surfaces increases
Solution Approach 1:
The harmful metal surfaces are extracted from the exterior of the buckle and confined to the internal metal part. The plastic part is designed to completely cover all metal surfaces that could potentially contact the helmet or user skin, eliminating the scratching hazard while keeping the manufacturing process relatively simple by using standard molding techniques.
3Object-affected harmful factors
If complex co-molding processes are used to encase metal parts, then protection from sharp edges is improved, but manufacturing cost and complexity increase
Solution Approach 1:
Rather than using complex co-molding to create a fully integrated metal-plastic buckle, the invention segments the buckle into separate metal and plastic components that are manufactured independently and then assembled. This approach reduces manufacturing complexity by allowing each component to be produced using standard, simpler processes while still achieving the protective encasement of metal parts.
Solution Approach 2:
The plastic part serves as an intermediary component that bridges the metal internal structure and the external environment. It provides the protective function by covering metal surfaces while allowing the metal part to maintain its structural integrity. This intermediary approach achieves protection without requiring complex integration processes.
Data Source
AI summary
A buckle assembly for a chin strap of a helmet has a metal part connected to a non-marring part. The metal part includes a metal plate with an outer perimeter, end portions and a center portion, and a slot in each end portion and a snap member fixed to the center portion. The non-marring part includes a tray with end and side walls. The end and side walls together defining an inner perimeter corresponding to and receiving the outer perimeter of the metal plate. A shelf extends side-to-side on an inner surface of each end wall, a plurality of locking tabs are on an inner surface of each side wall and at least one intermediate portion is connected to the inside surface of each side wall. The metal plate rests on the shelves and on the intermediate portion(s) and is being locked in the tray by the locking tabs.