Compressed Helmet Lining Assembly for Impact Damping
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Solution Overview
Problem
Current helmets for two-wheeled vehicles face challenges in maintaining impact resistance due to bonding issues between damping parts and the shell, leading to potential disassembly and reduced shock absorption, along with complex and costly manufacturing processes.
Innovation Solution
A helmet design featuring a shell with a cushioning lining composed of distinct parts that are compressed by a central radial support, avoiding direct bonding to the shell and allowing for adjustable densities, enabling improved damping quality and easier maintenance by replacing only faulty parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If damping parts are bonded to the inner surface of the shell, then the assembly is held together, but the bonding weakens over time and the shock-absorbing padding can come apart
Solution Approach 1:
The invention removes the bonding operation from the assembly process. Instead of gluing damping parts to the shell, the damping lining is inserted as a complete assembly that relies on friction and compression forces, eliminating the bonding step entirely and its associated reliability issues.
Solution Approach 2:
The invention introduces an intermediary retention mechanism - the friction and compression forces generated by the compressed foam lining itself - to hold the assembly together without chemical bonding. The compressed state of the foam creates sufficient friction against the shell to prevent disassembly.
2Ease of manufacture
If the damping lining is molded as a single piece, then the manufacturing process is simpler, but the density cannot be adjusted independently for different regions
Solution Approach 1:
The invention segments the damping lining into multiple independent damping parts that can be separately molded with different densities, shapes, and material properties. Each part can be optimized for specific impact zones while maintaining ease of manufacturing through modular assembly.
3Reliability
If the entire damping lining is replaced when one part fails, then the helmet maintains full protection, but waste is generated and costs increase
Solution Approach 1:
The segmented design of the damping lining allows individual damping parts to be replaced independently. When one part fails, only that specific part needs to be replaced rather than the entire lining, reducing material waste and replacement costs while maintaining protective function.
Solution Approach 2:
The modular design enables selective replacement of only the failed damping part, allowing the remaining functional parts to be retained and reused. This reduces waste by keeping usable components in service longer.
4Ease of manufacture
If gaps exist between the inner surface of the shell and the outer surface of the lining, then the molding process is easier, but shock absorption quality deteriorates in impact events
Solution Approach 1:
The invention changes the density parameter of the foam lining in the radial direction, creating a gradient where the foam is more densely packed near the shell interface. This ensures good contact and shock absorption quality while accommodating manufacturing tolerances.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances impact resistance by maintaining the damping lining in a compressed state without bonding, reduces waste, and simplifies manufacturing by allowing precise density adjustment and molding to fit the head's shape, improving comfort and effectiveness.
Implementation Method 1
the radial support being configured to put the plurality of pieces into a state of compression
Implementation Method 2
the insertion by shrink fitting of the central part
Data Source
Figure 1A~2
Figure 3
Figure 4A~4B
AI summary
The invention relates to a protective helmet (1) comprising a shell (10), and a shock-absorbing lining (11) covering an inner surface (101) of the shell (10) and comprising a plurality of separate parts (110), each of which has an edge (1101) in contact with the edge (1101) of at least one other part of the plurality of parts (110), and in which the plurality of parts (110) defines a lower edge (111) characterized in that the plurality of parts (110) comprises: - at least three parts whose edges (1101) define upper edges (1102) together forming a closed perimeter (112); - a central piece (110a) located in a space delimited by the closed perimeter (112), the edge of which (1101) applies and exerts radial support on each of the upper edges (1102), the radial support being configured to put the plurality of pieces (110) into a state of compression.