Deep Drawn Helmet Preform Forming to Reduce Wrinkling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing helmet forming systems face issues such as wrinkling, bridging, and non-uniformity in prepreg stacks during the formation of deep drawn helmets, leading to weakened ballistic performance and increased production time.
Innovation Solution
A helmet forming system utilizing a forming draw ring and a non-forming draw ring to clamp a prepreg stack, which is then advanced relative to a punch to form a deep drawn helmet preform, minimizing wrinkling and bridging without slits or darts, and incorporating temperature control and vacuum sealing to enhance material flow and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deep drawing process is used to form helmet preforms from prepreg stacks, then the helmet can be produced, but wrinkling and bridging occur during formation
Solution Approach 1:
The prepreg stack is pre-heated before forming to make the material more pliable and easier to form without wrinkling or bridging. This preliminary heating action prepares the material in advance to accommodate the forming process while maintaining uniformity and structural integrity
Solution Approach 2:
The patent applies controlled heating to change the temperature parameter of the prepreg stack during forming. This parameter change makes the material more formable while preventing defects like wrinkling and bridging, thereby improving both manufacturing precision and the reliability of the final product
2Productivity
If conventional helmet forming systems are used, then helmets can be produced, but the production time is relatively long (almost an hour or more)
Solution Approach 1:
The patent uses controlled heating to change the temperature parameter of the prepreg stack, making the material more pliable and easier to form. This reduces the forming time significantly while maintaining product quality, thereby improving productivity and reducing time loss
3Shape
If excess material accumulates around the circumference during forming, then the helmet preform can be formed, but buckling occurs which degrades ballistic performance
Solution Approach 1:
The patent applies controlled heating to change the temperature parameter of the prepreg stack, making the material more formable and easier to shape without buckling. This allows the helmet preform to be formed correctly while maintaining uniform material distribution and preserving ballistic performance
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 system reduces wrinkling and bridging, improves ballistic performance, and shortens production time by forming high-quality helmet preforms with consistent thickness and fiber orientation, enhancing structural integrity.
Implementation Method 1
The vacuum seal is configured to remove air from between the plies of the prepreg stack
Implementation Method 2
the punch has a heated pliable surface that facilitates material flow and formation of the helmet preform
Data Source
AI summary
A system for forming a deep drawn helmet and method therefor are disclosed. The system includes a forming draw ring and a non-forming draw ring and supports a prepreg stack between a forming aperture of the forming draw ring and a non-forming aperture of the non-forming draw ring. The system clamps a flange portion of the prepreg stack between a contact surface of the forming draw ring and a contact surface of the non-forming draw ring, which forms a clamped assembly of the rings and the prepreg stack. The system then forms a deep drawn helmet preform from the prepreg stack of the clamped assembly. The same system or a different forming system then consolidates one or more of the preforms into a final deep drawn helmet. The system can control sliding of the flange during forming of the helmet preform without reducing the flange clamping force.