Dual-Layer Protective Helmet Shell with Localized Material Distribution
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Solution Overview
Problem
Existing protective helmets face challenges in achieving high impact resistance without excessive weight, particularly with ABS shells, which compromise comfort due to increased weight, and in-molding technology helmets lack stability for accessory fixation.
Innovation Solution
A protective helmet design featuring a dual-layer coating system with a cap-shaped and crown-like portion made of different thermoplastic materials, where the crown-like portion provides enhanced impact resistance and occupies critical protection areas, while the cap-shaped portion is lighter and allows for accessory fixation, and a deflector device integrates air intake and anti-penetration functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ABS shell technology is used, then impact resistance is improved, but weight increases compromising comfort
Solution Approach 1:
The helmet shell uses different materials for different regions: the crown-like portion (covering temples, forehead, and nape) is made of ABS material with high impact resistance, while the cap-shaped portion (top area) is made of lighter polycarbonate material. This local differentiation allows the helmet to provide enhanced protection where impacts are most likely and severe, while reducing weight in areas where full protection is less critical.
2Weight of moving object
If in-molding technology is used, then weight is reduced, but ability to stably fix accessories deteriorates
Solution Approach 1:
The crown-like portion made of ABS material provides stable surfaces and structures for fixing accessories such as ventilation elements and visor buttons, while the cap-shaped polycarbonate portion maintains lightness. The ABS material's properties in the crown-like region enable reliable accessory attachment without compromising overall helmet weight.
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 design achieves improved impact resistance and comfort by distributing more resistant materials to critical areas and using lighter materials elsewhere, while enabling secure accessory attachment and enhanced ventilation/penetration protection without significantly increasing the helmet's weight.
Implementation Method 1
the cap-shaped portion is made using in-molding technology
Data Source
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AI summary
The present disclosure relates to a helmet (10) including an energy absorption layer (15) and an outer coating (17) adapted to coat said energy absorption layer (15). The outer coating includes a cap-shaped portion (20) arranged in a top area of the helmet (10) and a crown-like portion (21) arranged at least partially around said cap-shaped portion (20) at least in the region of the temples of a user, wherein the crown-like portion (21) has a greater impact resistance than the cap-shaped portion (20).