Foam-Plastic Protector Assembly for Durable Impact Dissipation
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Solution Overview
Problem
Existing foam protectors in sports equipment become less efficient over time due to softening from repeated impacts, necessitating a combination with harder components to maintain impact dissipation.
Innovation Solution
A foam insert is removably received within a plastic sleeve, forming a foam-plastic protector with a gap covered by the plastic sleeve's overlapping portion, allowing the foam insert to be inter-locked and partially exposed, providing structural reinforcement while maintaining ease of replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam protectors are used alone, then they are efficient at dissipating impact energy initially, but they become softer over time due to repeated impacts, reducing their protection efficiency
Solution Approach 1:
The patent combines foam material with a harder outer shell to create a composite protector. The foam core maintains impact energy absorption capabilities while the harder shell provides structural integrity and resistance to permanent deformation, resolving the contradiction between initial protection efficiency and long-term durability
Solution Approach 2:
The protector is divided into distinct functional layers: an inner foam layer for energy absorption and an outer harder shell for structural support. This segmentation allows each material to perform its optimal function without compromising the other, maintaining reliable protection over extended service life
2Reliability
If foam protectors are combined with harder components like plastic reinforcement, then impact dissipation is improved, but the complexity of the device increases
Solution Approach 1:
The foam insert is nested within the plastic shell, with the foam fitting into a cavity or channel formed by the shell's overlapping portions. This nesting arrangement combines the benefits of both materials while maintaining a compact, integrated structure that does not significantly increase overall device complexity
Solution Approach 2:
The foam insert and plastic shell are combined into a single integrated protector unit where the harder shell provides structural framework and the foam fills the internal space for energy absorption. This merging creates a unified component that achieves enhanced protection without requiring separate assembly systems
3Strength
If foam inserts are permanently fastened to protective sport padding, then structural integrity is improved, but ease of repair and replacement is reduced
Solution Approach 1:
The attachment system transitions from permanent to dynamic/reversible fastening. Velcro straps or similar removable fasteners allow the foam insert to be securely attached during use for structural integrity, yet easily removed and replaced when needed, resolving the contradiction between strength and ease of repair
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 foam-plastic protector maintains impact dissipation efficiency by combining the energy-absorbing properties of foam with the structural rigidity of plastic, ensuring consistent protection without the need for permanent fastening, facilitating easy repair or replacement.
Implementation Method 1
foam insert having a front surface and a rear surface... efficient at dissipating the energy received during hard impacts
Implementation Method 2
plastic sleeve being harder than the foam insert... structural rigidity of plastic
Data Source
AI summary
A foam-plastic protector includes a foam insert having a front surface and a rear surface. A plastic sleeve is harder than the foam insert and has a base and an overlapping portion spaced from the base to define a gap. The foam insert is received against the base and inter-locked with the plastic sleeve. A covered portion of the foam insert is positioned within the gap and covered by the overlapping portion of the plastic sleeve. A remainder of the foam insert is exposed. A protective sport padding and a method of assembling same are also disclosed. The foam insert may be fixedly attached to the protective sport padding.