Integrally Formed Safety Helmet With Graded Foam Density
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Solution Overview
Problem
Conventional safety helmets face issues with material cost, manufacturing complexity, and wearer discomfort due to increased weight and thickness, which affect the distribution and transmission of external impact forces, leading to inadequate protection and comfort.
Innovation Solution
An integrally formed safety helmet structure featuring a shell body, foam filling body, and structure body with geometrical array texture structures, where the foaming density progressively increases from outer to inner layers, forming a multilayer complex reinforcement system that enhances structural strength, reduces material usage, and simplifies manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the plastic shell is increased to enhance surrounding converging force and ensure sufficient impact force distribution, then the protection effect is improved, but the material cost increases and the total weight of the helmet increases causing wearer discomfort
Solution Approach 1:
The patent applies local quality by creating a complex foam filling body with different density regions: a low-density foam filling body for outer layer and a high-density foam filling body for inner layer near the wearer's head. This localized density variation allows the outer shell to be thinner while maintaining protection效果, as the high-density inner foam provides additional support without increasing overall helmet weight significantly.
Solution Approach 2:
The patent uses composite materials by combining foam material with different density characteristics in a layered structure. The low-density foam provides initial impact absorption and distribution, while the high-density foam provides structural support and prevents inner foam breakdown. This composite approach achieves superior protection with reduced material usage and weight compared to a uniformly thick plastic shell.
2Strength
If the density of the high-density foam filling body is increased to enhance support strength and protection effect, then the protection effect is improved, but the wearer experiences uncomfortable feeling when wearing the safety helmet
Solution Approach 1:
The high-density foam filling body is strategically positioned only in the inner layer nearest to the wearer's head, while the outer layer uses low-density foam. This localized high-density region provides necessary support strength at the critical interface with the wearer's head without making the entire helmet excessively heavy or uncomfortable. The gradual density transition from outer to inner layers optimizes both protection and comfort.
3Strength
If multiple separate components (plastic shell, foam filling body, block body) are assembled layer by layer to provide shock-absorbing effect, then the protection effect is improved, but the manufacturing process becomes time-consuming and manufacturing cost increases
Solution Approach 1:
The patent merges the shock-absorbing function and the foam filling body into a single integrated complex foam filling body structure. Instead of assembling separate plastic shell, foam filling body, and block body components layer by layer, the invention creates a unified foam structure with varying density regions that performs all shock-absorbing functions. This integration dramatically simplifies the manufacturing process, reduces assembly time, and lowers manufacturing costs while maintaining superior protection效果.
Solution Approach 2:
The complex foam filling body uses composite foam material with different density regions formed in a single manufacturing process. The low-density and high-density foam regions are created within one integrated foam structure rather than assembling separate components. This composite foam approach achieves multi-layer shock-absorbing效果 while enabling one-step manufacturing, significantly improving productivity compared to traditional multi-component assembly.
4Strength
If multiple separate components are assembled manually layer by layer, then the shock-absorbing effect is improved, but the material cost and manufacturing cost are higher and the manufacturing process cannot be speeded
Solution Approach 1:
The invention combines multiple shock-absorbing components into a single complex foam filling body that can be manufactured in one process. The merged structure includes both low-density and high-density foam regions that work together to provide superior shock-absorbing effect. This consolidation eliminates the need for manual assembly of multiple components, reducing both labor costs and manufacturing complexity, thereby significantly lowering overall manufacturing cost.
Solution Approach 2:
The complex foam filling body is designed to self-form with appropriate density distribution through a single manufacturing process. The foam material automatically creates the required low-density outer region and high-density inner region during the foaming process, eliminating the need for manual positioning and assembly of separate components. This self-organizing property of the foam structure simplifies manufacturing and reduces costs.
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 provides a lightweight, high-security helmet that effectively distributes and absorbs external impact forces, reducing the burden on the wearer and minimizing material usage, while ensuring full protection against various impacts.
Implementation Method 1
the foam material is heated to expand and combine into the foam filling body (20) and bond with the shell body (10) and the structure body (30)
Data Source
AI summary
An integrally formed safety helmet structure includes an assembly of a helmet shell or a shell body, a foam filling body enclosed in the shell body and a structure body. Geometrical array texture structures are disposed at the assembling interfaces between the shell body, the structure body and the foam filling body. In manufacturing, by means of a mold or molding module and solid foaming technique, the foam filling body is integrally formed to bond with the shell body and the structure body and the geometrical array texture structures so as to form a compact and rigid multilayer complex reinforcement structure. The complex reinforcement structure not only can enhance the structural strength of the entire safety helmet, but also has the advantages of material-saving, lightweight, high security and easy manufacturing.