Head-Protecting Cap with Integrated Resilient Connecting Webs
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Solution Overview
Problem
Existing protective head caps are complex to manufacture and lack sufficient protection if padding elements are removed or missing, while also being costly to produce.
Innovation Solution
A protective head cap design featuring a shock-absorbing arrangement with resilient connecting webs that are displaceable for impact absorption, integrated with a rigid shell body made from plastic, allowing for flexible placement and easy manufacture through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional padding elements (foam bodies, spacer fabrics) are used in protective head caps, then comfort and impact protection are provided, but the manufacturing complexity increases significantly
Solution Approach 1:
The patent integrates the shock-absorbing arrangement directly into the shell body as a unified structure. The connecting webs are formed as an integral part of the shell body through injection molding, eliminating the need for separate padding elements and their complex assembly processes. This merging of functions reduces manufacturing complexity while maintaining impact protection.
Solution Approach 2:
The patent changes the material parameter from traditional foam/padding materials to a plastic material that can be injection molded. The shell body is made from a plastic material that allows for the integration of resilient connecting webs through standard injection molding processes, simplifying manufacturing while providing the necessary shock-absorbing properties.
2Reliability
If complex shock-absorbing arrangements (torsion sleeves, rigid pins, spring systems) are implemented, then impact energy absorption is improved, but the manufacturing process becomes more difficult and expensive
Solution Approach 1:
The shock-absorbing arrangement is merged with the shell body into a single integrated component. The connecting webs are formed directly as part of the shell body through injection molding, eliminating the need for separate torsion sleeves, rigid pins, or spring systems that would require complex assembly processes.
Solution Approach 2:
The patent replaces complex mechanical shock-absorbing systems (torsion sleeves, spiral springs, multiple rigid components) with a simplified resilient structure formed by connecting webs integrated into the shell body. This substitution uses the inherent elasticity of the plastic material and the geometric design of the connecting webs to provide shock absorption without complex mechanical mechanisms.
3Reliability
If multiple separate components (absorber pan, absorber plate, torsion sleeves, rigid pins) are assembled, then shock absorption is achieved, but production time and cost increase
Solution Approach 1:
The patent combines multiple separate shock-absorbing components (absorber pan, absorber plate, torsion sleeves, rigid pins) into a single integrated shell body structure. The connecting webs are formed as one piece with the shell body through injection molding, eliminating the need for assembly operations and significantly improving production efficiency.
Solution Approach 2:
The shock-absorbing structure is pre-formed as an integral part of the shell body during the injection molding process. The connecting webs are created in their final configuration during the initial manufacturing step, eliminating the need for subsequent assembly operations and reducing production time.
4Ease of manufacture
If padding elements are removed or missing, then manufacturing is simplified, but sufficient protection is no longer provided
Solution Approach 1:
The patent merges the protective function directly into the shell body structure. The connecting webs are an integral part of the shell body, providing shock absorption without requiring separate padding elements. This ensures protection is maintained even when no additional padding is present.
Solution Approach 2:
The shell body itself provides the shock-absorbing function through its integrated connecting webs. The structure is self-sufficient and does not require external padding elements to provide protection. The connecting webs are designed to deform and absorb impact energy directly, making the system self-protecting.
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 provides an extremely high level of protection, is cost-effective to produce, and offers enhanced wearing comfort with a simple and inexpensive manufacturing process, while maintaining flexibility in usage.
Implementation Method 1
The at least one connecting web is resiliently displaceable at least in regions for shock absorption. It is shifted when corresponding external forces act on it, such as in the event of an impact or impact.
Implementation Method 2
When a force acts on the absorber arrangement from above, the torsion sleeve is pushed axially onto the rigid pin, which leads to its twisting. As a result, the torsion sleeve is plastically deformed and absorbs impact energy.
Implementation Method 3
It is also advantageous if the at least one connecting web springs back into its rest or initial position after the impact force has been applied.
Data Source
AI summary
The invention relates to a head-protecting cap. The head-protecting cap has a shell body (6) which has a forehead region (7) for at least partially covering the forehead of a person wearing the head-protecting cap, also has a back-of-the-head region (8) for at least partially covering the back of the head of the person wearing the head-protecting cap, further has a top-of-the-head region (9), which is arranged between the forehead region (7) and the back-of-the-head region (8) and is intended for at least partially covering the top of the head of the person wearing the head-protecting cap, and bounds a head-accommodating space (18) for accommodating the head of the person wearing the head-protecting cap. The head-protecting cap also has an impact-damping arrangement (14), which comprises at least one impact-damping-spring device (15). The at least one impact-damping-spring device (15) has in each case two spaced-apart connection bodies (16) which adjoin the shell body (6) and project outwards in each case from the shell body (6). This setup comprises, moreover, in each case at least one connecting crosspiece (17), which extends in a bridge-like manner between the connection bodies (16) and, for impact-damping purposes, can be displaced resiliently at least in certain regions. The shell body (6) and the impact-damping arrangement (14) are of single-piece configuration.