Helmet Chinbar Attachment via Docking Frame Segmentation
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Solution Overview
Problem
Existing helmet designs, particularly those without integrated chinbars, fail to provide adequate facial protection during various sports and activities, leaving the wearer's lower face exposed to potential impacts.
Innovation Solution
A helmet assembly with a detachable chinbar that includes an attachment portion coupled to a docking frame, allowing for easy assembly and improved manufacturing efficiency, featuring a liner, outer shell, and docking frame configuration that enhances facial protection by securely attaching the chinbar to the helmet using rivets and channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a detachable chinbar attachment system is used, then ease of manufacture and assembly are improved, but the structural complexity of the attachment mechanism increases
Solution Approach 1:
The chinbar attachment system is divided into separate components: a docking frame integrated into the helmet liner, an attachment portion on the chinbar, and rivets for fastening. This segmentation allows each component to be manufactured independently and assembled efficiently, improving ease of manufacture while the modular design actually reduces overall complexity compared to integrated chinbars.
Solution Approach 2:
The docking frame acts as an intermediary component between the helmet liner and the chinbar attachment portion. It provides a standardized interface that simplifies the attachment process and enables easy assembly/disassembly while maintaining structural integrity, resolving the contradiction between ease of manufacture and structural complexity.
2Object-affected harmful factors
If the docking frame is disposed within the liner channel, then facial protection is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The docking frame is nested within the liner channel structure, with the attachment post extending through the channel. This nesting arrangement provides inherent positioning and alignment features that guide the attachment portion during assembly, improving facial protection while reducing the need for high manufacturing precision through self-aligning geometric features.
Solution Approach 2:
The liner channel and docking frame are pre-configured with specific geometric features (channel shape, post position, opening locations) that predetermined the attachment geometry. This preliminary action ensures proper alignment and positioning during assembly, improving protection while minimizing precision requirements during final assembly.
3Strength
If rivets are used to couple the attachment portion to the docking frame, then connection strength is improved, but the manufacturing process complexity increases
Solution Approach 1:
The attachment system is designed to be self-servicing during assembly: the rivets are inserted through pre-aligned openings in the attachment portion and docking frame, creating a self-contained fastening mechanism that requires minimal additional tools or complex processes while providing strong mechanical connection.
Data Source
AI summary
A helmet assembly may include a helmet and an integrated chinbar. The chinbar may include an attachment portion and the helmet may include a docking frame. Coupling together of the attachment portion to the docking frame may couple the chinbar to the helmet. The attachment portion may then be secured to docking frame to secure the chinbar to the helmet. In certain embodiments, the attachment portion may be coupled to the docking frame of an interior side of the liner. Thus, the attachment portion may accordingly be disposed on the side of the liner closer to a wearer's face.