Helmet Foam Injection Eliminates Shell Liner Gaps
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Solution Overview
Problem
Conventional helmet manufacturing methods result in gaps between the shell and liner due to partial adhesion, compromising the structural strength and protection provided by the helmet.
Innovation Solution
A method involving the production of a shell and a protector, where a foam material is introduced into a die with the shell and protector, expanded under heat and pressure to bind tightly, eliminating gaps and enhancing structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shell and liner are coupled together by glue or fastening-unfastening means, then the manufacturing process is simple and cost-effective, but gaps appear between the shell and liner, reducing structural strength
Solution Approach 1:
The patent combines the shell, liner, and cheek/neck protectors into a single integrated structure by injecting foam material that expands to fill and bind all components together simultaneously, eliminating the need for separate coupling processes and ensuring complete gap elimination throughout the entire assembly
Solution Approach 2:
The foam material serves as an intermediary substance that is injected into the assembly and expands to fill gaps between components, binding the shell, liner, and protectors together into a unified structure with uniform adhesion throughout
2Strength
If a large amount of glue is used to enable the shell and liner to fit each other seamlessly, then the structural strength is improved, but the cost and weight of the helmet increase
Solution Approach 1:
The patent changes the physical state and distribution parameters of the binding material by using foam injection that expands uniformly throughout the assembly, creating consistent adhesion with minimal material usage compared to traditional glue application methods that require excessive amounts to achieve seamless fitting
3Quantity of substance
If the shell and liner are adhered together partially for cost control, then the manufacturing cost is reduced, but gaps appear that affect structural strength
Solution Approach 1:
The foam material acts as an intermediary that is injected into the assembly and expands to fill all gaps between components, providing uniform binding throughout the entire structure with controlled material usage, eliminating the need for partial adhesion while maintaining structural integrity
Solution Approach 2:
The patent changes the distribution parameter of the binding material from concentrated glue application to uniform foam expansion throughout the assembly, achieving complete gap elimination and consistent adhesion with optimized material consumption
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 method ensures a tight fit of the foam liner within the shell and protector, significantly enhancing the structural strength and protection of the helmet by minimizing gaps and distributing impact evenly.
Implementation Method 1
introducing a foam material into the die, apply heat and pressure to the foam material such that the foam material expands and binds to an inner side of the shell and an inner side of the protector
Implementation Method 2
apply heat and pressure to the foam material such that the foam material expands and binds
Implementation Method 3
apply heat and pressure to the foam material such that the foam material expands and binds
Data Source
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AI summary
A helmet (10) manufacturing method involves: producing a shell (20) and a protector (30), the shell (20) having two opposing cheek-protecting portions (24), the protector (30) having a jaw-protecting portion (34) and a neck-protecting portion (36) connected to the jaw-protecting portion (34); putting the shell (20) and the protector (30) in a die (12) such that bottom edges of the cheek-protecting portions (24) of the shell (20) connect to a top edge of the neck-protecting portion (36) of the protector (30); introducing a foam material (40) into the die (12), apply heat and pressure to the foam material (40) such that the foam material (40) expands and binds to an inner side of the shell (20) and an inner side of the protector (30); and taking a helmet (10) finished product out of the die (12). Therefore, both the jaw-protecting portion (34) of the integrally-formed protector (30) and the helmet (10) finished product are reinforced.