Helmet Light Source Protection During Injection Molding
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Solution Overview
Problem
Helmet with hidden light sources face high defective rates due to light sources cracking and deforming under high temperature and pressure during the injection process of the manufacturing process, resulting in poor light emission.
Innovation Solution
A method involving a light source protector and belt with accommodating holes for the light sources, which are aligned with light transmitting portions and secured within the helmet housing, allowing a buffer material to be injected and forming a base, thus protecting the light sources from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light source is hidden inside the helmet housing during injection molding, then the appearance is improved and protection is enhanced, but the light source is damaged by high temperature and pressure causing high defective rate
Solution Approach 1:
The helmet is divided into multiple molding stages: first molding the helmet housing with light transmitting portions, then separately molding the light source belt with light sources positioned in accommodating holes, and finally assembling them together. This segmentation allows the light sources to be protected during their own molding process while ensuring proper positioning in the final assembly.
Solution Approach 2:
The light source belt is pre-formed with light sources positioned in accommodating holes before assembly with the helmet housing. The light sources are preliminarily fixed in their protective positions within the light source belt structure, ensuring they are protected from damage during the injection molding process and subsequent handling.
2Ease of manufacture
If the light source is exposed on the surface or in a groove, then the manufacturing process is simpler, but the appearance is degraded and the light source is vulnerable to external impact
Solution Approach 1:
The light source belt with light sources is nested within the helmet housing structure. The light source belt is inserted into the helmet housing and fixed in position, with the light sources positioned within accommodating holes that are recessed into the housing. This nesting provides protection while maintaining a relatively simple manufacturing process through modular assembly.
3Productivity
If injection material is injected into the light source, then the light emitting surface is covered, but this results in poor light emission and high defective rate
Solution Approach 1:
The light sources are extracted from the main injection molding process and placed in a separately formed light source belt. The light sources are positioned in accommodating holes within the light source belt structure, which is then assembled to the helmet housing. This extraction prevents injection material from contacting and covering the light emitting surfaces, while maintaining production efficiency through integrated molding of protective structures.
Solution Approach 2:
The light source belt acts as an intermediary structure between the helmet housing and the light sources. It provides accommodating holes that protect the light sources from direct exposure to injection material while allowing light transmission. The light source belt is molded separately and then assembled to the housing, serving as a protective mediator that prevents contamination of the light emitting surfaces.
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 effectively reduces the defective rate of helmets with hidden light sources by preventing light source damage during the injection process, ensuring consistent and effective light emission.
Implementation Method 1
a light transmitting portion (101) and the other lightproof portions (103)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method for manufacturing a helmet with hidden light sources includes: fixing a helmet housing (10) with at least one light transmitting portion (101) to a base mold; providing a light source protector (30) and a light source belt (20), and fixing the light source protector to the light source belt, wherein the light source belt comprises a circuit board (201) and a plurality of light sources (203) mounted on, wherein the light source protector comprises a plurality of accommodating holes (305) corresponding to the light sources one by one, and the light sources each are received in a corresponding accommodating hole and enclosed by the light source protector and the circuit board; aligning the light sources to the light transmitting portion and fixing the light source protector to an inner surface of the helmet housing; and injecting a buffer material into the base mold to form a base.