Cycling Helmet Mould Support Template for Single-Step Co-Moulding
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Solution Overview
Problem
The conventional moulding process for cycling helmets is inefficient due to a high number of steps, long production times, significant downtimes, and quality defects at overlapping areas between components, leading to increased production costs and reduced productivity.
Innovation Solution
A support template for moulds that simplifies the moulding process by enabling simultaneous and precise positioning of all components and inserts within the mould, reducing the need for multiple moulding cycles and manual steps, using a frame with support surfaces, engaging pins, and centring pins to ensure accurate alignment and blocking mechanisms for secure placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional two-step moulding process is used with manual component mounting between steps, then quality control can be performed at each stage, but the number of process steps and production time increase significantly
Solution Approach 1:
The patent combines multiple components (base body, upper shell, lower ring, and inserts) into a single moulding operation. The mould is designed with multiple cavities and feeding channels that allow simultaneous injection of polystyrene for all components in one cycle, eliminating the need for separate moulding steps and manual assembly operations between steps.
Solution Approach 2:
The mould is pre-configured with all necessary feeding channels, steam holes, and cavity positions for multiple components before the moulding process begins. This preliminary arrangement allows all components to be formed simultaneously in a single operation, avoiding subsequent assembly steps and reducing overall production time while maintaining quality control.
2Ease of operation
If multiple manual steps are performed between moulding cycles for component mounting, then component positioning can be adjusted, but the downtime of the moulds and total production time increase
Solution Approach 1:
The patent merges the positioning and moulding operations into a single integrated process. The mould is designed with predetermined positions for all components, and the support template ensures accurate placement of inserts and components during the single moulding cycle, eliminating the need for separate positioning steps and reducing mould downtime.
3Adaptability or versatility
If components are mounted manually between moulding cycles, then assembly flexibility is maintained, but the number of process steps increases and production efficiency decreases
Solution Approach 1:
The mould is segmented into multiple independent cavities and feeding channels, each capable of forming a specific component simultaneously. This segmentation allows for flexible configuration of different components (base body, upper shell, lower ring, inserts) within the same mould structure, maintaining assembly flexibility while reducing the number of process steps to a single operation.
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
This solution significantly reduces production time, lowers costs, and ensures high-quality helmets by eliminating defects at overlapping areas, allowing for a single-step moulding process with improved productivity and component alignment.
Implementation Method 1
the polystyrene, in the form of small balls, undergoes a softening and expansion process inside the cavity of the mould
Implementation Method 2
the polystyrene, in the form of small balls, undergoes a softening and expansion process inside the cavity of the mould
Implementation Method 3
The support template is provided with at least one frame which comprises at least one support portion for the support of at least one component (C1, C2) of a helmet to be obtained by means of a moulding or co-moulding process, placed on a first side (2a) of the frame (2)
Implementation Method 4
using a frame with support surfaces, engaging pins, and centring pins to ensure accurate alignment and blocking mechanisms for secure placement
Data Source
AI summary
A support template for moulds for sports helmets, in particular cycling helmets, provided with at least one frame includes: at least one support portion, placed on a first side of the frame, for the support of at least one component of a helmet to be obtained by a moulding or co-moulding process, the support portion being configured to keep the respective component of the helmet to be obtained according to a predetermined position inside a respective mould; at least one centring portion placed on the first side of the frame and arranged to engage a respective centring seat made on the respective mould so as to ensure the alignment of the latter with the support template and keep the centred positioning of the component of the helmet according to a predetermined configuration; and at least one grip portion to allow manual engagement of the support template by an operator.