Safety Helmet Shock-Absorbing Shell Resilient Fixation
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Solution Overview
Problem
Existing safety helmets require a substantial connection between the shock-absorbing shell and the helmet shell, which can lead to wear and tear, and complicate the manufacturing and assembly processes.
Innovation Solution
The safety helmet design incorporates a holding ring permanently connected to the helmet shell, with a resilient element between the holding ring and the shock-absorbing shell, allowing the shock-absorbing shell to be held in place without a direct mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shock-absorbing shell is connected to the helmet shell by connection in substance (bonded connection or foaming), then the shock-absorbing shell is securely fixed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent divides the fixation system into separate functional components: a holding ring structure with holding elements that mechanically engages with the shock-absorbing shell, rather than using a monolithic bonded connection. This segmentation allows each component to be manufactured independently and assembled through simple mechanical engagement, reducing manufacturing complexity while maintaining secure fixation.
Solution Approach 2:
The holding ring acts as an intermediary component between the helmet shell and the shock-absorbing shell. Instead of directly bonding the shock-absorbing shell to the helmet shell, the holding ring mediates the connection through mechanical holding elements, simplifying the manufacturing process while ensuring reliable positioning and fixation.
2Reliability
If the shock-absorbing shell is connected to the helmet shell by bonded connection or foaming, then the shock-absorbing shell is securely fixed, but the assembly time increases
Solution Approach 1:
The holding ring with its holding elements is pre-configured to mechanically engage with the shock-absorbing shell in a predetermined manner. This preliminary arrangement of fixation elements eliminates the need for time-consuming bonding or foaming operations during assembly, as the components are designed to snap or slide into place through simple mechanical engagement.
Solution Approach 2:
The patent replaces chemical bonding mechanisms (adhesives, foaming) with a purely mechanical fixation system using holding elements that engage with the shock-absorbing shell. This mechanical substitution dramatically reduces assembly time while maintaining secure fixation, as mechanical engagement can be achieved through simple insertion or snapping actions rather than requiring curing time for bonds.
3Reliability
If a holding structure with holding elements is used to hold the shock-absorbing shell, then the shock-absorbing shell is securely positioned without connection in substance, but the device complexity increases
Solution Approach 1:
The holding ring serves multiple functions simultaneously: it provides structural support, positions the shock-absorbing shell, and secures the shell through its holding elements. By consolidating these functions into a single multi-functional component rather than using separate complex mechanisms, the overall device complexity is minimized while achieving secure positioning without bonded connections.
Solution Approach 2:
The holding elements of the holding ring are designed with flexible properties, allowing them to deform during assembly and then maintain a secure grip on the shock-absorbing shell. This flexibility enables simple snap-fit or elastic retention mechanisms that provide reliable positioning without requiring complex rigid structures or bonded connections.
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 design ensures the shock-absorbing shell is securely positioned relative to the helmet shell, reducing the risk of undesired movements and wear, while simplifying the manufacturing and assembly processes.
Implementation Method 1
at least one resilient element, which seeks to press the shock-absorbing shell from the inside against the helmet shell
Implementation Method 2
The shock-absorbing shell (1) adjoins the helmet shell (2) and is configured to absorb kinetic energy, especially kinetic energy that acts on the safety helmet from the outside
Data Source
AI summary
A safety helmet (100) includes an arched helmet shell (2), an arched shock-absorbing shell (1), a holding ring (3, 11) and a resilient element (14). The holding ring (3, 11) is permanently connected to the helmet shell (2). The shock-absorbing shell (1) adjoins a holding ring edge. The resilient element (14) is supported at the holding ring (3, 11), projects over the holding ring edge and acts to move the shock-absorbing shell (1) away from the holding ring (3, 11) and to press shock-absorbing shell (1) against the helmet shell (2). A process for manufacturing such a safety helmet (100) is provided. According to the process, first the shock-absorbing shell (1) is placed first into the helmet shell (2) and the holding ring (3, 11) is then attached to the helmet shell (2).