Hinged Pad for Protective Gear Using Thermal Fusion

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Solution Overview

Problem

Existing protective gear padding, such as helmet padding, faces issues with adhesive requirements, labor-intensive assembly, and suboptimal connection between padding members, leading to potential detachment and unsatisfactory finish.

Innovation Solution

The development of hinged padding for protective gear, comprising dual-layer membranes with pad members that are pivotable and assembled using a temperature-treating process to form a hinge, allowing for easier integration into protective gear shells without adhesives between pads and membranes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is used to connect padding members to the rigid outer shell and to each other, then the padding members can be securely connected, but the assembly becomes labor-intensive and padding members may still detach

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the adhesive-based mechanical connection system with a thermal fusion system. The membrane material is heat-treated to fuse padding members to each other and to the shell, eliminating the need for adhesives and reducing assembly complexity while maintaining secure connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the membrane material through temperature treatment. By heating the membrane to a fusion temperature and then cooling it, the material transitions from a flexible state to a fused state, creating permanent bonds without adhesives.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If multiple padding members are assembled with adhesives, then the protective gear can be constructed, but the assembly process becomes labor-intensive

Engineering Contradiction:

Improveassembly efficiencyVSAvoidassembly process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple assembly steps into a single thermal fusion process. Instead of separately applying adhesives to each padding member and allowing them to cure, the heat treatment simultaneously fuses all padding members to each other and to the shell in one operation, significantly improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the multi-step adhesive application and curing process with a single thermal fusion process, simplifying the assembly procedure and reducing labor requirements while maintaining connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If expanded polymer pad is used for shock absorption, then the protective capacity is improved, but the finish shows traces of foam beads and is not optimal

Engineering Contradiction:

Improveshock absorption capacityVSAvoidsurface finish quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses a flexible membrane material that encapsulates the expanded polymer pad. This membrane layer provides a smooth, uniform surface finish that conceals the foam bead traces inherent to expanded polymer materials, while the membrane itself can still transmit shock absorption forces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure combining the expanded polymer pad (for shock absorption) with a membrane material (for smooth finish). This composite approach allows each material to perform its optimal function - the polymer provides protection while the membrane provides aesthetic finish.

Inventive Principle:

Principle #40Composite materials

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 reduces assembly complexity, enhances the durability and fit of padding, and improves moisture evaporation, addressing the issues of detachment and finish quality while accommodating the evolving needs of athletes in sports.

Implementation Method 1

a dual-layer membrane (30, 40) sandwiching the first pad member (31) and the second pad member (32), between a first of the layers and a second of the layers... the dual-layer membrane consisting of a generally non-rigid material such that the first pad member (31) and the second pad member (32) are at least pivotable with respect to another

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

temperature treating the die such as to fuse the first membrane to the second membrane to form a hinge between the at least two pad members

Methodology Applied

Scientific EffectThermal fusion: Heating

Data Source

PatentUS7464414B2Hinged pad for protective gear

Publication Date: 2008.12.16 TION MCD

AI summary

Hinged padding for protective gear comprises a first and a second pad member. A dual-layer membrane sandwiches the first pad member and the second pad member, between a first of the layers and a second of the layers. The first and the second pad member are separated from one another in such a way that the two layers of the dual-layer membrane are coplanar between the sandwiched pad members. The dual-layer membrane consists of a generally non-rigid material such that the first pad member and the second pad member are at least pivotable with respect to another, whereby the hinged padding is adapted to be shaped to be accommodated in a shell of protective gear. A process for assembling the hinged padding is also described.