In-Molded Helmet Chinbar Embedding for Weight Reduction
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Solution Overview
Problem
Traditional helmet designs with unitary construction of the chinbar and shell result in increased weight, reduced ventilation, and compromised impact absorption performance.
Innovation Solution
The helmet features a chinbar that is manufactured as an individual component, embedded within the padding of the helmet shell, allowing for reduced weight and increased ventilation while maintaining impact absorption standards through the use of materials like Kevlar, carbon fiber, and polycarbonate, and incorporating a cage structure with flanges that are embedded within the padding for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the chinbar and shell are constructed as a unitary structure, then the structural strength and impact resistance are improved, but the helmet weight increases and ventilation is reduced
Solution Approach 1:
The chinbar is separated from the shell as an independent component rather than being unitarily constructed. The chinbar includes a cage structure with attachment members that can be independently manufactured and then attached to the shell, allowing each component to be optimized separately for weight and strength.
Solution Approach 2:
The attachment members are embedded within the padding material to secure the chinbar to the shell. This nesting approach integrates the attachment mechanism within the existing padding structure rather than requiring separate fastening systems, reducing overall weight while maintaining structural integrity.
2Stability of the object's composition
If the chinbar and shell are constructed as a unitary structure, then the structural integrity is improved, but the ventilation capability is reduced
Solution Approach 1:
By separating the chinbar from the shell, the design allows independent optimization of ventilation pathways in the shell while maintaining the structural integrity of the chinbar through its own cage construction and attachment mechanism.
3Ease of manufacture
If the chinbar and shell are constructed as a unitary structure, then the manufacturing simplicity is improved, but the impact absorption performance is compromised
Solution Approach 1:
The chinbar utilizes composite construction with a cage structure and attachment members made from materials optimized for impact absorption. The attachment members are embedded in padding material, creating a composite assembly that maintains reliability while allowing independent manufacturing of components.
Data Source
AI summary
A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.