Modular Aerodynamic Hump for Motorcycle Garments
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Solution Overview
Problem
Traditional aerodynamic humps for motorcyclist garments are laborious and costly to customize, require multiple molds for each shape and size, and are difficult to replace, while also compromising on aesthetics and functionality.
Innovation Solution
A modular aerodynamic hump design consisting of a standardized base body for housing airbag and hydration components, combined with a customizable covering body made from thermoformed polyurethane, allowing easy replacement and adjustment of the aerodynamic profile using interchangeable covering bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional injection molding or thermoforming is used to create aerodynamic humps, then the hump body can be obtained with internal cavities for airbag components, but the humps become particularly heavy and expensive, and customization requires a separate mold for each shape and size
Solution Approach 1:
The hump is divided into two separate components: a standardized base body (made by injection molding) and a customizable covering body (made by thermoforming). This segmentation allows the base body to be produced once with precise internal cavities, while the covering body can be customized by changing only the thermoformed shell, eliminating the need for new molds for each customization.
Solution Approach 2:
The invention changes the manufacturing parameter approach by using thermoforming (a flexible process) for the covering body instead of injection molding (a rigid process requiring expensive molds). This allows the same manufacturing process to produce various shapes and sizes by simply changing the heated sheet and molding conditions, not the mold itself.
2Reliability
If traditional single-piece humps are used, then aerodynamic function is provided, but customization and replacement are laborious and complicated processes
Solution Approach 1:
By separating the hump into a permanent base body and a removable covering body, the invention enables easy replacement of the covering body without affecting the aerodynamic structure. The base body remains fixed to maintain aerodynamic performance, while the covering body can be quickly swapped by removing fastening elements.
Solution Approach 2:
The covering body is designed to be dynamically replaceable through removable fastening elements (screws, clips, or adhesive systems), transforming the static single-piece hump into a dynamic system where the aerodynamic shell can be changed without replacing the entire assembly.
3Ease of manufacture
If handmade inserts are used inside the hump for airbag components, then component housing is achieved, but the appearance becomes unaesthetically pleasing and unprofessional
Solution Approach 1:
The internal cavity in the base body is designed as an integrated, precision-molded feature rather than requiring handmade inserts. This segmentation of functions (base body provides structural housing, covering body provides aesthetic finish) eliminates the need for crude internal modifications while maintaining both functionality and appearance.
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
Enables quick, cost-effective customization and replacement of the hump, maintaining high aerodynamic performance and aesthetic appeal, while allowing for efficient mass production and easy integration with existing garments.
Implementation Method 1
a customizable covering body made from thermoformed polyurethane
Data Source
Figure 1~2
Figure 3~4
AI summary
Aerodynamic hump (2) for garment (3), preferably sport garment, in particular for motorcycle suit or jacket, the hump comprising: - an underlying base body (4), - a portion (10) with a substantially laminar developing, preferably part of said garment (3), which is positioned externally and above with respect to said underlying base body (4), - at least one covering body (6) which is positioned externally and above said portion (10) and is removably associated with the underlying base body (4), said at least one covering body (6) having at least one external surface portion (11), configured so as to define and give, alone or in combination with said base body (4), an aerodynamic effect to said hump, - fastening means (15, 15') configured to constrain said covering body (6) to the underlying base body (4) by crossing said portion (10) with a substantially laminar development.