Segmented Shock-Absorbing Helmet Liner Design
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Solution Overview
Problem
Existing shock-absorbing liners for protective helmets are complex to manufacture and lack design flexibility without compromising shock-absorbing performance.
Innovation Solution
A shock-absorbing liner design featuring integrally moulded parts with ribs and channels that can be easily assembled, allowing for greater design freedom and improved shock absorption by optimizing the orientation and arrangement of protuberances and recesses, which can be made from different materials and densities to suit specific helmet designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shock-absorbing liners are manufactured using traditional multi-part moulding and overmoulding processes, then the structural integrity and shock-absorbing performance are maintained, but the manufacturing complexity increases and design flexibility is reduced
Solution Approach 1:
The liner is divided into multiple separate parts (first part with protuberances, second part with recesses) that can be manufactured independently using simple integral moulding processes, then assembled together. This segmentation allows each part to be produced with straightforward manufacturing while the combination provides the desired complex functionality and shock-absorbing performance.
2Adaptability or versatility
If conventional integral moulding processes are used for the liner, then manufacturing steps are reduced, but design freedom and adaptability for different helmet configurations are limited
Solution Approach 1:
By dividing the liner into separable first and second parts with complementary protuberances and recesses, the design can be adapted to different helmet configurations by modifying individual parts independently. The assembly process remains simple due to the self-aligning nature of the protuberance-recess engagement mechanism.
3Strength
If shock-absorbing materials are oriented with protuberances normal to the inner curved surface, then compressive strength is optimized for impact absorption, but manufacturing complexity and production time increase
Solution Approach 1:
The liner is segmented into a first part containing the shock-absorbing materials with protuberances oriented for optimal compressive strength, and a second part that can be简单地 assembled. This allows the critical shock-absorbing components to be manufactured with proper material orientation using simple integral moulding, while avoiding complex multi-step overmoulding processes.
4Reliability
If multiple sub-parts are assembled and overmoulded to form the liner, then structural integrity is achieved, but manufacturing time and production costs increase
Solution Approach 1:
The liner uses segmented first and second parts that are assembled through simple protuberance-recess engagement without requiring time-consuming overmoulding operations. The structural integrity is maintained through the mechanical interlocking of the segmented parts, achieving reliability with reduced manufacturing cycle time.
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
The simplified manufacturing process and increased design flexibility do not compromise shock-absorbing performance, enabling the creation of lighter, more flexible helmets with enhanced impact absorption capabilities across various impact zones.
Implementation Method 1
the ribs of said at least one primary group and the channels of所述至少一个 secondary group being sized and shaped so that, by translating said first part and said second part one towards the other in a direction parallel to the demoulding direction, the second part matches the first part and said ribs engage into said channels
Implementation Method 2
This particular orientation of the conical protuberances and conical recesses, with an axial direction normal to an inner curved surface of the liner, is aimed to make the shock-absorbing materials of the parts to work mainly at compression when the helmet receives an impact on its outer shell
Data Source
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AI summary
A shock-absorbing liner for a protective helmet, comprising at least an integrally moulded first part (2) shaped as a curved thin body and comprising a primary group (72) of ribs (6) extending in height along a same demoulding direction (X2) of said first part (2) and in length along a side (3) of said first part (2), and at least an integrally moulded second part (42) shaped as a curved thin body and comprising a secondary group (92) of channels (8) extending in depth along a same demoulding direction (X1) of said second part (41) and in length along a side (5) of said second part (42). By translating the two parts (2, 42) one towards the other in a direction parallel to the demoulding direction (X2) they fit together, with said ribs (6) engaging into said channels (8). The invention also comprises a protective helmet provided with said liner.