Single-Piece Helmet Suspension With Overmolded Ventilated Padding
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Solution Overview
Problem
Suspension assemblies for hard hats and helmets require multiple parts, leading to increased cost and complexity in design and development.
Innovation Solution
A suspension assembly with a single-piece frame and an overmolded pad, where the pad is integrated onto the frame using a one-step, two-shot injection molding process, providing ventilation and moisture-wicking properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple parts are used in suspension assembly, then functionality and comfort are improved, but design and development cost increase
Solution Approach 1:
The patent combines the pad and suspension frame into a single integrated component manufactured through overmolding. The pad material is overmolded onto the suspension frame in a single manufacturing process, eliminating the need for separate pad components and reducing assembly steps while maintaining comfort and ventilation functionality.
Solution Approach 2:
The integrated suspension assembly performs multiple functions simultaneously: the pad provides comfort and moisture-wicking properties, the frame provides structural support and ventilation through aligned holes and slots, and the single-piece construction reduces manufacturing complexity. This multi-functional design addresses various requirements in one component.
2Reliability
If multiple parts are used in suspension assembly, then functionality is improved, but device complexity increases
Solution Approach 1:
The patent merges the pad and suspension frame into a single integrated component. The overmolding process combines two previously separate parts (pad and frame) into one unified structure, reducing the total part count while preserving the functional benefits of both components.
Solution Approach 2:
While integrating components, the patent maintains functional segmentation through strategic placement of holes and slots. The pad holes align with frame slots to create ventilation pathways, and the pad material is positioned to provide comfort in specific zones, maintaining functional differentiation within the integrated structure.
3Ease of manufacture
If traditional assembly method is used, then manufacturing flexibility is maintained, but production efficiency decreases
Solution Approach 1:
The overmolding process combines the manufacturing of the pad and suspension frame into a single operation. Instead of producing separate components and assembling them, the integrated molding process creates the complete assembly in one step, significantly improving production efficiency while maintaining manufacturing flexibility through configurable hole and slot patterns.
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 integrated design reduces production costs and enhances comfort by combining ventilation and sweat management in a single, cost-effective assembly.
Implementation Method 1
the pad is a sweatband having moisture-wicking properties
Data Source
AI summary
Methods, assemblies, and/or the like are provided. In accordance with various embodiments of the present disclosure there is provided a suspension assembly including a suspension frame having a lower band including one or more band holes configured to provide ventilation to a wearer of the suspension frame; and an upper band having one or more slots; and a pad overmolded onto the suspension frame, wherein the pad has one or more pad holes, wherein the one or more pad holes are configured to be aligned with the one or more slots such that the one or more pad holes are configured to provide ventilation to the wearer of the suspension frame. In some embodiments, the pad is overmolded onto the upper band of the suspension frame. In some embodiments, the suspension frame is a single piece including the lower band and the upper band.