Single-Piece Ratchet Buckle Assembly for Helmet Retention
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Solution Overview
Problem
Conventional ratchet buckle assemblies are expensive and heavy due to multiple components, and they can fail under high forces, posing safety risks in helmets during impacts, such as those from automobiles or trees, leading to potential injury or suffocation.
Innovation Solution
A single-piece moulded ratchet strap and buckle assembly with a flexible spring area and a locking tooth, where the buckle is formed as one injection-moulded component, allowing easy engagement, adjustment, and release of the strap, and featuring a stop mechanism and support bars to prevent unintentional release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (case, ratchet pawl, plastic cam, return spring) are used to achieve ratchet functionality, then the retention strength and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (case, ratchet pawl, plastic cam, return spring) into a single integrated ratchet buckle assembly. The locking pawl, ratchet teeth, and spring mechanism are all formed as one piece through injection molding, eliminating the need for separate parts while maintaining the retention functionality.
Solution Approach 2:
The single-piece ratchet buckle performs multiple functions that were previously distributed across separate components: it provides the case structure, contains the ratchet teeth, houses the locking pawl, and incorporates the return spring mechanism. This multi-functional design reduces complexity while maintaining reliability.
2Strength
If multiple components made of high strength metallic material are used to resist high loads, then the strength and safety are improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent uses composite material construction by injecting different materials into different regions of the single-piece buckle. High strength metallic material is used for load-bearing components (locking pawl, ratchet teeth) while lighter materials are used for non-critical areas, optimizing the weight-strength ratio.
Solution Approach 2:
Different regions of the single-piece buckle are made from materials with different properties. The locking pawl and ratchet teeth are made from high strength material where load resistance is critical, while other portions can be made from lighter materials, creating local optimization of material properties.
3Ease of manufacture
If a single-piece moulded buckle is used to reduce complexity and cost, then the manufacturing cost and weight are reduced, but the retention strength may be compromised
Solution Approach 1:
By merging all functional elements into a single piece through injection molding, the patent eliminates assembly steps and reduces manufacturing complexity while maintaining retention strength through proper material selection and structural design in the single-piece construction.
4Ease of manufacture
If the retention strap is made from conventional materials to reduce cost, then the manufacturing cost is reduced, but the safety under high impact forces is compromised
Solution Approach 1:
The retention strap uses composite material construction with high strength materials in critical load-bearing areas, allowing cost-effective manufacturing while maintaining safety under high impact forces through strategic material placement rather than uniform expensive material usage.
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 solution reduces production costs, enhances safety by preventing strap failure under high forces, and ensures easy operation with a simple and secure locking mechanism, suitable for helmets and other sporting goods.
Implementation Method 1
a flexible spring area on its top side, joined only at a front end thereof. In this way, this top spring side can then flex up and down around this joined end
Data Source
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AI summary
Disclosed is a ratchet strap and buckle assembly comprising an adjustment ratchet strap (20) comprising a ratchet strap end (21), and a plurality of ratchet teeth (22) arranged thereon and a single-piece buckle (10) having a locking tooth (14) and a flexible top element (12), wherein the single-piece buckle comprises a passageway for the ratchet strap end to be inserted therein, and wherein the flexible top element is configured to engage with at least one of the plurality of ratchet teeth using the locking tooth upon insertion.