Sprayed Polymeric Trim for Helmet Edge Protection
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Solution Overview
Problem
Conventional rubber gaskets and molded trims on helmets are prone to delamination, are labor-intensive to apply, and result in helmets that are heavy, with long adhesive cure times, leading to increased weight and reduced durability.
Innovation Solution
A sprayed-on polymeric material is applied directly to the helmet shell, providing a trim that conforms to the shape, offering increased strength, durability, and reduced weight, with improved adhesion and manufacturing efficiency, eliminating the need for separate adhesives and reducing processing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rubber gaskets or molded trims are used on helmet edges, then the helmet provides edge protection, but the helmet becomes heavier and requires long adhesive cure times
Solution Approach 1:
The patent combines the trim material and adhesive into a single integrated sprayed composition. The trim is applied as a sprayable composition that simultaneously adheres to the helmet shell and forms the protective trim edge, eliminating the need for separate adhesive application and curing steps.
Solution Approach 2:
The patent extracts the adhesive function from the separate trim application process and integrates it into the sprayable trim composition itself. This allows the trim to be applied in a single step without requiring additional adhesive materials or extended cure times.
2Strength
If conventional rubber gaskets or molded trims are used on helmet edges, then the helmet provides edge protection, but the manufacturing process becomes more complex and labor-intensive
Solution Approach 1:
The patent merges multiple manufacturing steps (trim preparation, adhesive application, and trim attachment) into a single spray application step. The sprayable composition is applied directly to the helmet shell in one operation, significantly simplifying the manufacturing process.
Solution Approach 2:
The sprayable trim composition is self-adhering, meaning it contains its own adhesive properties and does not require separate adhesive materials or complex application procedures. The composition applies itself to the helmet shell through the spraying process.
3Loss of time
If sprayed-on polymeric material is applied directly to the helmet shell, then the trim adheres strongly and curing time is reduced, but the material must be sprayable and adherent by design
Solution Approach 1:
The patent uses a composite sprayable composition that combines polymeric trim material with adhesive components in a single formulation. This composite material provides both the structural trim function and the adhesive bonding function, enabling rapid adherence without requiring separate materials.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the trim material to make it sprayable while maintaining its structural integrity and adhesive properties. The material is formulated with specific viscosity, particle size, and chemical composition parameters that enable spray application and rapid curing.
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 sprayed-on polymeric material results in a trim that is lighter, more durable, and easier to manufacture, with enhanced abrasion and chemical resistance, and improved bonding to the helmet shell, meeting or exceeding design requirements for military helmets.
Implementation Method 1
A sprayed on trim directly adhered to the helmet shell
Implementation Method 2
A coefficient of friction of the material is greater than a coefficient of friction of the helmet shell
Data Source
AI summary
Various embodiments of helmets and methods of their manufacture are disclosed. In some embodiments, the helmet includes a helmet shell having a helmet shell edge and/or a mounting location for mounting an accessory to the helmet shell. A material that is adherent to the helmet shell may be sprayed onto the helmet shell edge of the helmet shell to form a trim. Alternatively, the material may be sprayed onto a portion of the helmet shell associated with either a mounting location for mounting an accessory or a position for a mounted accessory.