Steam-Formed Double-Layer Sports Helmet EPS EPP
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Solution Overview
Problem
Conventional sports helmets face challenges in achieving both anti-hitting capability and softness, resulting in poor wearing comfort due to the use of high-density materials like EPS for shock absorption.
Innovation Solution
A steam-formed double-layer sports helmet design featuring a surface hard shell, a middle EPS material layer, and a lower EPP material layer, where the EPS layer provides water resistance and heat resistance, and the EPP layer offers shock resistance and energy absorption, with both layers being bonded together using high-temperature steam forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-density EPS material is used for shock absorption, then anti-hitting performance is improved, but wearing comfort deteriorates due to high hardness
Solution Approach 1:
The helmet divides the shock absorption function into two separate layers: an outer EPS layer for anti-hitting performance and an inner EPP layer for wearing comfort. This segmentation allows each layer to be optimized for its specific function without compromise.
Solution Approach 2:
The helmet uses a composite structure combining two different foam materials (EPS and EPP) with distinct properties. The outer EPS provides hardness for impact resistance, while the inner EPP provides softness for comfort, achieving both requirements simultaneously.
2Ease of manufacture
If a single material is used for shock absorption, then manufacturing simplicity is maintained, but dual functionality (hardness and softness) cannot be achieved
Solution Approach 1:
The shock absorption system is segmented into two functional layers, each made from a single material type. This maintains manufacturing simplicity for each layer while achieving dual functionality through their combination.
Solution Approach 2:
By using composite materials (EPS + EPP), the helmet achieves versatility in providing both hardness and softness functions that a single material cannot deliver, while the standardized layering process keeps manufacturing relatively simple.
3Strength
If high-density material is used throughout the helmet, then anti-hitting performance is improved, but weight increases
Solution Approach 1:
The helmet applies different material densities to different regions/layers based on functional requirements. The outer layer uses higher density EPS for impact resistance, while the inner layer uses lower density EPP for comfort and weight reduction, optimizing the weight-strength balance.
Solution Approach 2:
The composite structure combines materials of different densities strategically, using the lighter EPP material in the inner layer to reduce overall weight while maintaining anti-hitting performance through the outer EPS layer.
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 helmet achieves improved anti-hitting performance, water resistance, heat resistance, and reduced weight while enhancing wearing comfort through the combination of EPS and EPP material layers, offering effective shock absorption and thermal insulation.
Implementation Method 1
the EPS layer provides water resistance and heat resistance
Implementation Method 2
the EPS layer provides water resistance and heat resistance
Implementation Method 3
the EPP layer offers shock resistance and energy absorption
Implementation Method 4
the EPP layer offers shock resistance and energy absorption, with both layers being bonded together using high-temperature steam forming
Implementation Method 5
both layers being bonded together using high-temperature steam forming
Data Source
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AI summary
The present invention discloses a steam-formed double-layer shock-absorption sports helmet, including a helmet body. The helmet body (1) includes a surface hard shell (2), an EPS material layer (3) and an EPP material layer (4) successively mounted together in a fitting manner. The surface hard shell is wrapped on an outer surface of the EPS material layer. The EPP material is wrapped on an inner surface of the EPS material layer.