Thermoplastic Polyurethane Shock Absorber for Helmet Impact Protection
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Solution Overview
Problem
Conventional safety helmets with foam or Styrofoam buffering strips provide inadequate shock absorption and are prone to air leakage and sweat permeation, leading to reduced protection and odor issues.
Innovation Solution
A resilient shock-absorbing device composed of thermoplastic polyurethane absorber layers with exposed foam members, eliminating the need for adhesives and inflatable components, and featuring a waterproof breathable cover layer for enhanced durability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam or Styrofoam buffering strips are used in the intermediate layer, then the helmet structure is simple and easy to manufacture, but the shock-absorbing capability is insufficient when subjected to excessive external impact
Solution Approach 1:
The patent uses a composite buffering structure combining thermoplastic polyurethane (a flexible polymer material) with foam blocks. The thermoplastic polyurethane layer provides elasticity and shock absorption, while the foam blocks provide additional cushioning. This composite approach resolves the contradiction by achieving superior shock-absorbing capability without excessive structural complexity.
Solution Approach 2:
The patent changes the material parameter from conventional foam/Styrofoam to thermoplastic polyurethane, which has superior elastic properties and shock-absorbing characteristics. This material parameter change enables the buffering strips to effectively absorb excessive external impacts while maintaining manufacturability.
2Strength
If air is introduced into the intermediate layer to enhance shock absorption, then the shock-absorbing effect is improved, but air leakage occurs reducing protection effectiveness
Solution Approach 1:
The patent replaces the air-filled structure (which is prone to leakage) with solid thermoplastic polyurethane buffering strips. While air provides good shock absorption, it leaks over time. The solid polymer material provides sustained shock-absorbing protection without leakage, resolving the reliability issue.
Solution Approach 2:
The patent substitutes the air-based shock absorption mechanism with a solid polymer-based mechanism. The thermoplastic polyurethane material provides mechanical shock absorption through its elastic properties, replacing the pneumatic system that suffers from leakage problems.
3Ease of operation
If the inner protective layer is made of fabric material for comfort, then wearability is improved, but sweat easily permeates into the buffering strips causing odor
Solution Approach 1:
The patent introduces an intermediate protective layer between the fabric inner layer and the buffering strips. This intermediary layer acts as a barrier that prevents sweat from permeating into the buffering strips, thereby eliminating the odor problem while maintaining the fabric's wearability benefits.
4Stability of the object's composition
If adhesive is used to fix buffering strips within the intermediate layer, then the buffering strips are securely positioned, but the structure becomes more complex and adhesive residue may cause issues
Solution Approach 1:
The patent merges the buffering strips with the intermediate layer by integrating the thermoplastic polyurethane material directly into the layer structure. This eliminates the need for separate adhesive fixation, reducing structural complexity while maintaining secure positioning through the unified construction.
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 device provides improved shock absorption, prevents sweat penetration, and maintains structural integrity, ensuring better protection and ease of cleaning.
Implementation Method 1
Each of the first and second outer tube halves is made of a thermoplastic elastic material
Implementation Method 2
a plurality of first foam members filled respectively in the first outer tube halves and each having a surface exposed from a respective one of the first outer tube halves
Implementation Method 3
a plurality of juxtaposed resilient first outer tube halves heat-sealed to each other
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A resilient shock-absorbing device includes an absorber body (100, 100', 100a, 100b, 100c) having top and bottom faces and including first and second absorber layers (2, 2', 2c, 3, 3', 3c). The first absorber layer (2, 2', 2c) includes a plurality of juxtaposed resilient first outer tube halves (21, 21c) heat-sealed to each other, and a pluralityof first foammembers (23, 23') filledrespectively in the first outer tube halves (21, 21c) . The second absorber layer (3, 3', 3c) includes a plurality of juxtaposed resilient second outer tube halves (31, 31c) heat-sealed to each other, and a plurality of second foam members (33, 33') filled respectively in the second outer tube halves (31, 31c). The first and second absorber layers (2, 2' , 2c, 3, 3', 3c) form respectively the top and bottom faces of the absorber body (100, 100', 100a, 100b, 100c). Each of the first and second outer tube halves (21, 21c, 31, 31c) is made of a thermoplastic elastic material. Each of the first and second foam members (23, 23', 33, 33') has a segment-shaped cross section.