Helmet Visor Supporting Frame Segmentation
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Solution Overview
Problem
The existing manufacturing process for helmets results in dimensional variations between shells and visors, leading to less-than-ideal assembly quality and difficulty in replacing gaskets, compromising the visor's sealing and protection effectiveness.
Innovation Solution
A supporting frame for the visor that is molded to fit the helmet's front opening, incorporating a gasket and pivoting mechanisms, allowing precise assembly and independent control of dimensional tolerances, and facilitating easy gasket replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a generally continuous gasket is fitted directly on the shell running along the entire perimeter of the opening, then the visor achieves effective closure and tightness against infiltrations, but the assembly quality is compromised due to dimensional variations in the shell production process
Solution Approach 1:
The gasket system is segmented into two independent parts: the gasket element fitted to the shell and the supporting frame fitted to the visor. This segmentation allows each component to be manufactured and assembled independently, compensating for dimensional variations in the shell production process while maintaining effective sealing closure.
2Ease of manufacture
If the gasket is fitted directly on the shell, then the visor can be assembled, but the gasket replacement becomes difficult and compromises the quality of the end product
Solution Approach 1:
The gasket system is divided into replaceable modules: the gasket element can be independently removed and replaced from the shell side, while the supporting frame remains fixed to the visor. This modular segmentation enables easy gasket replacement without requiring disassembly of the entire visor assembly.
Solution Approach 2:
The supporting frame acts as an intermediary element between the visor and the gasket. By fitting the gasket to the shell and the frame to the visor, the system creates a mediating structure that simplifies both initial assembly and subsequent maintenance operations.
3Productivity
If the shell is manufactured using molding, painting, and manual steps, then the helmet can be produced, but dimensional variations are introduced among end products
Solution Approach 1:
The gasket system is segmented into two independently manufactured components that can accommodate dimensional variations in the shell. The supporting frame is precision-manufactured separately and fitted to the visor, while the gasket element is fitted to the shell, allowing each component to be optimized independently for its specific function.
Solution Approach 2:
The system allows for parameter adjustments in the assembly process, where the supporting frame and gasket element can be positioned and fitted to compensate for dimensional variations in the shell, maintaining consistent assembly quality across different helmet units.
Data Source
Figure 1
Figure 2~3
AI summary
A supporting frame (1) for the visor of a helmet. The frame is adapted to be connected to the shell of a protective helmet so as to be arranged at the front opening (4) of the shell. The frame further has a shape adapted to follow the perimeter of the front opening of the helmet and supports at least one gasket element (2).