Wedge Wire Sports Face Mask Impact Strength
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Solution Overview
Problem
Existing sports face masks made of metal wires face challenges in balancing impact strength, weight, visibility, and aesthetics, particularly due to limitations in wire cross-sectional shapes and attachment methods, which affect comfort, reliability, and manufacturing costs.
Innovation Solution
The development of face guards using bended metal wires with wedge wire cross-sections, featuring a tapered shape and flat surface portions, which provide improved strength, reduced weight, and enhanced aesthetics while minimizing obstruction of vision, along with notched joints and efficient welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional round or flat metal wires are used in face masks, then manufacturing is simple and成本低, but impact strength is insufficient and weight is high
Solution Approach 1:
The patent applies asymmetry by using wedge-shaped wire cross-sections instead of traditional round or flat wires. The wedge shape has different dimensions in different directions, with the tapered portion providing enhanced impact resistance in specific directions while maintaining lighter weight. This asymmetric geometry optimizes the strength-to-weight ratio and impact distribution characteristics of the face mask wires.
Solution Approach 2:
The patent changes the geometric parameters of the wire cross-section from traditional round or flat shapes to a specific wedge shape with defined dimensions. The wedge-shaped wire has a first dimension (width) and a second dimension (thickness) where the width is greater than the thickness, creating optimized mechanical properties for impact resistance while reducing overall weight compared to traditional wire configurations.
2Strength
If thicker metal wires are used to increase impact strength, then protection is improved, but weight increases and visibility is obstructed
Solution Approach 1:
The wedge-shaped wire cross-section uses asymmetric geometry where the width dimension is optimized for impact resistance while the thickness dimension is minimized to reduce weight. This asymmetric design allows the wire to provide maximum protection in the direction of potential impacts (using the wider dimension) while maintaining minimal weight (using the thinner dimension perpendicular to impact direction).
Solution Approach 2:
The patent applies local quality by concentrating material in the wedge-shaped cross-section where it is most needed for impact resistance, rather than uniformly distributing material throughout the wire. The tapered portion of the wedge shape provides localized strength enhancement at critical impact zones while reducing material usage in non-critical areas, thereby reducing overall weight.
3Reliability
If more wires are added to improve protection coverage, then safety is enhanced, but weight increases and manufacturing complexity increases
Solution Approach 1:
The wedge-shaped wire serves multiple functions simultaneously: it provides impact resistance, reduces weight, improves aesthetics, and maintains structural integrity. This multi-functional design element replaces the need for additional reinforcement wires that would otherwise be required to achieve the same level of protection, thereby reducing overall structural complexity while enhancing protection reliability.
Data Source
AI summary
A sports face guard for a sports headgear includes a plurality of interconnected wires, wherein a wire of the plurality of interconnected wires has a cross section has a wedge surface with a first longest dimension, the first longest dimension of the wedge surface being in a direction of a major axis of the wire; a base surface with a second longest dimension, the second longest dimension of base surface being in a direction that is perpendicular to the major axis of the wire, the second longest dimension being less than the first longest dimension; wherein the first longest dimension of the wedge surface is longer than the second longest dimension of the second base surface; and wherein the second base surface of the wire comprises a substantially flat or concave surface portion.