CN113942260A

CN113942260A - Method for manufacturing safety helmet rubber shell reinforcement and helmet structure manufactured by method

Info

Publication number: CN113942260A
Application number: CN202010688091.8A
Authority: CN
Inventors: 何昌宪
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-07-16
Filing date: 2020-07-16
Publication date: 2022-01-18
Anticipated expiration: 2040-07-16
Also published as: CN113942260B

Abstract

The invention discloses a manufacturing method for strengthening a rubber shell of a safety helmet and a helmet structure manufactured by the method. The manufacturing method comprises the following steps: procedure a, providing at least one fiber layer and at least one shell (plastic) of thin flat plate structure; the combined operation of the process B, the fiber layer is attached to the shell to form (or define) a primary body; the forming operation of the process C, providing a first forming module to heat and press the primary body, so that the shell at least partially combines or enters the fiber layer, and forms the helmet-shaped (or profile) assembly; and the foaming combination operation of the process D, namely arranging the foaming material in the assembly, and matching with the second forming module to fill the foaming material into the connecting assembly to form a helmet structure. Under the condition of conforming to the strength of the whole structure, the functions of reducing the weight of the helmet, improving the complex and time-consuming processing of the old method and the like are achieved.

Description

Method for manufacturing safety helmet rubber shell reinforcement and helmet structure manufactured by method

Technical Field

The invention relates to a manufacturing method for strengthening a rubber shell of a safety helmet and a helmet structure manufactured by the method; in particular to a technology for combining a fiber layer (or fabric) and a shell body which is in a flat structure through operations such as a forming module and the like to combine the fiber layer and the surface of the shell body.

Background

The application of a plastic shell to cooperate with an impact-resistant filling body formed by heating a foaming material and to make the plastic shell tightly cover and adhere to the foaming filling body to complete a safety helmet or safety helmet structure, which provides protection for people performing ball games, riding sports, etc., has become the prior art. For example, exemplary embodiments are provided in U.S. patent application Nos. 4466138 Safety Helmet with A Shell Injected from thermoplastic And Method for The Manufacture of Safety Helmet, Taiwan, No. 85101810 Method for Helmet Manufacture, And so on.

The structure of the safety helmet is characterized in that the external rubber shell resists the outburst-through impact of an external object, and the foamed filler provides buffering and dispersing transmission effects of impact force when being impacted by external force, so as to achieve the effect of protecting the head of a user.

One problem associated with the manufacture of such helmets is that, in order to increase the feel or appeal of such safety helmets, the surface of the helmet is typically painted or otherwise provided with a plurality of colors (e.g.,

sheet) pattern layer or fabric overlay of cloth-like material, etc. In practice, after the plastic case is molded, a pattern layer or a cloth material is applied and stuck to the surface (or a set position) of the plastic case. As known to those skilled in the art, the manufacture of this helmet structure has the following drawbacks:

1. the application of the pattern layer or the textile material must be done by skilled personnel. The pattern layer paster or fabric is arranged and adhered on the surface position or area of the helmet according to the design plan; if the skill of the operator is not sufficiently skilled, it often results in the pattern layer or web material being applied being rough or wrinkled proximate the edges, which is particularly likely to occur in the area of the contoured edges of the pattern layer or web material.

This is because, during the pasting process, in order to make the whole pattern layer sticker or cloth smoothly pasted on the surface of the plastic shell, the operator will push the pattern layer or cloth instinctively to make the main area of the pattern layer or cloth flatly pasted on the surface of the plastic shell as much as possible, so that the local edge of the pattern layer or cloth often protrudes or can not be matched with the contour of the plastic shell (or is located at the correct position of the contour of the plastic shell).

Particularly those having elastic stickers or cloths, which have edges that protrude or do not conform to (or are in the correct position of) the contours of the plastic shell. Usually, the operator must spend additional time to trim and try to avoid damaging other painted or pasted parts. This represents considerable difficulty in manufacturing or machining operations and increases manufacturing time.

2. In the former method, in order to reduce the situation that the edge of the pattern layer or the cloth protrudes or the contour of the plastic shell cannot be matched (or is positioned at the right position of the contour of the plastic shell), the size of the pattern layer or the cloth is required to be special so as to enable the pattern layer or the cloth to be matched with the set area on the plastic shell as much as possible. The dimensions of those patterns or cloth materials having elasticity are often difficult to control.

3. If the skilled person is not skilled enough, the frequency of the above-mentioned local areas of the pattern layer or the edge of the cloth causing a situation like a squeeze or a wrinkle is significantly increased. In particular, when the adhesive is applied, the adhesive is stuck on other areas of the adhesive case to cause contamination, which is sometimes caused by unskilled workers.

Moreover, in the prior art, when the pasting operation of the pattern layer or the cloth is carried out, the operator still needs to rely on a great amount of labor and cannot use a machine to execute a great amount of processing operation, which shows that the operator is difficult to obtain a great amount of skilled operators; and the control of the manufacturing quality of the product is not easy.

Typically, the above reference data reflects that it is still less than ideal in terms of design and fabrication considerations for safety helmet construction. If the structural structure of the helmet is re-designed and considered, the structure of the helmet is different from the prior structure, the manufacturing and processing types of the helmet can be changed, and the helmet is different from the prior art; substantially, the disadvantages of the prior art are also improved. That is, if one attempts to ameliorate or overcome the problems we have discussed above, we have found that its construction and composition must take into account the following design issues:

1. the structure design of the helmet is different from the operation and structure in the prior art under the condition of meeting the safety requirement, and the structural form of the helmet which is simple to manufacture and has the trend of light and thin design is achieved.

2. The provided operation method should make the edge part of the pattern layer or cloth material protrude or the situation that the plastic shell contour can not be matched is reduced as much as possible, so as to improve the situations that the existing helmet contour and the pattern layer or cloth material are not smooth in joint, time-consuming in processing or manufacturing, large amount of skilled labor is needed, the reject ratio is high, and the like.

3. In particular, methods are provided for tensioning a fibrous layer (e.g., a pattern layer or a cloth material) to provide an elastic reaction or rebound upon impact of an external force on the housing.

Disclosure of Invention

Accordingly, it is a primary object of the present invention to provide a method for manufacturing a rubber shell reinforcement for a safety helmet and a helmet structure manufactured by the same.

In order to achieve the purpose, the invention adopts the following technical means:

the invention relates to a manufacturing method for strengthening a rubber shell of a safety helmet, which comprises the following steps:

process (a) providing at least one fiber layer 50 and at least one shell 10; the housing 10 is made in a flat plate structure; the fibre layer 50, the shell 10 has a

first face

51, 11 and a

second face

52, 12, respectively;

flow (B) providing a combination of attaching the first side 51 of the fiber layer 50 to the second side 12 of the housing 10 to form the primary body 40;

the process (C) provides a molding operation, such that the first molding module 60 heats and presses the primary body 40, so that at least a portion of the surface texture of the shell 10 enters the fiber layer 50 to form the primary body 40 in a bonded state, and the primary body 40 is formed into a helmet-shaped assembly 99.

Preferably, the process (C) is followed by a process (D) of providing a foam bonding operation, disposing the foam material in the assembly 99, forming the foam material into the elastic structure 30 with the second forming module 65, and filling the coupling assembly 99 to form a helmet structure 100. Under the condition of conforming to the strength of the whole structure, the functions of reducing the weight of the helmet, improving the complex and time-consuming processing of the old method and the like are achieved.

Wherein, preferably, the primary body 40 of the process (B) can be pressurized by the module 45, and the auxiliary fiber layer 50 is attached to the housing 10.

Wherein, preferably, between the first face 51 of the fiber layer and the second face 12 of the housing in the process (B), the adhesive 44 is disposed, and the auxiliary fiber layer 50 is attached to the housing 10.

Preferably, the process (C) inserts the texture structure on the surface of the shell 10 into the fiber layer 50, and expands the texture structure of the fiber layer 50, so that the fiber layer 50 is in a tense state along the contour of the surface of the shell 10.

Preferably, the process C) inserts the tissue structure of the surface of the shell 10 into the fiber layer 50, and expands the structural tissue of the fiber layer 50, so that the fiber layer 50 is in a tense state along the contour of the surface of the shell 10.

Wherein, the thickness of the shell 10 is preferably made of a plate body with the thickness of 0.5 mm-2.0 mm.

Further, the present invention also provides a helmet structure manufactured according to the manufacturing method for reinforcing the rubber shell of the safety helmet, comprising:

a combination of a shell 10 and a fibrous layer 50 disposed on the shell 10;

at least a portion of the surface tissue of the shell 10 enters the fiber layer 50 and is defined as a bonded state. The fiber layer is tensioned along the contour of the shell (surface), and when the shell is impacted by external force, the fiber layer (auxiliary shell) generates elastic reaction force or rebound action.

Preferably, the fiber layer 50 is formed by connecting a plurality of sheets into a whole fiber layer 50.

Wherein, preferably, the housing 10 is formed by connecting a plurality of flat plates into a whole housing 10.

Wherein, preferably, the fiber layer 50 forms a tension state along the surface contour of the shell 10; the inner surface of the shell 10 is provided with an elastic structure 30 made of a foam material, and the elastic structure together form a helmet structure 100.

Drawings

FIG. 1 is a schematic of scheme A of the present invention; the structural aspects of the fiber layer and the shell (or thin flat plate structure) are shown.

FIG. 2 is a schematic of flow B of the present invention; showing the case where the fiber layer is attached to the shell to form a primary body.

FIG. 3 is a schematic of flow C of the present invention; the primary body is shown assembled with a first forming module to form a helmet-shaped or contoured component assembly.

FIG. 4 is a schematic plan view of the present invention; the structural condition of the shell surface tissue bonding or entering the fibrous layer is depicted.

FIG. 5 is a schematic of flow D of the present invention; the assembly and foam are depicted in combination with a second shaped module to form a helmet structure.

FIG. 6 is a schematic diagram of an operational embodiment of the present invention; depicting the case where an external impact force (or positive force) impacts the assembly or helmet structure.

FIG. 7 is a schematic diagram of another operational embodiment of the present invention; depicting the case where an external impact force (or shear force) in an oblique angle direction impacts the assembly or helmet structure.

Description of the symbols:

10 casing

11. 51 first side

12. 52 second side

30 elastic structure

40 primary body

44 adhesive layer

45 module

50 fiber layer

60 first Forming Module

65 second molding module

99 assembly

100 helmet structure

Detailed Description

Referring to fig. 1, the method for manufacturing the rubber shell reinforcement of the safety helmet of the present invention is described by selecting an embodiment of a safety helmet for sports wear; the safety helmet may be in the form of a football helmet, hockey helmet, engineering helmet, mountain climbing helmet, horse hat or half-or full-face helmet worn by a bicycle, locomotive, ski, racing car …, etc.

In the following description, reference will be made to the upper, lower, bottom or outer, inner, etc., portions thereof being referred to in the direction shown in the drawings. For example, a component oriented toward the wearer is defined as a first face (or inner face, inner edge) and a component oriented opposite or away from the wearer is defined as a second face (or outer face, outer edge).

Referring to fig. 1, 2 and 3, the method for manufacturing a safety helmet includes:

process a, providing at least one fiber layer 50 and at least one shell 10; the fabric layer 50 is selected from cloth, fabric …, or the like for the purpose of illustrating embodiments. The housing 10 is made of plastic, PC or the like and is formed into a flat plate structure.

The fibrous layer 50, the shell 10 is shown defining or having a

first side

51, 11, a

second side

52, 12, respectively. In one embodiment, a plurality of fiber layers 50 may be connected to form a single fiber layer 50.

A flow B providing a combined operation; the primary body 40 is formed by attaching the fiber layer 50 (or the first side 51 of the fiber layer) to the case 10 (or the second side 12 of the case) in a flat plate body structure.

In a possible embodiment, the phantom line portion of fig. 2 shows that after the fiber layer 50 is attached to the housing 10, it can be pressed together by means of a module 45 (e.g. a roller), which assists in attaching the fiber layer 50 to the housing 10. Or between the fiber layer 50 (or the first side 51 of the fiber layer) and the shell 10 (or the second side 12 of the shell), an adhesive 44 can be arranged (as shown in phantom lines) to assist in attaching the fiber layer 50 to the shell 10.

Referring to FIG. 3, a molding operation is provided in the process C. The forming operation provides the first forming module 60 to heat and press the primary body 40 to form the primary body 40 into a helmet-shaped (or contoured) assembly 99. And, the fabric layer 50 acts like a protective layer and may provide a variety of designs and/or text ornamentation.

Fig. 4 illustrates the operation of process C, wherein at least a portion of the surface texture of the shell 10 (or the second side 12 of the shell) is bonded or incorporated into the fiber layer 50 (or the first side 51 of the fiber layer) to form (or define) a bonded state. Moreover, the bonding state causes the tissue structure of the shell 10 (surface or second side 12) to be inserted into the fiber layer 50, and slightly expands the structural tissue of the fiber layer 50, so that the fiber layer 50 is in a tension state along the contour of the shell 10 (surface), and when the shell 10 is impacted by external force, the fiber layer 50 (auxiliary shell 10) generates an elastic reaction force or rebound action.

In particular, the operation of the process C also provides a curved profile of the shell 10 (and/or the fabric layer 50), and the auxiliary fabric layer 50 is under tension (or tight) along the shell 10, which significantly improves the problems of the prior art, such as wrinkling of the fabric adhered to the shell, time consuming, and failure to provide a reinforcing effect for the plastic shell structure.

It can be understood that the combination of the fiber layer 50 and the shell 10 disclosed in the above embodiments helps to generate a complementary structural strength effect therebetween, which is beneficial to reduce the thickness of the shell 10 and thus the weight and volume of the helmet; for example, allowing for shell 10 thickness applications

Is made of a plate body (non-thin (glue) film type).

Referring to FIG. 5, a process D for providing a foaming bonding operation is shown. The foaming bonding operation arranges a (solid) foamed material within the assembly 99; the second molding module 65 is heated to fill the coupling assembly 99 with the foam (the cushioning elastic structure 30) to form a helmet structure 100. Under the condition of conforming to the strength of the whole structure, the functions of reducing the weight of the helmet, improving the complex and time-consuming processing of the old method and the like are achieved.

The helmet structure manufactured by the manufacturing method for reinforcing the rubber shell of the safety helmet comprises a shell 10 and a fiber layer 50 arranged outside the shell 10 (or on the second side 12); furthermore, at least a part of the surface tissue (or the second surface 12 tissue) of the shell 10 is bonded or enters into the fiber layer 50 to form the above-mentioned bonding state, so that the fiber layer 50 forms a tension state along the contour of the shell 10 (surface), and when the shell 10 is impacted by external force, the fiber layer 50 (the auxiliary shell 10) generates an elastic reaction force or a springback effect.

In the modified embodiment, the helmet structure 100 is configured by disposing the elastic structure 30 formed of the foamed material on the first surface 11 (or the inner surface) of the shell.

Referring to fig. 6, when an external impact force (or a positive force) impacts the assembly 99 or the helmet structure 100, the shell 10, the elastic structure 30 and/or the fabric layer 50 respectively generate different elastic deformation amounts to reduce the speed of the external impact force, so as to jointly load the external impact force to generate a buffering and absorbing effect, and transmit the external impact force to the whole assembly 99 or the helmet structure 100 in a dispersing manner, thereby achieving the effect of preventing the external impact force from penetrating through the assembly 99 or the helmet structure 100, and reducing or reducing the occurrence of brain damage.

When the external impact force disappears, the elastic structure 30 and/or the elastic force (or resilience) of the fiber layer 50 assist the structural characteristics of the housing 10 to return to the original assembly position as much as possible.

Referring to fig. 7, when an external impact force (or a shearing force) impacts the assembly 99 or the helmet structure 100, different elastic deformation amounts are respectively generated by the shell 10, the elastic structure 30 and/or the fiber layer 50, and the external impact force is commonly loaded to generate a buffering and absorbing effect, so as to reduce the displacement motion generated by the rotational acceleration of the external impact force or the lateral rotational force (including the low-gravity rotational impact force), and the displacement motion is dispersedly transmitted to the whole assembly 99 or the helmet structure 100, so as to buffer and absorb, reduce the acceleration and the torsion generated by the external impact force, and reduce or reduce the occurrence of brain injury.

And an effect of assisting the structural characteristics of the housing 10 to return to the original assembled position as much as possible by the tensile elastic force (or the resilient force) of the elastic structure 30 and/or the conjugate fiber layer 50 after the external impact force disappears.

Compared to the conventional rubber shell structure of the safety helmet, the combination of the shell 10 and the fabric layer 50 is helpful to increase the elastic force of the shell 10, and is also beneficial to form a better structural strength of the shell 10, the elastic structure 30 and/or the assembly 99 for loading the external impact force.

Typically, the method of manufacturing the rubber-reinforced safety helmet and the helmet structure made by the method include the following advantages and considerations over the older method:

1. the combined structure of the housing 10, the fabric layer 50 (and/or the elastic structure 30) has been redesigned; for example, application jobs

(and/or operation D) to generate a stable combination of the fiber layer 50 of the primary body 40 and the housing 10, which is not only easy and convenient to manufacture, but also changes the manufacturing and processing types of the prior art, and is different from the prior art; moreover, the structure is beneficial to the subsequent operation of forming the helmet structure and the like, and is obviously different from the structural form of the existing safety helmet.

2. At least partial area of the shell 10 is combined with or enters into the structural organization of the fiber layer 50, so that the fiber layer 50 forms a tension state along the contour of the shell 10, and can generate an elastic reaction force or a rebound effect when external force impacts the shell 10, so that the shell further conforms to the effects of manufacturing simplification and light and thin design of a helmet under the condition of having ideal structural strength; and the function of complementing structural strength is generated between the helmet body and the helmet body, so that the thickness, the weight, the volume and the like of the helmet are obviously reduced.

3. In particular, the above-mentioned operation method can make the edge portion of pattern layer or cloth material be projected or can't fit the condition of rubber shell contour, and can reduce as far as possible, and can improve the conditions of that the existent helmet contour and pattern layer or cloth material are not smooth, and can produce wrinkle, and its processing or making process is time-consuming, and needs lots of skilled manual work, and its reject ratio and material cost are high.

The above description is only for the purpose of illustrating the present invention and is not intended to limit the scope of the present invention, which is defined by the appended claims.

Claims

1. A method for manufacturing a safety helmet rubber shell reinforcement is characterized by comprising the following steps:

procedure (A) for providing at least one fibrous layer (50) and at least one shell (10); the shell (10) is made into a flat plate structure; the fiber layer (50) and the shell (10) respectively have a first surface (51, 11) and a second surface (52, 12);

a step (B) of providing a combined operation of attaching the first face (51) of the fiber layer (50) to the second face (12) of the housing (10) to form the primary body (40);

the process (C) provides a molding operation, the first molding module (60) heats and presses the primary body (40), the shell (10) at least partially penetrates into the fiber layer (50) to form the primary body (40) in a bonding state, and the primary body (40) forms a helmet-shaped assembly (99).

2. The method of claim 1, wherein the process (C) is followed by a process (D) of providing a foam bonding operation, disposing the foam material in the assembly (99), forming the foam material into the elastic structure (30) with the second molding module (65), and filling the coupling assembly (99) to form a helmet structure (100).

3. A method of manufacturing a safety helmet shell reinforcement according to claim 1 or 2, wherein the primary body (40) of the process (B) is pressurized by means of a module (45), and the auxiliary fiber layer (50) is attached to the shell (10).

4. A method of manufacturing a safety helmet shell reinforcement according to claim 1 or 2, wherein the adhesive (44) is disposed between the first face (51) of the fiber layer and the second face (12) of the shell in the process (B), and the auxiliary fiber layer (50) is attached to the shell (10).

5. The method for manufacturing a rubber-shell reinforcement for a safety helmet according to claim 1 or 2, wherein the process (C) inserts the texture of the surface of the shell (10) into the fiber layer (50) and expands the texture of the fiber layer (50) to form a tense state of the fiber layer (50) along the contour of the surface of the shell (10).

6. The method for manufacturing a rubber-shell reinforcement for a safety helmet according to claim 3, wherein the process (C) inserts the texture of the surface of the shell (10) into the fiber layer (50) to expand the texture of the fiber layer (50) so that the fiber layer (50) is in a tense state along the contour of the surface of the shell (10).

7. The method for manufacturing a rubber-shell reinforcement for a safety helmet according to claim 4, wherein the process (C) inserts the texture of the surface of the shell (10) into the fiber layer (50) to expand the texture of the fiber layer (50) so that the fiber layer (50) is in a tense state along the contour of the surface of the shell (10).

8. The method for manufacturing a rubber-shell reinforcement for safety helmets according to claim 1 or 2, wherein the thickness of the shell (10) is made of a plate of 0.5mm to 2.0 mm.

9. The method for manufacturing a rubber-shell reinforcement for safety helmets according to claim 5, wherein the thickness of the shell (10) is made of a plate of 0.5mm to 2.0 mm.

10. A helmet structure made by the method of manufacturing a safety helmet rubber shell reinforcement according to claim 1, comprising:

a combination of a housing (10) and a fibrous layer (50) disposed on the housing (10);

the shell (10) has at least a partial surface texture which enters the fiber layer (50) and is defined in a bonding state.

11. Helmet structure in accordance with claim 10 characterised in that the fibre layer (50) is applied in the form of a plurality of sheets joined to form a single fibre layer (50).

12. Helmet structure in accordance with claim 10 or 11 characterised by the fact that the shell (10) is connected to the structure of a whole shell (10) by means of a plurality of plates.

13. Helmet structure in accordance with claim 10 or 11 characterised in that the fibre layer (50) is tensioned along the contour of the surface of the shell (10); an elastic structure (30) made of a foam material is provided on the inner surface of the shell (10) to constitute a helmet structure (100).

14. Helmet structure according to claim 12 characterised in that the fibrous layer (50) is stressed along the contour of the surface of the shell (10); an elastic structure (30) made of a foam material is provided on the inner surface of the shell (10) to constitute a helmet structure (100).