TWI849666B - A manufactur method of carbon fiber safety helmet structure - Google Patents

Abstract

A manufacture method of carbon fiber safety helmet structure, which is composed by at least one metal mesh layer, at least one inner carbon fiber cloth layer pasted on the inner surface of said metal mesh layer, and at least one outer carbon fiber cloth layer pasted on the outer surface of the said metal mesh layer.

Description

Manufacturing method of carbon fiber helmet structure

The present invention relates to a safety helmet, and more particularly to a method for manufacturing a carbon fiber safety helmet structure composed of at least one helmet shell-shaped metal mesh layer, an inner carbon fiber cloth layer adhered to the inner surface of the metal mesh layer, and an outer carbon fiber cloth layer adhered to the outer surface of the metal mesh layer.

Taiwan's unique geographical environment has resulted in more than 1 million motorcycles being registered each year. Motorcycles have long been an indispensable means of transportation in Taiwan. However, riding a motorcycle is like riding a car. A slight collision can easily cause casualties and even break up many families. In order to reduce motorcycle casualties, the government enacted a law in 1997 to require motorcycle riders to wear helmets.

The traditional helmet shell is to form the outer shell of the helmet and the inner foam cushioning body into semi-finished products and then fit them together. However, this method will cause gaps between the helmets and prevent them from fitting tightly. If the rider is hit at high speed, it will cause a secondary impact and cause more serious injuries.

Patent No. 229144 discloses an improved manufacturing method for a helmet shell. The helmet shell is also composed of an outer shell and a foamed cushion. The outer shell is made of a pressure-resistant material with a pattern painted by a vacuum forming technique, and the bottom edge of the shell is folded inward from the outside. In the manufacturing process of the helmet, a hat-shaped mold filled with foaming material is used in advance to foam in a high-temperature steam chamber. After the foam cushioning body is formed into a hat shape, the upper and lower shells are put together and placed in the same mold for secondary foaming to achieve a close-fitting molding effect. Since the foam cushioning body can be closely attached to the inner surface of the shell, and at the same time, during the manufacturing process, the secondary foaming is completed in the mold, so the surface shape and pattern of the shell after vacuum forming and coating will not be destroyed, so as to achieve the effect of safe and beautiful use of the helmet.

Patent No. 201016157 discloses a method for manufacturing a helmet shell, which comprises the following steps in sequence: (A) preparing an outer mold shell with its shell opening facing upward; (B) stacking at least one first glass fiber material on an inner shell surface of the outer mold shell, and then evenly pouring a liquid glue on the surface of the first glass fiber material, and then applying a filling (C) stacking at least one second glass fiber material on an inner surface of the first glass fiber material, and then evenly pouring a liquid glue on the surface of the second glass fiber material, and then applying an inflation heating effect to harden a second glass fiber layer that is bonded to the first glass fiber layer as a whole.

Patent No. 201019863 discloses a method for manufacturing a helmet shell, comprising the following steps: (a) preparing an outer mold shell with its shell opening facing upward; (b) filling the outer mold shell with a fiberglass unit, and taking a flow guide material with an area smaller than the inner shell area of the outer mold shell, and stacking it between the outer mold shell and the fiberglass unit, or burying it in the fiberglass unit; and (c) pouring a glue on the fiberglass unit, and applying an inflation heating effect to the glue so that the glue can be evenly diffused and hardened to completely cover the fiberglass unit and the flow guide material. It mainly uses a smaller area of diversion material to divert the adhesive, so that the helmet shell has a uniform structure of rubber coating, which can produce excellent impact resistance and puncture resistance.

Patent No. 174718 discloses a method for manufacturing a helmet shell and an inner cushioning body by close fitting molding. The method comprises a shell divided into two sections, an upper shell and an inner cushioning body filled with foam. The upper and lower shells are high pressure and impact resistant shells formed of impact resistant materials. The bottom edge of the lower shell is folded inward from the outside. The upper and lower helmet shells are first glued or solidified by high frequency, and then placed in a female mold of the same type. A male mold is inserted into the concave part of the female mold, and then the foaming material is injected from the male mold to the inner wall of the shell, filling the space in the male mold and the upper and lower shells. Then the buffer body can be tightly attached to the inner surface of the helmet shell to enhance the safety of use.

From the patents cited above, we can see that the manufacturers have different ways of manufacturing helmets, which are mainly composed of a helmet shell and a foamed cushioning body, or a helmet shell and a glass fiber layer. Although it has cushioning elasticity, the overall weight of the helmet composed of a plasticized material shell and glass fiber is still very heavy, which will cause considerable pressure on the wearer, and its force-bearing strength is often insufficient.

In view of the above-mentioned defects in conventional helmets, the inventor has finally come up with the manufacturing method of the carbon fiber helmet structure of the present invention after years of research, testing and correction.

Therefore, the main purpose of the present invention is to provide a method for manufacturing a carbon fiber helmet structure, which is composed of at least one metal mesh layer, at least one inner carbon fiber cloth layer adhered to the inner surface of the metal mesh layer, and at least one outer carbon fiber cloth layer adhered to the outer surface of the metal mesh layer.

The second purpose of the present invention is to provide a method for manufacturing a carbon fiber helmet structure, wherein the inner carbon fiber cloth layer is formed by a plurality of carbon fiber cloth strips stacked up and down and cross-glued to each other.

In order to help the review committee members to have a deeper understanding of the purpose, shape, structural device features and functions of the present invention, the following examples are given with diagrams to explain the structure of the present invention in detail as follows:

100: Carbon fiber helmet

200:Metal mesh layer

300: Inner carbon fiber cloth layer

400: Outer carbon fiber cloth layer

210:Metal grid

220: Cap shell mold

230: External force

240: Cap shell mold cavity

310: Inner carbon fiber cloth layer

410: Outer carbon fiber cloth layer

500: Carbon fiber cloth

510, 510a: first carbon fiber cloth strip

520, 520a: second carbon fiber cloth strip

530, 530a: The third carbon fiber cloth strip

600: Epoxy resin adhesive

710: Inner layer of full-piece carbon fiber cloth

720: Outer layer of whole piece carbon fiber cloth

800: Straps

810, 820: Metal mesh layer

910, 920, 930: Carbon fiber cloth layer

940: Finished hat shell

T:Cap

Figure 1 is a cross-sectional schematic diagram of the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 2 is a schematic diagram of the molding of the metal mesh layer of the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 3 is a three-dimensional schematic diagram of the bottom surface of the metal mesh layer of the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 4 is a three-dimensional schematic diagram of the top of the metal mesh layer of the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 5 is a schematic diagram of the carbon fiber cloth being divided into strips in the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 6 is a schematic diagram of the process of attaching the carbon fiber cloth to the inner surface of the metal mesh layer in the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 7 is a schematic diagram of the process of attaching the carbon fiber cloth to the outer surface of the metal mesh layer in the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 8 is a schematic diagram of the manufacturing method of the carbon fiber helmet structure of the present invention, in which the inner layer of the whole carbon fiber cloth is attached to the inner surface of the inner carbon fiber cloth layer.

Figure 9 is a schematic diagram of the manufacturing method of the carbon fiber helmet structure of the present invention, in which the outer layer of the whole carbon fiber cloth is attached to the outer surface of the outer carbon fiber cloth layer.

Figure 10 is a three-dimensional schematic diagram of the manufacturing method of the carbon fiber helmet structure of the present invention, in which the strap is attached to the outer surface of the helmet brim.

Figure 11 is a cross-sectional schematic diagram of the second embodiment of the manufacturing method of the carbon fiber helmet structure of the present invention.

Figure 12 is a schematic diagram of the second embodiment of the metal mesh layer forming method of the carbon fiber helmet structure manufacturing method of the present invention.

The manufacturing method of the carbon fiber helmet structure of the present invention is shown in Figure 1. The carbon fiber helmet 100 is composed of at least one metal mesh layer 200, at least one inner carbon fiber cloth layer 300 adhered to the inner surface of the metal mesh layer 200, and at least one outer carbon fiber cloth layer 400 adhered to the outer surface of the metal mesh layer 200. The carbon fiber helmet 100 thus composed is not only light in weight, but also has excellent endurance strength and will not cause pressure on the wearer's head.

Please refer to FIG. 2 for the manufacturing method of the carbon fiber helmet structure of the present invention. When manufacturing the metal mesh layer 200, a flat metal grid 210 made of metal materials such as aluminum wire, iron wire or stainless steel wire is first placed on top of a shell mold 220, and then an external force 230 is applied to the metal grid 210 so that the metal grid 210 is uniformly pressed into the shell mold cavity 240 of the shell mold 220, thereby manufacturing a shell-shaped metal mesh layer 200 as shown in FIG. 3 or FIG. 4.

The manufacturing method of the carbon fiber helmet structure of the present invention can use a plain woven carbon fiber cloth, a woven carbon fiber cloth, a Kevlar fiber cloth or an open woven carbon fiber cloth. Different grades of carbon fiber with a modulus of 100~500GPa can be used.

After the cap-shaped metal mesh layer 200 is formed, as shown in FIG. 5, a whole piece of carbon fiber cloth 500 is cut to be divided into a plurality of long carbon fiber cloth strips 510, 520, 530..., and then epoxy resin adhesive 600 is sprayed on the upper surface of each carbon fiber cloth strip 510, 520, 530..., and after about 1 to 5 minutes, when the epoxy resin adhesive 600 on the surface of each carbon fiber cloth strip 510, 520, 530... has a suitable viscosity, it is pasted.

Please refer to FIG. 6 for the manufacturing method of the carbon fiber helmet structure of the present invention. During the manufacturing process, the inner surface of the metal mesh layer 200 is firstly pasted. During pasting, the top T of the metal mesh layer 200 is used as the cross center, and the first carbon fiber cloth strip 510 is first pasted along the inner surface of the metal mesh layer 200 by passing through the top T. Since the carbon fiber cloth strip is in the shape of a long strip, the worker can ensure that the first carbon fiber cloth strip 510 is evenly pasted on the inner surface of the metal mesh layer 200 to avoid the generation of wrinkles.

Secondly, the second carbon fiber cloth strip 520 is similarly pasted along the inner surface of the metal mesh layer 200 through the cap top T, so that the second carbon fiber cloth strip 520 and the first carbon fiber cloth strip 510 are overlapped and crossed at the cap top T position. Similarly, the long strip carbon fiber cloth strip can be easily and evenly pressed to the inner surface of the metal mesh layer 200 to avoid the generation of wrinkles.

Then, the third carbon fiber cloth strip 530 is attached to the inner surface of the metal mesh layer 200 from the gap between the second carbon fiber cloth strip 520 and the first carbon fiber cloth strip 510. The third carbon fiber cloth strip 530 and the second carbon fiber cloth strip 520 and the first carbon fiber cloth strip 510 are also stacked up and down and cross each other at the top T position. In this way, each carbon fiber cloth strip 510, 520, 530... is stacked up and down and crosses each other, and is attached to the inner surface of the metal mesh layer 200 one by one, forming an inner carbon fiber cloth layer 310 composed of a plurality of carbon fiber cloth strips stacked up and down and crosses each other.

Since the inner surface of the metal mesh layer 200 is an irregular curved surface, through such sequential attachment operations, it can be ensured that each carbon fiber cloth strip 510, 520, 530... can be firmly pressed and attached to the inner surface of the metal mesh layer 200, and wrinkles between the carbon fiber cloth strips 510, 520, 530... can be avoided when there are multiple layers of inner carbon fiber cloth, which will affect the manufacturing quality and strength of the helmet shell.

Please refer to FIG. 7. After the inner carbon fiber cloth layer 310 is bonded to the inner surface of the metal mesh layer 200, the carbon fiber cloth strips can be bonded to the outer surface of the metal mesh layer 200. During bonding, the first carbon fiber cloth strip 510a, the second carbon fiber cloth strip 520a and the third carbon fiber cloth strip 530a are similarly overlapped and cross-linked at the top T position with the top T of the metal mesh layer 200 as the intersection center, and are bonded to the outer surface of the metal mesh layer 200 one by one, forming an outer carbon fiber cloth layer 410 composed of a plurality of carbon fiber cloth strips.

In the manufacturing method of the carbon fiber helmet structure of the present invention, the inner carbon fiber cloth layer 300 attached to the inner surface of the metal mesh layer 200 can be composed of a plurality of inner carbon fiber cloth layers 310. The outer carbon fiber cloth layer 400 attached to the outer surface of the metal mesh layer 200 can also be composed of a plurality of outer carbon fiber cloth layers 410.

When the inner surface or outer surface of the metal mesh layer 200 is respectively completed with the majority of inner carbon fiber cloth layers 310 and the majority of outer carbon fiber cloth layers 410, and it is determined that each carbon fiber cloth layer has no wrinkles, an inner layer of a whole piece of carbon fiber cloth 710 can be attached to the surface of the majority of inner carbon fiber cloth layers 310 as shown in FIG. 8, and an outer layer of a whole piece of carbon fiber cloth 720 can be attached to the surface of the majority of outer carbon fiber cloth layers 410 as shown in FIG. 9, so as to enhance the surface finishing and strength of the overall cap shell.

Please refer to FIG. 10 for the manufacturing method of the carbon fiber helmet structure of the present invention. After the inner layer of the whole carbon fiber cloth 710 and the outer layer of the whole carbon fiber cloth 720 are attached, a bundle of straps 800 can be glued and tightened on the inner surface or the outer surface of the hat edge to make the overall hat shell tighter.

Please refer to FIG. 11 for the manufacturing method of the carbon fiber helmet structure of the present invention. The metal mesh layers 810 and 820 can be two layers or more, and the metal mesh layers 810 and 820 are separated from each other. The carbon fiber cloth layers 910, 920, 930... attached to the inner surface or outer surface of the metal mesh layers 810 and 820 can also be two layers or multiple layers. The number of layers of the metal mesh layers 810, 820 or the carbon fiber cloth layers 910, 920, 930... can be adjusted according to different uses or places.

Please refer to FIG. 12 , the manufacturing method of the carbon fiber helmet structure of the present invention can also directly use a finished helmet shell 940 available on the market as the helmet shell mold cavity of the helmet shell mold, provide a metal grid 210 and press it into the finished helmet shell 940 by external force 230 to directly form a helmet shell-shaped metal mesh layer 200.

In summary, the manufacturing method of the carbon fiber helmet structure of the present invention is indeed an unprecedented innovative structure. It has not been seen in any publication, and there are no similar products on the market. Therefore, there is no doubt that it is novel. In addition, the unique features and functions of the present invention are far beyond the common use, so it is indeed more advanced than the common use, and it meets the requirements of the application of the creation patent under the Patent Law of our country, so a patent application is filed in accordance with the law.

It should be noted that the above is a preferred specific embodiment of the present invention. If the changes made according to the concept of the present invention still do not exceed the spirit covered by the instructions and diagrams, they should be stated within the scope of the present invention.

100: Carbon fiber helmet

200:Metal mesh layer

300: Inner carbon fiber cloth layer

400: Outer carbon fiber cloth layer

Claims (4)

A method for manufacturing a carbon fiber helmet structure comprises the following steps: placing a flat metal grid made of a metal material such as aluminum wire, iron wire or stainless steel wire on top of a helmet shell mold, and then applying pressure to the metal grid by external force so that the metal grid is pressed into the helmet shell mold cavity of the helmet shell mold to form a helmet shell-shaped metal grid layer; taking a plurality of carbon fiber strips, and forming a plurality of carbon fiber strips on the surface of the plurality of carbon fiber strips. Spray epoxy resin adhesive on the surface, and then adhere the plurality of carbon fiber cloth strips to the inner and outer surfaces of the metal mesh layer in an overlapping and interlaced manner to form an inner carbon fiber cloth layer adhered to the inner surface of the metal mesh layer, and an outer carbon fiber cloth layer adhered to the outer surface of the metal mesh layer; and then adhere a whole piece of carbon fiber cloth to the outer surface of the inner carbon fiber cloth layer and the outer carbon fiber cloth layer. The manufacturing method of the carbon fiber helmet structure as described in claim 1, wherein the metal mesh layer can be two or more layers spaced apart from each other, and the inner carbon fiber cloth layer or the outer carbon fiber cloth layer can also be two or more layers respectively. The manufacturing method of the carbon fiber helmet structure as described in claim 1, wherein the helmet shell-shaped metal mesh layer can also be formed by pressing the flat metal grid into a finished helmet shell during manufacturing. The manufacturing method of the carbon fiber helmet structure as described in claim 1, wherein the plurality of carbon fiber cloth strips are cross-centered with the crown of the metal mesh layer, and are stacked up and down and cross-linked at the crown.

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