DESIGN THINKING METHODOLOGY FOR ENHANCED PROTECTION IN SPORTS AND TWO-WHEELER HELMETS USING HONEYCOM

Abstract

Abstract Motorbike riders are among the most susceptible road users. The improvement of the protection offered by motorcycle helmets through the use of non-conventional energy-absorbing materials could significantly reduce the number of motorcyclist fatalities. Their structure and protective capacity are altered in highenergy impacts. Besides their energy-absorption capability, their volume and weight are also important issues, since higher volume and weight increase the injury risk for the user's head and neck. Every year many workers are killed or seriously injured in the construction industry as a result of head injuries. Wearing an inappropriate safety helmet significantly reduces the risk of injury or even death. Protective headwear could save your life. At present strength of the helmet-using industry is less due to improper filling of material, uneven pressure distribution, and blow holes. The development aims to increase the strength of industrial helmets by' making the modified material in existing ones. Very purpose, shock absorbers such as honeycomb structures can be applied for crashworthiness improvement and the graded honeycomb structure is primarily introduced as a shock absorber, followed by the introduction of its absorbed energy and the force and acceleration applied to the occupant. This investigates the coupling of hexagonal aluminum honeycomb with polymeric foams for the design of innovative and safer motorbike helmets. The structure of the helmet will be modeled using ANSYS software and according to Indian standard IS 9844 to simulate head impact by various initial velocities. The experimental findings are later used to validate a finite element model of the prototype will be tested for improvement of energy absorption rate and will be validated.

Specification

FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See Section 8, rule 13)

NAME OF THE APPLICANTS & INVENTORS
DESIGN THINKING METHODOLOGY FOR ENHANCED PROTECTION IN SPORTS AND TWOWHEELER
HELMETS USING HONEYCOMB STRUCTURE
Name Nationality Address
Mr.K.NEHRU An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AEROSPACE ENGINEERING,
SNS COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641035.
Mr.M.RAMESH An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AEROSPACE ENGINEERING,
SNS COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641035.
Dr.A.ARUN NEGEMIYA An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AEROSPACE ENGINEERING,
SNS COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641035.
Mr.N.VENKATESH An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AEROSPACE ENGINEERING,
SNS COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641035.
Mr.T.KUMARASAN An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AERONAUTICAL ENGINEERING,
J.J. COLLEGE OF ENGINEERING AND TECHNOLOGY,
AMMAPETTAI, TIRUCHIRAPPALLI - 620009.
Dr.P.VIJAYAKUMAR An Indian
National
ASSOCIATE PROFESSOR
DEPARTMENT OF AERONAUTICAL ENGINEERING,
NEHRU INSTITUTE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), THIRUMALAYAMPALAYAM, COIMBATORE-
641105.
Mr.PJERMIA AROCK1A
PRAVIN
An Indian
National
ASSISTANT PROFESSOR
DEPARTMENT OF AERONAUTICAL ENGINEERING,
J.J. COLLEGE OF ENGINEERING AND TECHNOLOGY,
AMMAPETTAI, TIRUCHIRAPPALLI - 620009.
Dr.K.SUNDARARAJ An Indian
National
PROFESSOR,
DEPARTMENT OF AERONAUTICAL ENGINEERING,
KUMARAGURU COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641049.
Dr.M.SUBRAMANIAN An Indian
National
PROFESSOR
DEPARTMENT OF AEROSPACE ENGINEERING,
SNS COLLEGE OF TECHNOLOGY (AN AUTONOMOUS
INSTITUTION), SARAVANAMPATTI, COIMBATORE - 641035.

DESCRIPTION
Enhanced Impact Protection: Integrate honeycomb structures with Expanded Polystyrene (EPS) foams to improve energy absorption and shock dissipation.
Design Thinking: Empathize, Define, Ideate, Prototype and Test
Simulation and Analysis: Utilize CATIA, and FEA in ANSYS to model head impacts under various conditions, ensuring optimal protection.
Materials: Glass Fiber Reinforced Polymer, Epoxy Resin Ly566, Epoxy Harder Hy951, Wax Compliance with Safety Standards: Ensure the helmet design adheres to industry safety regulations such as IS 9844 for motorbike helmets.
Prototyping and Testing: Fabricate prototype helmets and perform physical impact tests to validate energy absorption and structural performance.

BACKGROUND ART
The energy absorption properties of two-layered materials made of EPS foams and aluminum honeycomb were assessed experimentally. The next step is the application of the two-layered material concept to the production of innovative and safer helmets. In this chapter, the impact response of a modified version of the AGV Gp-Tech helmet manufactured by Dainese SpA (Italy, a partner of the MYMOSA network), and here referred to as prototype, was investigated following UNECE 22_05 (2002) standards for testing helmets. The same tests were performed on unmodified Gp-Tech helmets, presenting the same dimensions, material properties, and overall weight. The dynamic responses of both the helmet typologies were compared, and the recorded Peak Linear Acceleration (PLA) and Head Injury Criterion (HIC) were used as evaluation criteria. In addition to the assessment of the shock absorption properties, the aim of this study was the collection of validation data for the FE modeling of honeycomb- reinforced helmets. The un-modified helmets tested in this investigation, which already meet the relevant standard, consisted of a fiber-reinforced outer shell, a multi-density foam energy absorbing liner, two- lateral cheek pads, a protective chin moulding pad, and a retention system.

NOVEL SYSTEM AND METHOD
> By combining honeycomb structures with polymeric foams, the helmet achieves higher energy absorption capacity and better shock attenuation. This innovative design significantly reduces the risk of traumatic brain injury (TBI) by limiting the acceleration of the head during impact.
> The modular nature of the honeycomb structure allows for easy customization of the helmet's protection zones, providing optimized safety for various activities and head shapes.
> The honeycomb composite significantly reduces the helmet's weight, improving comfort during prolonged use, without compromising the protective capabilities of the helmet.

CLAIMS:
1. A novel helmet design comprising a composite structure
2. Use of honeycomb material for energy dissipation and weight optimization
3. Customized helmet protection zones

4. Integration of polymeric foams for enhanced shock absorption

5. Method of computational analysis using Finite Element Analysis (FEA)

6. Impact.testing validation for helmet safety performance

7. Compliance with safety standards

8. Adaptive helmet structure for customization

9. Helmet system offering superior comfort and performance

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