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Modern American football helmets generally have a thermoplastic polycarbonate outer shell - Leaving Cert Engineering - Question a - 2020
Question a
Modern American football helmets generally have a thermoplastic polycarbonate outer shell. They also have an expanded polystyrene foam (EPS) internal liner. These he... show full transcript
Worked Solution & Example Answer:Modern American football helmets generally have a thermoplastic polycarbonate outer shell - Leaving Cert Engineering - Question a - 2020
Step 1
Name and describe, with the aid of a diagram, a polymer manufacturing process suitable for the mass production of the polycarbonate outer shell of the helmet.
Answer
The suitable polymer manufacturing process for the mass production of the polycarbonate outer shell is Injection Moulding.
Description: In this process, granulated thermoplastic polymer is fed into a barrel from a hopper. The screw within the barrel moves the polymer forward while heaters melt it into a liquid. Once the polymer reaches a sufficient consistency, a ram injects it into a mould to form the desired shape. This process is commonly used for producing items like children's toys, plastic chairs, food boxes, and, in this case, football helmet shells.
Diagram:
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Step 2
Outline two benefits of the use of expanded polystyrene foam (EPS) as a material for the inside liner of the helmet.
Answer
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Dissipates Shock: EPS effectively absorbs and dissipates impact energy, reducing the risk of injury to the player during a collision.
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Lightweight: The material is lightweight, allowing for a comfortable fit without adding unnecessary bulk to the helmet.