Brock’s new foam technology

Research about foam bead technology has been completed by Brock USA. The light feature of this process is to use polymer spheres that have a closed-cell structure. These spheres’ size must be between 2-7mm in diameter. Besides, an elastomeric coating is also added to the foam in order to increase the impact absorption. 

polymer spheres

This foam is then used to make the liner of helmets, and usually can be found in both single-impact helmets like motorcycle helmets and multiple-impact helmets such as hockey helmets. 

Either polyethylene or polypropylene spheres with different densities mixing with Brock’s foam helps the helmet liner works more effectively in absorbing external forces than mono-density foam.

Although thousands of microspheres used to make helmet liner and other protective gears seem directly connect with one another, the protective barriers appear to have air pockets. Both plastic and elastic deformations are used against external forces by the foam. This is one of the features that makes Brock become unique among others in the shock pads industry.

The Brock’s vice president of product development, Dave Bainbridge, shared, the function of the elastic coating is shown the most clearly when the helmets or pads suffer an impact. The hardness of the liner is directly proportional to the level of the impact energy. While a soft liner is more likely used against low-energy impact, the harder liner is desirable for high-energy impact. It is proved that Brock’s foam is an ideal material to make helmets and pads serving adventure sports. 

Another outstanding feature of this technology is the ability to cool the body by reducing unwanted agents that cause the pad to overheat. This material helps fresh air gets inside and promotes the evaporative cooling system thanks to abundant air channels.

Brock’s new technology has several benefits. It not only brings to wearers the best experience during strenuous exercise but it also shields users from injuries related to heat, for example, heat stroke or exhaustion. 

To produce standard foam, the Brock has to precisely control the mix ratio between ingredients. Therefore, all components of the two-part formulation can be delivered with perfect quantities. Nor do they ignore small numbers like a few grams in a short amount of time in seconds.

Fluid Research Corporation is the equipment contributor of Brock. With this new equipment, the manufacturing process becomes much simpler and more accurate. The advanced cavity pump technology eliminates basic errors when mixing materials. Its operation is also preprogrammed, so the machine can run without reprogramming after each production session.

progressive cavity pump technology

According to Bainbridge, the system has helped a lot in manufacturing different types of foam with different density. Manufacturers can save time for materials supply and program changes.

The fundamental ingredients in the foam is a two-part urethane. One of the two components has a filler. Maintaining stability and controlling constant dispersion are implemented by a material management unit through heating and recirculating the formulation.

When the machine stops working, the materials will not be trapped but will be transferred back to the feed tank to be stirred and prepared for the next cycle. Therefore, the situation where the material is not well mixed will never appear. Material containers supplied during the production process are also exchanged without adding any air into the system.

The supply containers operate separately from the system so they can be replaced without compromising the manufacturing process. 

Well, that is how the liner of motorcycle helmets, in particular, and other helmet and pads, in general, were made. We have more informative articles like this in Motorcycle Helmet information, you can visit and read on your own.

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