SIMPSON – HANS DEVICE


APPLICATION:

Motorsports. Head and neck safety device.

PREVIOUS LIMITING TECHNOLOGY:

Fiberglass/plastic molding.

CHALLENGE:

To create a lightweight head/neck restraint device that can be worn by a racecar driver during competition without limiting head mobility/visibility/fatigue/comfort. It had to withstand up to 10 G frontal impact without failure. Limited and very specific ultimate failure position allowed at even the highest of loads. High gloss, retail show quality surface required with in-molded graphics capable of withstanding acetone/high octane fuel environment.

SOLUTION

Standard and intermediate modulus carbon fiber/epoxy composite bladder molded structure weighing less than one pound (390 gms). It fits like a collar around the neck and beneath the shoulder safety straps tethering onto the back and sides of the helmet. Worldwide sales in the tens of thousands of units saving many, many drivers’ lives!

Image shows HANS device in production. Location is a manufacturing area with a row of large metal tools, with the shape of the HANS device embedded, sitting on a table top. The tool in the foreground has plys of prepreg laid up in the tool. Behind this, a technician is working on another tool, preparing the mold for processing.
Image shows the head and neck safety device in its tool in a production environment. The composite bladder molded structure has not been removed from the tool and there is resin flashing on the tool along the edges of the hardware where the tool halves met. The surface of the hardware is a high gloss carbon fiber weave.
Image shows the head and neck safety device just removed from its tool in a production environment. The composite bladder molded structure has resin flashing along the edges of the hardware where the tool halves met. The surface of the hardware is a high gloss carbon fiber weave.
Image shows three rows of completed HANS devices, placed in white slots. It is the head section of the device and includes the customer's branded graphics.
HANS device held up by a carbon fiber tube stand on a white background. Carbon fiber surface of the device is high gloss.
HANS device laying down on a white surface. The carbon fiber surface of the composite bladder molded structure is a weave with a glossy finish. This shows the head and one shoulder section.
HANS device laying down on a white surface. The carbon fiber surface of the composite bladder molded structure is a weave with a glossy finish. This image highlights the curved section, as the head and shoulder section transition to the chest panels.