The Designs and Testing of Biodegradable Energy-Absorbing Inserts for Enhanced Crashworthiness in Sports Helmets

This article addresses manufacturing structures made via injection molding from biodegradable materials. The mentioned structures can be successfully used as energy-absorbing liners of all kinds of sports helmets, replacing the previously used expanded polystyrene. This paper is focused on injection technological tests and tensile tests (in quasi-static and dynamic conditions) of several composites based on a PLA matrix with the addition of other biodegradable softening agents, such as PBAT and TPS (the blends were prepared via melt blending using a screw extruder with mass compositions of 50:50, 30:70, and 15:85). Tensile tests showed a positive strain rate sensitivity of the mixtures and a dependence of the increase in the ratio of the dynamic to static yield stress on the increase in the share of the plastic component in the mixture. Technological tests showed that increasing the amount of the plasticizing additive by 35% (from 50% to 85%) results in a decrease in the minimal thickness of the thin-walled element that can be successfully injection molded by about 32% in the case of PLA/PBAT blends (from 0.22 mm to 0.15 mm) and by about 26% in the case of PLA/TPS blends (from 0.23 mm to 0.17 mm). Next, the thin-walled elements (dimensions of 55 × 55 × 20 mm) were manufactured and evaluated using a spring-loaded drop hammer. The 60 J impact energy was tested in accordance with the EN 1078 standard. The dynamic crushing test included checking the influence of the materials' temperature (-20, 0, 20, and 40 °C) and the impact velocity. It was proven that the maximum deflection increases with increasing material temperature and an increase in the share of the plastic component in the mixture. The PLA15PBAT85 blend was selected as the most effective material in terms of its use as an energy-absorbing liner for sport helmets. Johnson-Cook and Cowper-Symonds material plasticizing models were constructed. Their use during dynamic FE simulation provided results that were in good agreement with those of the conducted experiment.