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研究生： 陳良軒
Chen, Liang-Hsuan
論文名稱： 基於有限元素分析之機車安全帽蜂巢結構緩衝層防護效能最佳化設計
An Optimal Design on Honeycomb Structure Liners to Increase the Protective Capability of the Motorcycle Helmet Based on Finite Element Analysis
指導教授： 黃才烱
Huang, Tsai-Jeon
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2026
畢業學年度： 114
語文別： 中文
論文頁數： 128
中文關鍵詞： 機車安全帽 、有限元素分析 、田口方法 、蜂巢結構 、頭部傷害指標
外文關鍵詞： Motorcycle helmet, Finite element analysis, Taguchi method, Honeycomb structure, Head injury criterion
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    • 台灣機車事故中頭部外傷為騎士致死主因。市售安全帽多採單一密度發泡聚苯乙烯（EPS）作緩衝層，面臨低速過硬無法潰縮、高速易提早緻密化之防護兩難。為突破此物理限制，本研究提出結合蜂巢幾何拓樸與CF45 黏彈材料之新型雙材料複合緩衝層設計，期望透過空間段差引導漸進式潰縮，全面提升綜合防護效能。
    本研究整合逆向工程、有限元素動態模擬與田口方法進行系統化分析。依據UNECE 22.06 規範建構測試邊界，以「蜂巢孔徑」、「蜂巢壁厚」與「CF45 填入深度」為控制因子，導入𝐿9 (34) 直交表，於LS-DYNA 中執行6.0、7.5 及8.2 m/s 三種初速之落樁衝擊模擬。
    變異數分析結果確認「填料置入深度」為影響頭部傷害指標（HIC）之首要關鍵因子。經推導最佳化之改造組參數（孔徑35 mm、壁厚8 mm 及填入深度17.5 mm），並與傳統全EPS 基準組比對，改造組於三種初速下之峰值線性加速度（PLA）降低了16.77% 至27.53%，HIC 更呈現35.93% 至45.13% 之巨幅改善。由力量-位移（F-D）曲線證實，此設計成功拉長了緩衝變形位移，並藉CF45 遲滯效應耗散動能以平緩衝擊波形。本研究在不增加整體厚度的前提下，將幾何空間的吸震利用率最大化，具體驗證了此複合配置於防護工程之卓越價值。

    This study proposes an optimal design for a novel composite motorcycle helmet liner to overcome the limitations of traditional single-density expanded polystyrene (EPS) liners,which struggle to provide balanced protection across varying impact energies. By integrating a hexagonal honeycomb topology with a viscoelastic damping material (CONFOR™ Foam 45, CF45), a progressive energy absorption mechanism was established. Finite element analysis (FEA) using LS-DYNA was employed to simulate drop-test impacts at 6.0, 7.5, and 8.2 m/s against a flat anvil, adhering to the UNECE 22.06 standard. The Taguchi method and analysis of variance (ANOVA) were applied to optimize geometric parameters. Results revealed that the CF45 filling depth is the most critical factor influencing the Head Injury Criterion (HIC). The optimized composite liner demonstrated a significant reduction in peak linear acceleration (PLA) and HIC, alongside an increase in total energy absorption across all tested velocities compared to the conventional EPS baseline. Analysis of force-displacement curves confirmed that the composite design effectively prolonged the crushing displacement and utilized mechanical hysteresis to dissipate kinetic energy, significantly enhancing overall head protection.

    中文摘要 I Abstract II 誌謝 VI 目錄 VII 表目錄 XI 圖目錄 XIV 符號說明 XVII 第一章 緒論 1 1.1 研究背景 1 1.2 研究動機與目的 4 1.3 論文架構 6 第二章 文獻回顧 8 2.1 安全帽之簡介 8 2.1.1 安全帽之防護機制之演進 8 2.1.2 安全帽種類與介紹 10 2.2 安全帽標準規範與測試設備 11 2.2.1 常見安全帽標準規範與衝擊測試比較 12 2.2.2 衝擊測試設備與組件 15 2.3 人類頭部解剖學與傷害機制 19 2.3.1 顱骨之幾何構造與物理特性 19 2.3.2 顱內結構與腦組織 20 2.3.3 頭部傷害機制與防護評估指標 21 2.3.4 測試頭型之幾何簡化 25 2.4 緩衝結構之吸能機制與探討 26 2.4.1 EPS 發泡材料之緩衝特性與限制 27 2.4.2 幾何拓樸與蜂巢結構 28 2.4.3 黏彈材料特性與多材質空間配置之影響 31 2.4.4 實驗設計法（DOE）於幾何參數優化之應用 33 第三章 研究方法 35 3.1 幾何建模與法規測試環境建構 35 3.1.1 安全帽 3D 光學掃描與逆向工程 36 3.1.2 UNECE 22.06 動態碰撞法規規範與評估指標 40 3.1.3 剛體測試頭型與鋼砧之幾何建模與選用 41 3.1.4 緩衝層之幾何建構與參數設計 44 3.2 有限元素模型建構與材料參數設定 50 3.2.1 幾何轉換與網格劃分 51 3.2.2 安全帽本體材料模型設定 52 3.2.3 剛性測試治具材料參數設定 56 3.2.4 接觸條件與全域空間定位設定 57 3.2.5 基準對照組建構與訊號濾波處理 61 3.2.6 田口方法與最佳化設計 61 3.2.7 田口方法概論與品質特性選定 62 3.2.8 控制因子與水準設定 63 3.2.9 直交表選用與實驗規劃 63 第四章 結果與討論 65 4.1 安全帽基準組測試與初步設計防護探討 65 4.1.1 安全帽基準組之碰撞測試結果 66 4.1.2 安全帽基準組之緩衝層探討 66 4.1.3 初步設計一：CF45 替換之碰撞測試結果 67 4.1.4 初步設計二：EPS 蜂巢結構之碰撞測試結果 68 4.2 田口方法 L₉(3⁴) 直交實驗結果與 S/N 比運算 69 4.2.1 L₉ 直交實驗之 PLA 與 HIC 數據 70 4.2.2 田口方法 S/N 訊號雜訊比轉換結果 72 4.3 控制因子與主效應分析（Main Effect Analysis） 75 4.3.1 控制因子對峰值線性加速度（PLA）之影響趨勢 76 4.3.2 控制因子對頭部傷害指標（HIC）之影響趨勢 79 4.4 變異數分析（Analysis of Variance, ANOVA） 82 4.4.1 PLA 之變異數與絕對貢獻度分析 83 4.4.2 HIC 之變異數與絕對貢獻度分析 85 4.5 最佳化參數組合與綜合防護效能評比 87 4.5.1 最佳化模型之重建與模擬驗證 87 4.5.2 峰值線性加速度與頭部傷害指標對比分析 89 4.5.3 頭型質心加速度分析 91 4.5.4 能量吸收機制分析 93 第五章 結論與未來展望 96 5.1 結論與未來建議 96 5.1.1 研究結論 96 5.1.2 未來研究方向與建議 97 參考文獻 98 附錄 A ECE22.06 測試頭型球座標數據表 103 附錄 B 傳統 EPS 緩衝層動態變形歷程 104 附錄 C 最佳化緩衝層設計動態變形歷程 107

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