MASTER'S THESIS Conceptual Design for a New Crash Pad How to Make a Small Surface Bigger and a Big Surface Smaller Peter Kroon Emma Landin Master of Science in Engineering Technology Industrial Design Engineering Luleå University of Technology Department of Business, Administration, Technology and Social Sciences Preface Numerous are the occasions when a spotter has cursed over the too small pad that constantly needs to be moved along when the bouldering mate progresses along the problem. Equal numerous are the occasions when cursed over the oversized pad that together with everything else should be fitted into the small space called trunk. With a desire and idea of achieving a change, this project was launched. We would like to take the opportunity to thank a number of persons who in different ways have been particularly helpful during the course of this project. Ben Moon at Moon Climbing for assistance over this project. Patrik Svensson, for his untiring commitment and helpful attitude. Camilla Grane, PhD Division of Work Science, LTU, for help with everything concerning the survey. Viktoria at Happy Homes for her happy manners and sponsoring of the prototypes. All the climbers participating both in the survey and the prototype tests. The Work-Shop participants for their willingness to spare some time for this important cause. Bror Tingvall, division of sound and vibrations, LTU, for assistance with the accelerometer tests. and Ernst Hellby, for great assistance with rendering models and his Photoshop skills. Peter Kroon & Emma Landin Luleå, 19th May 2011 Abstract Bouldering is a style of rock climbing without rope, often on natural boulders, hence the word bouldering. The climb is normally short and very intense, rarely higher than a few meters. As protection against injuries, a crash pad is placed on the ground, providing a shock absorbing surface for the falling climber. The size of the crash pad is an everlasting compromise between how big landing area that is needed and what is possible to transport. The purpose of this project was to investigate a partly new design for a crash pad, targeting this specific issue. The product development process started out with a pre-study, including market research, interviews and a web based-survey. The conclusion was that; when boulders buy a new crash pad, the absolutely most important features are the foam quality and size, i.e. protection against injuries. A benchmarking process was also carried out where twenty-one different medium-sized crash pads where compared in terms of size, weight, material, folding, harness system and additional features. Following the pre-study, a functional problem breakdown, ensued by a requirements list, were set up to support the product development process. The creative process started with a concept generation regarding the energy absorption. Through the Association-Discussion-Method and the Catalog Method, used within the group, as well as a Work- Shop, with non-climbing participants, a number of concept ideas were generated. In consultation with Ben Moon at Moon Climbing a Self-inflating Air-Pad Concept was selected. An information deepening process was carried out regarding theories, materials and technologies as well as trials of functional prototypes. The final concept consists of a layer of closed-cell foam on top of a self-inflating air mattress, enclosed within a common shell of durable fabric. The concept also includes an evolved harness system and graphic proposals which in addition can be adapted directly on the current range of Moon Climbing Crash Pads. The basic principle of the concept is that a part of the traditional foams shock absorption is exchanged for a controlled deflation of air, making it highly compressible and at the same time lighter, which in turn enables a pad with larger landing area, while maintaining easy handling to be used. Table of Contents 1. INTRODUCTION .......................................................................................... 9 1.1 BACKGROUND ..................................................................................................................... 9 1.2 MOON CLIMBING ................................................................................................................ 9 1.3 MOON CLIMBING CRASH PADS ..................................................................................... 10 1.4 PURPOSE AND GOAL ........................................................................................................ 10 1.5 TARGET GROUP ..................................................................................................................11 1.6 PRECONDITIONS ................................................................................................................11 1.7 DESIGN APPROACH ...........................................................................................................11 2. THEORY ....................................................................................................... 12 2.1 HONEYCOMB ..................................................................................................................... 12 2.2 SELF-INFLATING AIR MATTRESS .................................................................................. 12 2.3 PE-FOAM ............................................................................................................................. 13 2.4 PU-FOAM ............................................................................................................................. 13 2.5 FOAM HARDNESS ............................................................................................................. 14 2.6 THE DENIER SYSTEM ....................................................................................................... 14 2.7 NYLON ................................................................................................................................. 14 2.8 UNIVERSAL POWDER SNOW PREFILTER..................................................................... 14 3. METHOD ...................................................................................................... 15 3.1 PROJECT PLANNING ......................................................................................................... 15 3.2 INFORMATION GATHERING & ANALYSIS ................................................................... 15 3.2.1 Interview ........................................................................................................................ 15 3.2.2 Benchmarking ............................................................................................................... 16 3.2.3 Survey ............................................................................................................................ 16 3.3 DETERMINE THE PROBLEM ........................................................................................... 16 3.3.1 Problem Focus ............................................................................................................... 16 3.3.2 Problem Break Down .................................................................................................... 17 3.3.2.1 Functional Break Down ............................................................................................. 17 3.4 REQUIREMENTS LIST ....................................................................................................... 17 3.5 CONCEPT GENERATION ................................................................................................... 17 3.5.1 Associations-Discussion Method .................................................................................. 17 3.5.2 The Catalog Method ...................................................................................................... 18 3.5.3 Brainstorming ................................................................................................................ 18 3.5.4 Work Shop ..................................................................................................................... 18 3.6 CONCEPT EVALUATION & SELECTION ........................................................................ 18 3.6.1 Non-Methods ................................................................................................................. 18 3.7 FURTHER DEVELOPMENT ............................................................................................... 18 3.7.1 Prototypes ...................................................................................................................... 19 4. IMPLEMENTATION .................................................................................... 20 4.1 PROJECT PLANNING ......................................................................................................... 20 4.2 INFORMATION GATHERING & ANALYSIS ................................................................... 20 4.2.1 Interview ........................................................................................................................ 20 4.2.2 Benchmarking ............................................................................................................... 20 4.2.3 Survey ............................................................................................................................ 22 4.2.4 Analysis of the Moon Climbing Warrior Harness System ............................................ 24 4.3 DETERMINE THE PROBLEM ..........................................................................................