The present invention relates to a method for inan- ufacturing a helmet shell with a reflective surface for increased noticeability . The present invention also relates to a helmet shell manufactured by means of such a method. The present invention further relates to a helmet comprising such a helmet shell.

It is known to manufacture a motorcycle helmet with the purpose of giving the outer surface an increased attention value, A plurality of types of coating are used for this purpose. Stickers are also applied which are adhered to the surface of the helmet. The drawback hereof is that this is clearly not original decoration but a later decoration arranged by the user, and this detracts from the helmet. Such a sticker can also have a reflective function .

Attempts have further been made to arrange granu- lar material on a helmet shell in order to provide a reflective function. A drawback hereof is that a covering is necessary over the granular material and this limits the effect of the reflective function. Such a solution is further susceptible to damage and wear, which causes prema- ture loss of the reflective function.

In order to realize a durable and highly reflective solution the present invention provides a method for manufacturing a helmet shell with a reflective surface for increased noticeability, wherein the method comprises steps for:

- manufacturing a base material with a substantially plate shape, this base material being suitable for placing on a roll; - cutting unit quantities from the base material, this unit quantity being suitable for manufacturing at least one helmet;

- forming at least one helmet shell from the unit quantity;

- subjecting the formed helmet shell to a curing process; and

- adding reflective material in the form of reflective particles to the base material during the steps for manufacturing the base material.

A first advantage according to the present invention is that it becomes possible with this process to man ^¬ ufacture the base material in a continuous process, wherein the base material can be discharged onto a roll suita- ble for the manufacture of large numbers of helmet shells.

A further advantage of such a method according to the present invention is that a base material can be provided which is suitable for providing the desired reflective properties in the end product, and which is also de- formable in advantageous manner for the purpose of forming the end product wherein the reflective material is already firmly embedded in the base material. It hereby becomes possible to manufacture a helmet shell wherein the reflective material is present in wear-resistant manner in the helmet shell. A further advantage is that no cover layer is necessary to hold the reflective material in the helmet shell during its lifespan.

In a first preferred embodiment according to the present invention the method comprises steps for realizing that the reflective particles are situated in the end product at least partially on the surface or in directly visible manner thereunder. A highly durable reflective function is hereby achieved in advantageous manner, while also achieving that optical limitations of the reflective material are minimized.

In a further preferred embodiment the method comprises steps for realizing that the reflective particles are situated in the end product in the upper material layer of the helmet shell. This further prevents optical inhibition of the reflective properties.

The method preferably comprises steps for mixing the reflective material with a liquid or kneadable precur- sor for the base material. This provides a further possibility of improving the attachment or adhesion of the reflective material relative to the helmet shell.

A further preferred embodiment comprises steps for adding a curing component to the precursor for the base material. It hereby becomes possible to provide a deforma- ble base material in more reliable manner which, after simple shaping into a helmet shell in the soft state, can be converted to a hard state. An efficient production process hereby becomes possible, wherein the base material can be provided ready for use, including reflective material, and can later be deformed and processed into a helmet shell.

The method more preferably comprises steps for curing the base material under the influence of radiation, such as light, UV light, further electromagnetic and/or heat radiation after the step for forming the helmet shell from the unit quantity comprising the base material.

Providing heat and/or electromagnetic radiation enables an efficient and advantageous finishing of the helmet shell.

More preferably applied for the manufacture of the base material are suitable plastic materials such as PVC and PET, preferably supplemented with suitable curing components therefor. In order to provide a reflective material with a good reflection as well as positive surface properties for the end product, a further embodiment comprises steps for screening the reflective particles in order to obtain a fraction with a particle size which is optimal, such as 0.001-1 mm; 0.01-0.1 mm; 0.02-0.1 mm; 0.03-0.1 mm; 0.04- 0.08 mm; 0.04-0.06 mm; 0.02-0.06 mm; 0.04-0.07 mm; 0.05- 0.1 mm.

For the purpose of minimizing the required quanti- ty of reflective particles the method more preferably comprises steps for distributing reflective particles on a surface and arranging the precursor for the base material over the reflective particles. These steps have further advantageous effects in respect of arranging the reflec- tive particles close to the surface of the end product.

The method more preferably comprises steps for supplying a carrier material from a supply roll, arranging the precursor and the reflective material on the carrier material and discharging the carrier material with the precursor and the reflective material to a discharge roll. The base material can hereby be manufactured in efficient manner in a continuous process.

The base material is more preferably a laminate of different layers, the outer layer of which comprises the reflective material. An advantage of a laminate can be that the different layers together provide a stronger helmet shell than a single base material constructed from one material layer.

According to a further preferred embodiment, the steps for forming the helmet shell comprise vacuum drawing operations. The base material can hereby be urged by means of the vacuum force in the direction of the mould of a die preferably having the outer form of a helmet. With a cor- rect arrangement of the base material with the reflective material the reflective material will be directed towards the outside of the helmet shell after these operations have been performed.

The base material and/or the outer layer thereof more preferably comprises an adhesive and/or the base material and/or the outer layer thereof is scratch- resistant. This further increases the durability. The scratch-resistance is achieved by a suitable choice of ma- terial, such as a PVC material, a PET material, a polyester material, resins and/or for instance mixtures of these materials .

A further aspect according to the present invention relates to a method for manufacturing a base material according to the present invention and preferably arranging the base material on a roll. Advantages of this aspect according to the present invention are similar to the advantages described in respect of the above aspect and advantages as described hereinbelow with reference to pre- ferred embodiments.

A further aspect according to the present invention is a helmet shell with a reflective surface for increased noticeability, manufactured by means of a method according to one or more of the foregoing claims.

In a first preferred embodiment of this aspect the helmet shell comprises reflective particles which are situated in the end product in the upper material layer of the helmet shell and which are preferably situated partially on the surface and/or visibly thereunder.

A further aspect according to the present invention relates to a helmet comprising a helmet shell according to the present invention. Advantages of this aspect according to the present invention are similar to ad- vantages described in respect of the above aspect and advantages as described hereinbelow with reference to preferred embodiments.

The helmet according to this aspect more prefera- bly comprises a helmet shell according to the present invention in addition to a strengthening member arranged under the helmet shell, a protective member preferably comprising a foam material and a fastening member for fastening the helmet to the head.

Further advantages, features and details of the present invention will be described in greater detail hereinbelow on the basis of one or more preferred embodiments with reference to the accompanying figures.

Fig. 1 is a perspective view of a first preferred embodiment of a helmet shell according to the present invention .

Fig. 2 is a cross-sectional view of a base material according to the present invention.

Fig. 3 is a cross-sectional view of a further pre- ferred embodiment of a base material according to the present invention.

A first preferred embodiment (Fig. 1) according to the present invention relates to a helmet shell 1. This helmet shell is constructed from one or more plastic mate- rials such as a PVC material, a PET material, a polyester material, resins and/or for instance mixtures of these materials, having reflective particles for reflecting light incorporated in the visible top layer. It is important that the correct mixtures are applied for the purpose of obtaining a hard surface layer which prevents scratches. Such an anti-scratch layer is important for the durable appearance of the final helmet. A helmet according to the present invention can be modified to a motorcycle helmet, cycling helmet, sports helmet or the like. The shaping shown in the helmet shell is present for the purpose of a desirable appearance, wherein the bottoms 2 of the indentations can preferably be removed for the purpose of providing ventilation.

The reflective particles are preferably manufactured from a splintered glass having good reflective properties. Splintered glass has surface properties which are suitable for providing reflections. Splintered glass can also be manufactured and obtained very cheaply. In order to obtain a correct particle size a mixture of different particles can be filtered by means of a screen.

In the embodiment of Fig. 2 and 3 the base materi- al as according to claim 1 is indicated by the material within the designation or bracket 10.

Fig. 2 shows a cross-section of a base material of a helmet shell according to the present invention. Base material 12 is provided on at least the surface with glass splinters 11 for the purpose of providing the reflective properties. The base material is provided on the underside with an optional imprint 13 for the purpose of providing a background colour or a design that is visible on the outside. This also achieves that the reflection created by the incidence of white light acquires substantially the appearance of the background print colour of imprint 13. In the variant of Fig. 2 this layer 12 is supplied from a supply roll to a processing location where the glass splinters are added. Alternatively, it is possible for layer 12 to be formed from a mass prior to or at the location where the glass splinters are added.

Fig. 3 shows a further preferred embodiment. This preferred embodiment is also provided with a carrier mate- rial 14 arranged under an adhesive layer 12 holding glass splinters 11. An auxiliary layer 15 such as a primer is optionally present between these layers 12, 14. Layers 12, 14 and 15 together form the base material as according to claim 1 of this text. An advantage of the embodiment according to Fig. 3 is that a carrier material 14 can be supplied on a roll to a location where layer 12 with the glass splinters is arranged. An optional imprint is once again present on the underside for colouring purposes.

In alternative manner the carrier material can be a for instance gauzy, mesh-like material into which the material layer 12 penetrates.

In all embodiments at least the layer 12 is a mixture of basic substances and curing components, which com- bination will, after forming of base material 10, be cured to a form corresponding to the helmet shell under the influence of heat and/or electromagnetic radiation. Layer 14 is also flexible for ^' the purpose of forming the helmet shell. The choice of material for said layers may be per- formed within understanding of the present invention for the skilled person.

Once the base material has been formed and is available on the discharge roll, the discharge roll being used for storage and transport, the discharge roll is used as supply roll for a cutting process for the purpose of dividing the base material into units for the manufacture of individual helmets or groups of helmets. The method for manufacturing the base material for the units for manufacturing individual helmets therefore provides a very effi- cient production process, wherein both the reflective layer and the imprint can be realized. The imprint can be arranged before arrangement of layer 12 as well as after arrangement of layer 12 or forming of layer 12 depending on the process as described above. It is also possible to arrange the print layers after curing of the helmet shell.

After shaping of the base material to the shown form of the helmet shell, this latter is cured under the influence of temperature and/or electromagnetic radiation. The helmet shell is then ready for further processing to a helmet. It is possible here to remove parts 2 from the helmet shell for the purpose of ventilation. Further operations for the manufacture of the helmet, such as arrang- ing soft material as lining and fastening material for the purpose of fastening the helmet to the head, are per se known to the skilled person in the field of the manufacture of helmets.

For the present invention it is important that glass splinters can be arranged in the top layer against or close to the surface thereof, wherein a continuous process is preferably made possible in which the base material can be discharged onto a roll.

The present invention has been described in the foregoing on the basis of several preferred embodiments. Different aspects of different embodiments are deemed described in combination with each other, wherein all combinations which can be deemed by a skilled person in the field as falling within the scope of the invention on the basis of reading of this document are included. These preferred embodiments are not limitative for the scope of protection of this document. The rights sought are defined in the appended claims .