YTTERBORN, Stefan (Branta Stigen 12, Saltsjöbaden, S-133 38, SE)
WOXING, Jan (Bataljvägen 26B, Saltsjöbaden, S-133 33, SE)
YTTERBORN, Stefan (Branta Stigen 12, Saltsjöbaden, S-133 38, SE)
| CLAIMS
1. A multi sport helmet comprising an outer shell (1) and an inner vacuum formed shell (2), provided with air channels (9) between the two shells (1, 2), and a shock absorbing layer (3) present inside of the inner shell (2), through holes (6) are arranged in the combined part of the inner shell (2) and shock absorbing layer (3), which through holes (6) are open into the air channels (9) and covered by the outer shell (6), vents (6) leading into the air channels (9) are provided in the outer shell (1) and penetration protection (11) are provided at the inner shell (2) at least at areas (10), which positions correspond to the respective opposite positions of the vents (4) in the outer shell (1),
2. A multi sport helmet according to claim 1, wherein the penetration protection (11) is a net or a woven or non woven cloth.
3. A multi sport helmet according to claim 1 or 2, wherein the shock absorbing layer (3) is an in- moulded shock absorbing material.
4. A multi sport helmet according to claim 1, 2 or 3, wherein the penetration protection (11) is provided at the inside of the inner shell (2), i.e. between the inner shell (2) and the shock absorbing layer (3) .
5. A multi sport helmet according to any one of the previous claims, wherein the outer shell (1) is made of abs, polycarbonate or lexan.
6. A multi sport helmet according to any one of the previous claims, wherein the inner shell (2) is made of polycarbonate.
7. A multi sport helmet according to any one of the previous claims, wherein the penetration protection (11) is made of aramide fibres.
8. A multi sport helmet according to any one of the previous claims, wherein the shock absorbing layer (3) is made of expanded polypropylene.
9. A method for manufacturing a multi sport helmet according to any one of the previous claims, comprising the steps of - vacuum forming an inner shell (2),
- arranging penetration protection (11) at the inner shell (2) before in-moulding shock absorbing material (3) ,
- in-moulding shock absorbing material (3) inside the inner shell (2), and
- attaching an outer shell (1) at the outside of the inner shell (2 ) . |
MULTI SPORT HELMET
The present invention concerns a multi sport helmet and a method of manufacturing such a helmet.
Background information
For active people that perform a lot of different sports, requiring different types of helmets for different sports, it becomes inconvenient to buy, store and transport all the different helmets. Therefore, a lightweight, well ventilated and safe helmet is needed that can be used in multiple sports.
There are two main types of helmets on the market - in- mould helmets and hard-shell helmets.
In-mould helmets are produced by forming a sheet of, for example, polycarbonate by vacuum moulding it into a thin shell and then blow mould energy absorbing material, such as EPS, into the shell by in-mould technique. In this way, an extremely lightweight helmet is accomplished. This type of helmet is usually also provided with through holes for good ventilation of the head. The in-mould helmets are widely used in the areas of bicycling, skateboarding and when using roller blades and the like.
Hard-shell helmets differs radically from in-mould helmets, since hard shell helmets are built up by an outer hard shell of thicker polymer material, normally with a thickness in the range of 2-3,5 mm. The hard shell is injection moulded. Sometimes the hard shell is reinforced with fibres. Hard shell helmets are produced in substantially the following way. Firstly a hard shell is manufactured, which thereafter may be reinforced with for
example a layer of glass fibre laminated to the inside of the helmet. Secondly an inner energy absorbing part is produced. Thirdly the inner part is mounted inside the hard shell. And then cushioning and the like usually are applied to the inside. This type of helmet is widely used in the areas of motorcycling, skiing and the like with tougher requirements.
Standards There is a European helmet standard for helmets used in alpine sports, namely EN 1077. In-mould helmets usually do not qualify to this standard due to poor performance in penetration safety. In general, hard shell helmets qualify for this standard. There is another helmet standard for helmets for pedal cyclists and users of skateboards and roller skates, namely EN 1078. The main difference between the two standards is the penetration safety requirements of EN 1077.
Summary of the invention
The object of the present invention is to provide a lightweight, ventilated helmet that is safe enough to use in a variety of sports like skiing, snow board skiing, cycling, hiking, in different water sports and so on. Thus it ought to meet both standards, EN 1077 and EN 1078.
Preferably, it is possible to attach padding inserts for winter use in order to keep the wearer's head warm. The padding inserts are detached when the wearer would like a fully ventilated helmet.
The present object is met by a multi sport helmet according to claim 1 and it is produced in accordance with claim 9.
The basic principle of the present invention is to combine the two main types of helmets. Thus a helmet according to the invention has two shells - an outer hard shell and an inner vacuum formed shell. The essence of the invention is to strengthen at least the portions/areas of the inner shell positioned underneath the vents in the outer shell and thus provide penetration safety also at the vents. Thereby a helmet is provided which can fulfil the safety requirements of alpine helmets and the like and still be suitable, safe and comfortable for other sports where a light and vented helmet is needed, such as for cycling and water sports.
For example, penetration protection may be achieved by an inner shell that is thicker, at least at the portions/areas under the vents, or over all the inner shell. The inner shell is so thick that it will fulfil the penetration requirements of the suitable standards.
According to another example, which will be a much lighter solution than the thicker shell, the penetration protection may be arranged on the outside or, preferably, inside the inner shell. The penetration protection may be a net or a woven or non-woven fibre cloth. For example, aramide fibres are used. The fibres will preferably be locked in a final position for the fibres inside the inner shell by means of the shock absorbing material. The net or woven or nonwoven material will catch and prevent any sharp objects from penetrating through the vents into to the inner shell and shock absorbing layer.
Air vents are provided in the outer shell, for example as through holes in the outer shell. The air vents are connected to air channels, which are provided between the
inner shell and the outer shell. These air channels may be provided in the outer shell or in the inner shell or be a combination of both. The air channels transport air from the outside to the inside of the helmet where the head of the wearer is and vice versa.
The inner shell is preferably a vacuum formed shell, for example, made of abs, polycarbonate or lexan although other materials, such as thermo polymers, are conceivable. Preferably the air channels are formed in the vacuum formed inner shell. The outer shell is preferably of abs, polycarbonate or lexan although other materials, such as thermo polymers, are conceivable and is preferably injection moulded.
Preferably the shock absorbing material is in-moulded into the inner shell forming a shock absorbing layer, whereby the inner shell and shock absorbing layer forms a combined part of the inventive helmet. This combined part is preferably provided with through holes for ventilation of the head of the wearer. These through holes open into the air channels and are covered by the outer shell in order to prevent penetration at the through holes in case of accident. Thus, air can blow into the through holes and warm air inside the helmet can leave the helmet through said through holes. There will not be any through holes in the combined part at the portions/areas corresponding to the vents in the outer shell.
The shock absorbing material is preferably expanded polypropylene (EPP) since it has a multi impact property, i.e. will be able to withstand multiple impacts, and will not take up any water. Taking up of water could make the helmet heavier and diminish the shock absorbing property.
Thus, it is of course an advantage in for example water sports that the helmet will not take up any water. Other materials are conceivable, too, such as expanded polystyrene (EPS) .
Short description of drawings
The present invention will know be described by means of a preferred embodiment under referral to enclosed drawings, in which:
Fig. 1 shows a multi sport helmet according to a preferred embodiment of the present invention from the outside,
Fig. 2 shows the multi sport helmet of Fig. 1 from the inside,
Fig. 3 shows the inner shell and a shock absorbing layer inside the inner shell from the outside according to the preferred embodiment of the present invention,
Detailed description of preferred embodiments of the invention
In Fig. 1 a multi sport helmet according to a preferred embodiment of the present invention is shown. It comprises an outer shell 1, an inner shell 2 and a shock absorbing layer 3 inside of the inner shell 2, see Fig. 2. The outer shell 1 is provided with vents 4 for intake and outlet of air. The multi sport helmet is also provided with some kind of fastening straps 5 or the like.
In Fig. 2 the helmet is shown from the inside. Here, the shock absorbing layer 3 is clearly seen and between that and the hard shell 1 the inner shell 2 is present. The inner shell 2 is thin and vacuum formed. Through the inner shell 2 and the shock absorbing layer 3 through going holes 6 are provided. Extra comfort padding 7 may be provided inside the shock absorbing layer 3. The straps 5 may be fixed in the outer shell 1 and a space 8 may be provided between the inner shell 2 and the outer shell 1 for taking up the straps 5.
In Fig. 3 the inner shell 2 and the shock absorbing layer 3 is shown from the outside, i.e. the multi sport helmet with the outer shell 1 taken off. Preferably the shock absorbing layer 3 is blow moulded into the inner shell 2 with in-mould technique. As can be seen from the figure the through holes 6 goes through the combination of the inner shell 2 and the shock absorbing layer 3.
In the preferred embodiment air channels 9 are provided in the inner shell 2 as indents in the inner shell 2. The air channels 9 connect to the through holes 6 and the vents 4 so that air can flow into the vents 4, through the air channels 9 and into the through holes 6 so that fresh air can reach the wearer's head. Warm air may in turn leave through the through holes 6 via the air channels 9 and flow out of the vents 4. These air channels 9 may instead be provided in the outer shell or as a combination of both.
The air channels 9 are preferably widened at areas 10 having positions at the inner shell 2 that corresponds to the respective opposite positions in the outer shell 1 that are provided with the vents 4. In this light weight
helmet according to the preferred embodiment of the present invention, penetration protection 11 (only shown with dotted lines in Fig. 3) may be arranged on the outside or, preferably, inside the inner shell 2 at the areas 10. The penetration protection 11 may be a net or a woven or non-woven fibre cloth. For example, aramide fibres are used. In the preferred embodiment patches of fibre cloth are arranged inside the inner shell 2 at the areas 10, at least covering the areas 10, before the shock absorbing layer 3 is in-moulded.
The fibre material is preferably drapable, i.e. flexible over a double curved surface. The fibres are not locked in relation to each other before attachment inside the inner shell 2. But in the production of the helmet during the step of in-moulding the shock absorbing layer 3 into the inner shell 2 of the helmet the fibres will be locked in a final position for the fibres inside the inner shell 2 by means of the shock absorbing material 3. When the net or woven or nonwoven material 11 is applied in this way it will catch and prevent any sharp objects from penetrating through the vents into to the inner shell 2 and shock absorbing layer 3.
As seen in Fig. 1 the outer shell 1 covers all the through holes 6 in the combined part of the inner shell 2 and the shock absorbing layer 3.
The inner shell 2 is preferably a vacuum formed shell, for example, made of abs, polycarbonate or lexan although other materials are conceivable. The thickness of the inner shell material is in the range of 0,01-3 mm and preferably in the range of 0,3-1,0 mm. The inner shell 2 is not fibre reinforced.
The outer shell 1 is preferably of abs, polycarbonate or lexan. The shock absorbing material is preferably expanded polypropylene (EPP) since it has a multi impact property, i.e. will be able to withstand multiple impacts, and will not take up any water, which of course is an advantage in for example water sports. Other materials are conceivable, too, such as expanded polystyrene (EPS) .
Method for manufacturing a preferred embodiment
The inner shell 2 is vacuum formed into desired shape; the penetration protection 11, preferably in the form of a net, woven or non-woven fibre cloth, is attached inside the inner shell 2 at the positions 10 corresponding to the positions of the vents 4 in the outer shell 1; the inner shell 2 with the attached net, woven or non-woven fibre cloth 11 is placed in a female part of a form; a male part of the form is positioned in the form and spheres of expanded polypropylene (EPP) is blown into the form and thus into the inside of the inner shell 2 with the attached net or cloth 11. Hot gas is used to make the spheres of EPP to expand further and attach to each other and thus form a layer 3 of shock absorbing material. Thereafter the helmet is cooled down. Finally the outer shell 1 is fixed to the outside of the inner shell 2 and any extra cushioning and straps are attached.
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