“PROTECTIVE HELMET”

Field of the invention

The present invention relates to a helmet, or hard hat, designed to protect the head of a user against impacts. In particular, the present invention relates to a protective helmet, or hard hat, able to eliminate or reduce any impact damage suffered by the head of a user.

In the description below reference will be made, for the sake of brevity, to a motorcyclist’s helmet, but that which is described may apply to any type of helmet, or hard hat, suitable to protect the head of a user, for example motor sports competition helmets (for use in cars, on motorcycles, etc.), bicycle helmets, ski helmets or working helmets (helmets for excavator operators, building site helmets, etc,).

Prior art

According to the present state of the art there exist different types of helmet typically for sporting use or for working use. These helmets, or hard hats, are the instrument most widely used and suitable for protecting the head of the user against impact injuries and are therefore also defined as being protective helmets, or hard hats. In particular, the main purpose is that of providing a protective action against the possibility of any skull fractures.

In this connection, the essential elements of any type of protective helmet consist of an outer shell, namely the portion of the protective helmet in contact with the external environment, and an inner lining, namely the portion of the protective helmet which makes contact with the head of the user. The aforementioned essential elements cooperate in order to absorb the energy caused by a shock following an impact on the user’s head.

The outer shell is typically made of a material which is impact-resistant and allows the impact force to be distributed in an area which is greater than the impact area, thereby reducing the concentration of the stresses within a small area. The materials which are commonly used for the manufacture of the outer shell are thermoplastic materials such as polycarbonate (PC) or acrylonitrile butadiene styrene (ABS) or composite materials (FRP) with carbon or glass fibres in an epoxy resin or exclusively carbon or Kevlar fibres.

The inner lining is typically made of a material which is able to absorb the energy resulting from an impact, for example expanded polystyrene (EPS), expanded polypropylene (EPP) or materials with a similar mechanical behaviour. The inner lining is able to collapse gradually following an impact, thus reducing the accelerations transmitted to the head.

The form of the outer shell and the inner lining is designed so as to obtain a functional combination of the two elements which allows them to cooperate with each other so as to limit or prevent impact trauma.

It is also possible to envisage helmets in which the outer shell is defined directly by the inner lining, the latter being provided if necessary with one or more lining layers also used to ensure the rigidity of the outer surface, for example by means of a thermoplastic film.

It is clear that the design parameters both of the outer shell and of the inner lining are essential for obtaining a protective helmet able to obtain a gradual and controlled deceleration of the head in the event of an impact, while defining a structure which is functional for daily use. In particular, the main elements of the design are the thickness and the impact resistance of the outer shell, as well as the thickness and the density of the inner lining.

At present, in the motorcycling sector, numerous certifications for protective helmets, intended to ensure the protection of the head, are provided. In particular, in Europe protective helmets must be provided with an EU certificate which ensures correct functioning of the protective helmet from the point of view of safety in accordance with the relevant type-approval standard.

Considering the aforementioned European type-approval standards, the most current regulation in force is defined by ECE 22-06 for helmets, which provides for five different impact points within a helmet, namely the front, the back, the top, the side and the chin guard. These five points may be defined as being truly critical points since, when they are involved, they generally result in dramatic consequences. The helmets must not only be optimized in order to absorb and withstand given and set energy peaks due to heavy impacts, but they must also withstand weaker impacts, whereby the typeapproval test involves impacts against a flat anvil of the kerbstone type with 5.5 to 8.5 metres length. Moreover, the regulation involves a rotational acceleration test, which provides an indication of the damage suffered by the rider should the helmet strike laterally against a projection.

Although the design of protective helmets has evolved very rapidly over time, hitherto one of the main problems relates to the absorption of the initial impact force and the force by rotational impacts. During an impact, when the inner lining collapses completely, the non-absorbed energy part is transferred to the head, often resulting in injuries, also of a serious nature, in particular injuries which are not evident as a skull fracture or, at least upon initial examination, as a visible soft tissue injury. Only a small quantity of non-absorbed energy is reduced by the outer shell, by an amount estimated as being not more than 30%.

In order to improve the capacity for absorbing the impact forces, helmets provided with an inner lining consisting of deformable ABS cones have been developed, together with helmets made of two layers with different densities, i.e. an outermost layer, in the region of the outer shell, with a higher density, and an innermost layer, in the region of the user's head, with a lower density.

One problem associated with the aforementioned solutions consists in the fact that damping of the impact energy and, consequently, protection of the user’s head is performed by the inner lining, since the outermost lining provides for only mechanical protection against the impact, but not absorption thereof.

Moreover, the impact energy is redistributed rather then being dissipated, such that there is still a high risk of damage to the soft tissues, even where there is no evident signs of skull fractures, in particular during impacts resulting from sliding contact.

In order to improve the capacities for absorbing the impact forces during impacts, protective helmets with an increasingly greater thickness have been developed, these being therefore heavy and voluminous such that less prudent users are discouraged from using them.

A further problem of the aforementioned protective helmets consists in the difficulty of using them in hot weather conditions and for a long period of time, since the aforementioned thickness, as well as the components used, are unable to guarantee a suitably breathability during all conditions of use, this discouraging even further less prudent users from using them.

International Patent Application No. W02020/035807A1 describes a protective helmet comprising an outer shell and one or more impact energy absorption elements operatively connected to the outer shell, wherein the absorption elements comprise a working portion interposed between the end portions, wherein the section of the working portion along a surface transverse to an extension axis has an area smaller than the areas of the corresponding sections of the end portions and wherein the absorption elements have a breaking strength less than the breaking strength of the outer shell, so that in the event of impact the working portion is prone to break before the outer shell and before the end portions in order to allow the absorption of the energy from impact shocks.

This type of protective helmet therefore allows any rotational movements to be managed but, at the same time, the production cost of the protective helmet itself or the bulk and the weight involved are still high in order to guarantee optimum protection for the user.

It would therefore be desirable to provide a protective helmet which is able to minimize the aforementioned drawbacks. In this connection it would be desirable to provide a protective helmet able to ensure a better dissipation of the impact energy, while protecting the user’s head in the event of any type of impact. In particular, it would be desirable to provide a protective helmet which is able to ensure the aforementioned characteristics, while having a reduced weight and bulk and being simple to Summary of the invention

The object of the present invention is to provide a protective helmet able to minimize the aforementioned problems.

In particular, the object of the present invention is to provide a protective helmet which is functionally efficient, but low-cost so as to provide greater safety for users who require suitable protection.

The protective helmet comprises an outer shell and/or an inner lining and at least one absorption pad for absorbing the energy from impact shocks, designed to determine an area of absorption of the energy greater than the impact area which receives said shock, wherein the absorption pad is operatively connected to the outer shell and/or to the inner lining, with respect to the surface of the outer shell and/or of the inner lining, at the head of the user when in use, wherein the absorption pad comprises a covering designed to define a containment chamber, wherein the absorption pad comprises absorption means arranged inside the containment chamber; the protective helmet is characterized in that the absorption means comprise a plurality of spheres designed to allow the relative movement of the covering and said spheres, and wherein the spheres are designed to deform plastically in such a way as to reduce the impact energy transmitted to the head with respect to the energy generated by the impact force.

The protective helmet according to the present invention is able, therefore, both to provide protection from rotational impacts and to manage the dissipation of impact force energy by minimizing the energy to which the head of the user to be protected is subjected. More particularly, the relative movement of the covering and the spheres provides protection against rotational impacts while the deformation of the spheres themselves allows dissipation at least in part of the impact force energy.

According to one embodiment, the covering is provided with at least one elastic portion or is made with elastic material.

The elasticity of the covering material allows better relative movement of the covering and the spheres, therefore minimizing problems arising from rotational impacts.

According to one embodiment, the covering is defined by a single element provided with an opening for defining the containment chamber, or wherein the covering is defined by a first layer and by a second layer superimposed and joined together perimetrally to define the containment chamber.

In this way it is possible to define the covering either in a single element or by joining together several elements designed to define the containment chamber.

According to one embodiment, the covering is defined by a first layer and by a second layer superimposed and joined together perimetrally via a third layer to define the containment chamber wherein the third layer is provided with at least one elastic portion or is made with elastic material. In this way, it is possible to utilize the first layer and the second layer to define walls having a greater rigidity, while still allowing relative movement of the latter by means of the third perimetral layer and its elastic capacity.

According to one embodiment, the containment chamber comprises overpressure air, and wherein the spheres are arranged in said containment chamber in contact with the overpressure air.

According to one embodiment, the containment chamber comprises a filling liquid or a filling gel, and wherein the spheres are arranged in said containment chamber in contact with the filling liquid or filling gel.

The presence of overpressure air or of a filling liquid or filling gel also makes it possible to redistribute the impact force more gradually, reducing the weight and sizes of the protective helmet, while increasing its absorption capacity.

According to one embodiment, the spheres have at least in part diameters different from each other.

The different dimensions make it possible to differentiate the absorption capacity and to contain the energy more effectively.

According to one embodiment, the protective helmet comprises a first rigid support element and a second rigid support element, wherein at least one of the first rigid support element and the second rigid support element comprises at least one through-opening, wherein at least one of the energy absorption pads is interposed between the first rigid support element and the second rigid support element opposite the through-opening or at least partially protruding from the through-opening.

In this way, the possibility of protruding from the through-opening allows the absorption pad to improve the capacity for absorption of any rotational impacts.

According to one embodiment, the outer shell and/or the inner lining is provided with at least one cavity suitable for defining a housing seat for at least one of the absorption pads, and wherein the absorption pads are suitable for being housed at least partially inside the housing seat. In this way, it is possible to define a considerable improvement in the absorption of rotational impacts since the spheres allow a relative movement.

According to one embodiment, the protective helmet comprises at least one absorption element for absorbing energy from impacts, designed to determine an energy absorption area greater than the impact area which receives the impact and coupled to at least one of the absorption pads, wherein the absorption element is defined by an element elongated with respect to an extension axis, wherein the absorption element has a cavity which extends along the extension axis to define the inner surface of the absorption element, wherein the outer surface and the inner surface of the absorption element have the same convex polyhedron configuration provided with at least four sides, wherein the edges of the absorption element define hinges or folds for allowing the relative movement of the walls adjacent to the hinges or folds, and wherein the absorption element is designed to deform plastically inside the cavity in such a way as to reduce the impact energy transmitted to the head with respect to the energy generated by the impact force.

The polyhedron further allows the energy absorption capacity to be increased through the collapse of the polyhedral structure. Similarly, the capacity for movement of the walls with respect to the edges is able to complement the capacity for absorption of the rotational impacts.

Description of the figures

These and further characteristic features and advantages of the present invention will become clear from the description of preferred embodiments provided by way of a non-limiting example in the attached figures, wherein:

Figure 1 is a schematic cross-sectional view of a first preferred embodiment of the protective helmet according to the present invention;

Figure 2 is a schematic cross-sectional view of a second preferred embodiment of the protective helmet;

Figure 3 is a schematic cross-sectional view of a third preferred embodiment of the protective helmet;

Figure 4 is a schematic cross-sectional view of a fourth preferred embodiment of the protective helmet;

Figure 5 is a schematic cross-sectional view of a fifth preferred embodiment of the protective helmet.

Figure 6 is a schematic cross-sectional view of a sixth preferred embodiment of the protective helmet; Figure 7 is a schematic cross-sectional view of a seventh preferred embodiment of the protective helmet.

Detailed description of the invention

Figures 1-7 show a plurality of preferred embodiments of the protective helmet according to the present invention, in which, where possible, the numbering of identical elements in the various embodiments will be the same or will not be repeated.

In the description below reference will be made, for the sake of brevity, to a motorcyclist’s helmet, but that which is described may apply to any type of helmet, or hard hat, suitable to protect the head of a user, for example motor sports competition helmets (for use in cars, on motorcycles, etc.), bicycle helmets, ski helmets or working helmets (helmets for excavator operators, building site helmets, etc.). In particular, reference may be made to protective helmets of the full-face type, modular type or openface type (without chin guard). Protective helmets, whatever their type, may be provided with a plurality of components, including the closing strap, the visor and the ventilation system and these will not be described below in detail since they are not essential for the purposes of achieving the object of the invention.

A first embodiment is shown in Figures 1 and 2, in which according to a more detailed description the protective helmet 6 comprises a plurality of layers and in particular, from the outside to the inside, an outer shell 101, an inner lining 102 and a comfort padding layer 103, elements which may be also partially or totally not present according to further embodiments.

The outer shell 101 is preferably made of a material which is impact-resistant and allows the energy generated by the impact force to be distributed in an area which is bigger than the impact area, thereby reducing the concentration of the stresses within a small area. Preferably, the materials which are commonly used for the manufacture of the outer shell 101 are thermoplastic materials such as polycarbonate (PC) or acrylonitrile butadiene styrene (ABS) or composite materials (FRP) with carbon or glass fibres in an epoxy resin or exclusively carbon or Kevlar fibres. The thickness of the outer shell 101 may be defined according to the technical and strength requirements, without affecting the technical characteristics of the invention.

The inner lining 102 is preferably made of a material which is able to absorb the energy resulting from an impact, for example expanded polystyrene (EPS), expanded polypropylene (EPP) or materials with a similar mechanical behaviour. The inner lining 102 shown in the attached figures is made as one piece with a single density able to collapse gradually following the impact, thus reducing the accelerations transmitted to the head. In this case also, the type of structure and the thickness of the inner lining 102 may be realized and defined according to the technical and strength requirements, without affecting the technical characteristics of the invention.

The comfort padding 103, which represents the interface between the entire structure of the protective helmet 6 and the user's head, is preferably made by means of a combination of sponges covered with fabric, or other suitable material, which allow an increase in comfort during use of the protective helmet 6, but which in no way affect the capacity of the protective helmet 6 for absorbing the stresses to which it may be subjected.

It is likewise possible to provide helmets in which the outer shell is defined directly by the inner lining, the latter being possibly provided with one or more lining layers also used for stiffening the outer surface, for example by means of thermoplastic film.

The protective helmet 6 according to the first embodiment further comprises one or more impact energy absorption pads 16 designed to determine an energy absorption area greater than the impact area which receives the impact.

The absorption pad 16 is operatively connected to the outer shell 101 and/or to the inner lining 102, with respect to the surface of the outer shell 101 and/or inner lining 102, at the user's head when in use.

As shown in Figure 1, the absorption pad 16 is defined by suitable absorption means arranged inside a containment chamber 116, the latter being defined by means of a covering 216. The absorption pad 16 is schematically shown with dimensions and a position deliberately oversized with respect to the outer shell 101, the inner lining 102 or the comfort padding 103 for easier illustration thereof.

The containment chamber 116 therefore has a predetermined volume, at least with reference to a minimum volume and/or to a maximum volume, designed to accommodate the aforesaid absorption means, described in greater detail here below.

In the embodiment shown here, the abovementioned covering 216 is defined by a single element provided with an opening for allowing the definition of said containment chamber, i.e. of its contents. In Figure 1 described here, the covering pad 16 being already made and ready for use, the opening of the covering can be identified in the region of the element which protrudes from the aforesaid covering and defines the closing portion thereof, i.e. the portion joining together the opposite flaps of the single element used.

The covering 216 used is made with elastic material, in this way allowing better relative movement of the lining 216 and the absorption means arranged inside it, as described in greater detail here below, therefore minimizing rotational impact problems. A preferred material for the manufacture of the aforementioned covering 216 is spandex, a polyurethane-based synthetic fibre whose elastic elongation is very high and may be as much as 800%. Other materials, also with lower elongation percentages, may in any case be used.

According to further embodiments, not shown, the covering could also be provided with a single elastic portion, with several elastic portions or not have parts made with elastic material.

More particularly, the absorption means comprise a plurality of spheres 316 suitable for allowing the relative movement of the covering 216 and said spheres 316. These spheres 316 preferably have a diameter of between 0.5 mm and 6 mm, even more preferably between 1.5 mm and 3 mm. These dimensions are a good compromise between the volume occupied and the absorption capacity. Dimensions different from those described above may in any case be used. The spheres 316 are made of polyethylene or celluloid. Polyethylene allows the definition of a first part prone to elastic deformation followed by plastic deformation, or breakage. Celluloid has a much larger plastic deformation part, reaching breakage earlier. Both, however, ensure an excellent energy absorption capacity. It is possible to define the spheres using different materials, in any case able to deform plastically in such a way as to reduce the impact energy transmitted to the head with respect to the energy generated by the impact force, when stressed by an impact force, as described in greater detail here below.

The containment chamber 116 therefore has a volume occupied by the aforesaid spheres 316 as well as by air at atmospheric pressure, but different possibilities for filling the volume of the containment chamber 116 may be used. For example, in one embodiment (not shown), the containment chamber could also comprise overpressure air, where the spheres would be arranged in said containment chamber in contact with the overpressure air. In the same way, in one embodiment (not shown), the containment chamber could comprise a filling liquid or a filling gel, wherein the spheres would be arranged in said containment chamber in contact with the filling liquid or filling gel.

The presence of overpressure air or of a filling liquid or gel therefore allows the impact force to be redistributed more gradually, reducing the weight and dimensions of the protective helmet while increasing the absorption capacity.

The spheres 316 which define the absorption means are capable of deforming plastically in such a way as to reduce the impact energy transmitted to the head with respect to the energy generated by the impact force, when stressed by an impact force.

The protective helmet 6 according to the present invention allows, therefore, both protection from rotational impacts and management of the dissipation of impact force energy by minimizing the energy to which the head to be protected is subjected. More particularly, the relative movement of covering 216 and spheres 316 provides protection against rotational impacts while the deformation of the said spheres 316 allows the dissipation of at least part of the impact force energy.

As shown in Figure 1, the spheres 316 have at least in part diameters different from one another, although there are no differences in terms of number. In particular, the absorption pad 16 of the protective helmet 6, according to that shown, comprises three different types of spheres which can be differentiated according to their corresponding dimensions.

The different dimensions allow the absorption capacity to be differentiated and the energy to be contained more effectively.

According to further embodiments, not shown, the spheres could all be realized with dimensions different from each other or all with the same size. In the same way, the number of a group of spheres of a particular size could be the same as or different from a group of spheres with a different size. Therefore, in the case of impact, the protective helmet 6 according to the present invention makes it possible to reduce or eliminate the energy resulting from both direct impacts and from rotational impacts.

In the case of direct-shock impact, the absorption pad 16 first allows compression of the volume of the containment chamber 116, this compression being transferred at least in part to the spheres 316 and involving a deformation, which is initially elastic, until plastic deformation or breakage of the said spheres 316 occurs, whereby the spheres may change their form or even break.

In the same way, in the case of a rotational-shock impact, the contact between the spheres or between the latter and the covering 216 allows initially the relative movement both of different covering portions 216 and the spheres 316 themselves and of the covering 216 and the spheres 316, for example caused by the rolling of the spheres inside the containment chamber 116 or by the rolling of the spheres on the inner surface of the same containment chamber 116 or by the elongation of the elastic material with which the aforementioned covering 216 is at least partially made. Finally, plastic deformation or breakage of said spheres 316 occurs, whereby the spheres may change their form or even break.

According to one embodiment, not shown, the outer shell and/or the inner lining may be provided with at least one cavity suitable for defining a housing seat for at least one of the absorption pads. In this case, the absorption pads are able to be housed at least partially inside the housing seat.

In this way, it is possible to define a considerable improvement in the absorption of rotational impacts in that the spheres allow a relative movement.

Figure 2 shows a second embodiment of the protective helmet 7 according to the present invention. In this embodiment, the protective helmet 7 substantially corresponds to the protective helmet 6 and will therefore be described in greater detail only as regards its distinguishing features.

In particular, the protective helmet 7 in accordance with the second embodiment comprises a covering defined by a first layer 217' and by a second layer 217" superimposed and joined together perimetrally so as to define the containment chamber 116. In this case, the perimetral joint may be more or less bigger in size depending on the technical design and feasibility requirements of the absorption pad 17. Figure 3 shows a third embodiment of the protective helmet 8 according to the present invention. In this embodiment, the protective helmet 8 substantially corresponds to the protective helmet 6 and will therefore be described in greater detail only as regards its distinguishing features.

In particular, the protective helmet 8 in accordance with the third embodiment comprises a covering defined by a first layer 218’ and by a second layer 218” superimposed and joined together perimetrally by means of a third layer 218”’ so as to define the containment chamber 116. In this case, the third layer 218”’ is provided with at least one elastic portion or is made with elastic material.

In this way, it is possible to use the first layer 218’ and second 218” layer to define walls with greater rigidity, while allowing the relative movement thereof by means of the third 218’” perimetral layer and its elastic capacity.

The first layer 218’ and the second layer 218” may be defined both by a rigid structure, with the third layer 218’” alone having the elastic part, and by an elastic or partially elastic structure.

In the third embodiment, shown here in Figure 3, the dimensions of the first layer 218’ and of the second layer 218” are different, where the arrangement of the corresponding protective helmet 8 over the head to be protected may be realized both by means of the larger base and by means of the smaller base.

Figure 4 shows a fourth embodiment of the protective helmet 9 according to the present invention. In this embodiment, the protective helmet 9 substantially corresponds to the protective helmet 6 and will therefore be described in greater detail only as regards its distinguishing features.

More particularly, the protective helmet 9 in accordance with the fourth embodiment comprises a toroidal-shaped absorption pad 19.

Figure 5 shows a fifth embodiment of the protective helmet 7A according to the present invention. In this embodiment, the protective helmet 7A substantially corresponds to the protective helmet 7 and will therefore be described in greater detail only as regards its distinguishing features.

In particular, the protective helmet 7A in accordance with the fifth embodiment comprises a first rigid support element 110 and a second rigid support element 120, wherein at least one of the first rigid support element 110 and the second rigid support element 120 comprises at least one through-opening 1101, and wherein at least one of the energy absorption pads 16 is interposed between the first rigid support element 110 and the second rigid support element 120 opposite the through-opening 1101.

In this way, the possibility of being able to exit from the through-opening 1101 allows the absorption pad 16 to improve its absorption capacity for any rotational impacts.

According to a further embodiment, not shown, it is also possible to arrange the absorption pad at least partially protruding from the through-opening, in this way facilitating the protrusion therefrom, i.e. there being the possibility of placing the protective helmet by means of one of the rigid support elements or by means of the absorption pad protruding therefrom.

Figure 6 shows a sixth embodiment of the protective helmet 6A according to the present invention. In this embodiment, the protective helmet 6A substantially corresponds to the protective helmet 6 and will therefore be described in greater detail only as regards the distinguishing features. The protective helmet 6A in accordance with the sixth embodiment comprises a plurality of absorption pads 16 coupled together by means of a coupling structure 130. In particular, this coupling structure 130 is preferably made using a flexible material capable of changing the relative arrangement of the aforementioned absorption pads 16. According to a particular application, the coupling structure 130 may be made using nonwoven fabric suitable for being integrally joined together with the respective coupling pads 16 or provided with suitable housings for allowing the removability of the same coupling pads 16. This support structure 130 may also comprise at least one portion provided with suitable openings designed to ensure breathability in the sections not affected by the said coupling pads 16.

According to further embodiments, not shown, the coupling structure may also be made with different materials or be of the rigid type.

Figure 7 shows a seventh embodiment of the protective helmet 6B according to the present invention. In this embodiment, the protective helmet 6B substantially corresponds to the protective helmet 6 and will therefore be described in greater detail only as regards its distinguishing features.

The protective helmet 6B comprises a plurality of impact energy absorbing elements 11 able to determine an energy absorption area greater than the impact area which receives the impact, being coupled to at least one of the absorption pads 16. In particular, the absorption pad 16 shown in Figure 7 is coupled to one of the walls of the absorption element 11 along the outer surface but, according to further embodiments, the impact energy absorption pad 16 could be arranged at least partially inside the cavity of the absorption element 11, this cavity being described in greater detail here below.

The absorption elements 11 are defined by elements elongated with respect to an extension axis and arranged side-by-side with respect to the same extension axis. More particularly, the aforementioned absorption elements 11 are arranged side-by-side with respect to the extension axis with an orientation that is the same for all of them.

According to further embodiments, not shown, the absorption elements may have a different orientation while maintaining the relative side-by-side arrangement with respect to the extension axis. For example, one or more of the absorption elements could be rotated with respect to its axis of symmetry in order to position a different edge or side compared to the adjacent absorption element. In the same way, although arranged side-by-side, the absorption elements could be arranged in different planes.

Furthermore, according to a further embodiment, not shown, it is possible to define the structure of the protective helmet with a single absorption element, whereby the size of the same must be such as to satisfy the requirements of reception and/ or absorption of impact energy of the required area. By way of example, it is possible to use a polygon defined by a trapezium with a base that is very wide in relation to the height in such a way as to allow the coverage of a large area while maintaining a relative compactness of the protective helmet without compromising the functionality thereof. Again by way of example, it is possible to arrange the smaller base of the aforementioned trapezoid opposite the head to be protected, exploiting a larger area for impact, the ample possibility of movement of the side walls, as well as the collapse of the larger base inside the associated cavity, described in greater detail here below, for absorption of the energy.

The absorption elements 11 shown in the seventh embodiment are operatively coupled integrally, more particularly they are coupled integrally with respect to the corresponding contact edges 411 in pairs.

Different possibilities for integral coupling may be used in accordance with further embodiments described in greater detail here below.

The coupling of the absorption elements also allows them to be manufactured from a single element, therefore reducing production costs as well as assembly costs, and enabling better management of impact energy absorption.

The absorption elements 11 have a convex polyhedron type configuration with five sides, as defined with respect to the outer surface 111 of the said absorption elements 11. The same convex polyhedron configuration with five sides is also envisaged for the inner surface 211, defined by a cavity 311 that extends along the extension axis.

The aforementioned configurations may be different, according to different embodiments not shown, again of the convex polyhedron type but with a number of sides equal to at least four.

Moreover, the cavity 311 is of the through-type and has a continuous cross-section along the entire extension, but according to further embodiments, not shown, cavities of the non-through type may be provided, for example having a wall in at least one of the ends and/ or at an intermediate plane.

Preferably, the material from which the absorption elements 11 are made is selected from polystyrene, ABS or celluloid.

Polystyrene allows definition of a first part of elastic deformation followed by plastic deformation, or breakage. The ABS material has a much larger part of plastic deformation, reaching breakage sooner. On the contrary, celluloid can be used to define even somewhat complex structures of the absorption element, selecting as required the load which defines the plastic deformation, or breakage, of the same. In any case, depending on the design specifications, all of the abovementioned materials are capable of ensuring excellent energy absorption capacity.

In this respect, the walls of the absorption elements 11 preferably have a thickness of between 0.5 mm and 6 mm, preferably between 1.5 mm and 3 mm.

These dimensions constitute a good compromise between the occupied volume and the absorption capacity.

According to further embodiments, not shown, the absorption elements may have wall thicknesses different from those preferred thicknesses, being both smaller than 0.5 mm and larger than 3 mm, depending on the technical design requirements as well as the production cost involved.

Moreover, according to further embodiments, not shown, the walls have thicknesses at least partially different from one another or portions with a different thickness. For example, it is possible to use different thicknesses along the length of the abovementioned extension axis, or only for some of the walls.

The different thicknesses make it possible to differentiate the absorption capacity and to contain the energy more effectively, managing in this way both the dissipation of the impact force energy and the relative movement of the walls for protection against rotational impacts.

Considering the possible materials which can be used, it is also possible to define absorption elements provided with different densities, while having the same thickness of the walls. As described above for the thickness, it is also possible to provide walls which have densities at least partially different from each other or portions with a different density, so the same considerations described above may apply. The absorption elements 11, regardless of the number of sides with which the convex polyhedron is defined, are in fact capable of deforming plastically inside the cavity 311 in such a way as to reduce the impact energy transmitted to the head with respect to the energy generated by the impact force.

The edges 411 identified by the convex polyhedron of each absorption element define hinges, or folds, so as to allow relative movement of the walls adjacent to the hinges, or folds. This movement of the walls may be obtained in relation to one or more support elements coupled with the protective helmet according to the present invention, or with respect to a common base, such as to define a support plane during the reception of the impact force. Optionally, the abovementioned support plane could be defined by the same head to be protected on which the protective helmet according to the present invention may be applied.

The definition of the aforementioned hinges, or folds, may be obtained using one or more processes, not described here in detail and in full, these including, for example the formation of smaller wall thicknesses in the region of the hinges, or folds, or the formation of the portion close to the edges using a material different from that of the remaining portion of the absorption element, for example with a lower density, or by means of suitable machining processes or stock-removal.

In any case, it is possible to position the absorption elements 11 m contact, directly or indirectly, with the head to be protected both on one side of the polygon and at one of the edges 411, while obtaining the same technical effects. In the same way, it is possible to arrange the absorption pads 16 in contact, directly or indirectly, with the head to be protected.

Therefore, in the event of an impact, the protective helmet 6B according to the present invention is able to reduce or eliminate the energy resulting from both direct and rotational impacts.

In the event of a direct-shock impact, in addition to the functionality of the absorption pads 16 already described previously, the hinges, or folds, defined by the edges 411 of the polygons first allow the movement of the corresponding adjacent walls inside the cavity 311, with a deformation that is initially elastic, until plastic deformation or breakage of the actual polygons occurs with collapse of the walls inside the cavity 311.

In the same way, in the case of a rotational-shock impact, the hinges, or folds, defined by the edges 411 of the polygons first allow for the movement of the corresponding adjacent walls with respect to a support plane, for example determined by the head to be protected on which the protective helmet 1 itself is placed, until plastic deformation or breakage of the actual polygons occurs with collapse of the walls inside the cavity 311.

According to a further embodiment, not shown, the absorption elements comprise polygons having edges provided with embossing, for better formation of the aforementioned hinges, or folds. Considering the pentagonal shape of the polygon, embossing may be formed on part of the edges, for example only on three of the five edges defined by the edges opposite to the base wall, or embossing may be formed on any number of edges, embossing from one edge only to all the edges of the polyhedron. Moreover, the embossing could also be applied to only a portion of the absorption elements which define the protective helmet of the present invention.

Alternatively, it is possible to use different processes for making the edges in order to ensure better formation of the edges, for example making notches of any shape along the edges themselves, or along one or more portions thereof.

Notches or embossing facilitate the definition of hinges, or folds, without losing the continuity of the material used, thus reducing production costs.

According to a further embodiment, not shown, the absorption elements are provided with an open side. Considering the pentagonal shape of the polygon, the open side may be relative to the base wall and is completely open. In this way, it is possible to produce the absorption elements economically by means of cutting or moulding.

Moreover, the walls adjacent to the open side may have a greater thickness in the portion near the open side and a smaller thickness in the portion remote from the open side. In this way, the greater thickness of the walls near the open side makes it possible to define a support surface which is in any case sufficient to compensate for a missing side. According to further embodiments, not shown, the open side can be realized on any number of absorption elements, from a single absorption element to all of the absorption elements. Moreover, the open side could also be made by only partially removing the side of the absorption element intended to be open.

Alternatively, it is possible to provide protective helmets in which the open sides are made on different sides of the polygons that define the absorption elements.

Finally, according to further embodiments not shown, the walls adjacent to the open side may have a greater density in the portion near the open side and a smaller density in the portion remote from the open side. In this way, the greater density of the walls in the region of the open side makes it possible to define a support surface which is in any case sufficient to compensate for a missing side.

According to a further embodiment, not shown, the absorption elements may be coupled with respect to a support element which defines a common base. In this respect, the absorption elements are spaced so as to allow individual movement of each absorption element when subjected to the impact blow but they could equally well be arranged in contact for a greater rigidity of the protective helmet. According to this configuration, it is also possible to have a flexible support element, i.e. with greater flexibility than the absorption elements themselves, in this way allowing during use the arrangement with a configuration suitable for the head to be protected, for example curved, while still being adjacent to the same support element.

The embodiments described here may also be combined so as to provide further embodiments which are more complex, although not described in greater detail, considering that the combinations may be easily imagined by the person skilled in the art in the light of the description provided here.

In particular, the plurality of absorption elements is preferably such that they may be arranged alongside each other along a same plane and not superimposed or such that they may define structures with superimposed absorption elements. Likewise, the plurality of absorption pads is preferably such that they may be arranged alongside each other along a same plane and not superimposed or such that they may define structures with superimposed absorption pads.

The protective helmet according to the present invention is therefore able to maximize the protection of the user in the event of impact shocks.

The protective helmet according to the present invention, in fact, is able to both ensure protection from rotational impacts and manage the dissipation of the energy from the impact force, minimizing the energy to which the user’s head to be protected is subject. In particular, the relative movement of the lining and the spheres provides protection against rotational impacts, while the deformation of the spheres allows the impact energy force to be at least partly dissipated. Furthermore, the present invention is able to provide a functionally efficient, but low-cost protective helmet able to ensure greater safety for users who require suitable protection, both in the leisure/ sports sector and in the working sector.