Related Application

[001 ] This application claims priority from Australian Provisional Patent Application No 2017900369, filed on 7 February 2017, the disclosures of all of which are hereby expressly incorporated by reference in their entireties.

Field of the Invention

[002] The present invention relates to a helmet. In particular, the invention relates, but is not limited, to a helmet for equestrian sports and to a method of manufacturing the helmet.

Background of the Invention

[003] Any reference to or discussion of any document, act or item of knowledge in this specification is included solely for the purpose of providing a context for the present invention. It is not suggested or represented that any of these matters or any combination thereof formed at the priority date part of the common general knowledge, or was known to be relevant to an attempt to solve any problem with which this specification is concerned.

[004] Racing Australia introduced a high performance equestrian standard for helmets in 2012 called ARB HS 2012. The standard required the helmets to pass impact requirements over a range of impact forces for each individual test, rather than one impact force for each test. The standard also increased the impact attenuation properties of the helmet.

[005] However, at the time of filing the present application the standard has not been enforced because no existing commercially available helmets have been able to meet the standard.

[006] Accordingly, it would be desirable to provide a helmet that meets Racing Australia's stringent new standard for helmets.

Summary of the Invention

[007] According to a first aspect of the present invention there is provided a helmet for equestrian sports comprising:

an outer shell; and

an inner shell moulded in the outer shell so that the inner shell is bonded to the outer shell. [008] In an embodiment, the helmet further comprises an intermediate shell located between the outer shell and the inner shell.

[009] In an embodiment, the intermediate shell is located in at least a side portion of the helmet.

[010] In an embodiment, the intermediate shell is formed as a annular or cylindrical band.

[01 1 ] In an embodiment, the inner shell has non-uniform density.

[012] In an embodiment, the inner shell comprises a cranium portion that has a lower density and front, back and side portions of the inner shell have higher densities.

[013] In an embodiment, the lower density portion has a density in the range of about 35 - 60 g/L whereas the higher density portions have a density in the range of about 45 - 70 g/L.

[014] In an embodiment, the inner shell is formed from expanded polystyrene.

[015] In an embodiment, the inner shell is formed from a different material compared to the intermediate shell and/or the outer shell.

[016] In an embodiment, the helmet also comprises a lower shell that is attached to an edge of the outer shell.

[017] In an embodiment, the lower shell is U-shaped in cross-section.

[018] In an embodiment, the lower shell defines opposed side walls and the inner shell has a portion located between the opposed side walls of the lower shell.

[019] In an embodiment, the lower shell is formed from a different material compared to the inner shell, intermediate shell and/or outer shell.

[020] In an embodiment, the helmet meets Australia Standard ARB HS 2012.

[021 ] According to second aspect of the present invention there is provided a method of manufacturing a helmet for equestrian sports, the method comprising:

a) forming an outer shell;

b) placing the outer shell in a mould; and

c) forming an inner shell in the mould.

[022] In an embodiment, the method further comprises forming an intermediate shell in the mould prior to forming the inner shell, wherein the intermediate shell is located between the outer shell and the inner shell.

[023] In an embodiment, the intermediate shell is located in at least a side portion of the helmet.

[024] In an embodiment, the intermediate shell is formed as an annular or cylindrical band. [025] In an embodiment, the inner shell is formed with a non-uniform density.

[026] In an embodiment, step c) comprises forming the inner shell with a cranium portion that has a lower density and front, back and side portions of the inner shell have higher densities.

[027] In an embodiment, the lower density portion has a density in the range of about 35 - 60 g/L whereas the higher density portions have a density in the range of about 45 - 70 g/L.

[028] In an embodiment, the inner shell is formed from expanded polystyrene.

[029] In an embodiment, the inner shell is formed from a different material compared to the intermediate shell and/or the outer shell.

[030] In an embodiment, the method further comprises forming a lower shell in the mould prior to forming the inner shell so that the lower shell is attached to an edge of the outer shell.

[031 ] In an embodiment, the lower shell is U-shaped in cross-section.

[032] In an embodiment, the lower shell defines opposed side walls, whereby forming the inner shell in step c) comprises forming the inner shell between the opposed side walls of the lower shell.

[033] In an embodiment, the lower shell is formed from a different material compared to the inner shell, intermediate shell and/or outer shell.

[034] In an embodiment, the outer shell is formed by injection moulding or vacuum moulding.

[035] According to a third aspect of the present invention there is provided a helmet for equestrian sports meeting Australia Standard ARB HS 2012 made by the method of the second aspect.

Brief Description of the Drawings

[036] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying Figures in which:

Figure 1 is a cross-sectional view of a helmet according an embodiment of the present invention;

Figure 2A is a cross-sectional view of a helmet according to another embodiment of the present invention; and

Figure 2B is a magnified view of a portion of the helmet of Figure 2A. Detailed Description

[037] Referring to Figure 1 , a helmet 10 according to an embodiment of the present invention is shown in cross-section.

[038] The helmet 10 comprises an outer shell 1 1 that forms a dome to define the external shape of the helmet. The outer shell 1 1 is formed by injection moulding or vacuum moulding a suitable polymeric material such as polycarbonate. However, in other embodiments, the outer shell 1 1 is formed by moulding glass and/or carbon fibre. Injection moulding enables the outer shell to be formed with a consistent wall section at low cost. Vacuum moulding is better when producing a helmet with vents and for colouring and design (as injection moulding can only produce a single colour outer shell). Furthermore, vacuum moulding enables the outer shell to be formed with very thin wall section (<2 mm thick) to reduce the weight of the outer shell in regions which do not require as much impact protection.

[039] The helmet 10 also comprises a first inner shell 12 that is formed from a hard polymeric material such as polycarbonate. The first inner shell 12 is "in-moulded" with respect to the outer shell 1 1 . This involves placing the already formed outer shell 1 1 into a mould and forming the first inner shell 12 with the outer shell 1 1 in the mould. This results in the first inner shell 12 being bonded to the outer shell 1 1 which increases the strength, rigidity, crush resistance and puncture resistance of the helmet 10.

[040] The first inner shell 12 is shaped, at least in part, as a ring or annular/cylindrical band that extends around the front, back and sides of the helmet 10. That is, the first inner shell 12 forms a dome shape, in part, with an open upper portion. The first inner shell 12 does not extend to the top or cranium portion of the helmet 10. In this respect the first inner shell 12 is shaped to provide additional protection to the front, back and sides of a person's head, which are the parts of the head that are most susceptible to injury in equestrian sports. On this basis, the first inner shell 12 assists in reinforcing a lower portion of the outer shell 1 1 .

[041 ] The helmet 10 also comprises a second inner shell 13 that is formed from expanded polystyrene ('EPS'). The second inner shell 13 is shaped as an inner dome within the outer shell 1 1 . The second inner shell 13 is formed over the first inner shell 12 such that the first inner shell 12 is an intermediate shell between the outer and second inner shells 1 1 ,13. The second inner shell 13 is also "in-moulded" to the outer shell 11 and also to the first inner shell 12. The outer shell 1 1 , with the first inner shell 12 already moulded thereto, is placed in a mould and the second inner shell 13 is formed using techniques to mould expanded polystyrene objects known to a skilled person in the art. Because the second inner shell 13 is formed in this manner, it is bonded to the outer shell 1 1 and to the first inner shell 12. [042] The second inner shell 13 can be formed with portions at different densities. A top or cranium portion 20 of the second inner shell 13 has a relatively lower density than front, back and side portions 21 . By having the different density portions, the weight of the helmet 10 can be reduced by having a lower density in regions not requiring the same amount of strength and rigidity as other regions (ie. the front, back and sides of the helmet). The lower density regions have a density in the range of 35 - 60 g/L whereas the higher density regions have a density in the range of 45 - 70 g/L. It is also noted that the first inner shell 12 in this embodiment is located adjacent to the front, back and side portions 21 of the second inner shell 13 and does not extend up to the cranium portion 20.

[043] Referring now to Figures 2A and 2B, a helmet 1 10 according to another embodiment of the present invention is illustrated. The helmet 1 10 is similar to the helmet 10 of Figure 1 . Similar features of the helmet 1 10 shown in Figures 2A and 2B are designated with the same reference number but prefixed with the numeral 1 .

[044] The helmet 1 10 comprises an outer shell 1 1 1 , a first inner shell 1 12 and a second inner shell 1 13. The first and second inner shells 1 12, 1 13 are in-moulded to the outer shell 1 1 1 as described above for the inner shells 12, 13 of the helmet 10 shown in Figure 1 .

[045] The helmet 1 10 of Figures 2A and 2B also comprises a lower shell 130 that forms the lower part of the outer shell 1 1 1 structure of the helmet 1 10. The lower shell 130 is formed from a hard polymeric material such as polycarbonate. The lower shell 130 is connected to the base of the outer shell 1 1 1 and extends around the bottom lip 125 of the outer shell 1 1 1 . The lower shell 130 is also located below the first inner shell 1 12. In cross- section, the lower shell 130 has a U-shape with opposed walls 131 , 132 forming part of the inner and outer surfaces of the helmet 1 10 respectively. The outer wall 131 has an indentation 133 at its top, which is overlapped by the bottom lip 125 of the outer shell 1 1 1 so that the helmet 1 10 has a smooth finish.

[046] The lower shell 130 is "in-moulded" with respect to the outer shell 1 11 prior to the second inner shell 1 13 of expanded polystyrene is formed. Hence, the outer shell 1 1 1 is placed in a mould and the lower shell 130 moulded to the outer shell 1 1 1 so that they are bonded together. The polystyrene inner shell 1 13 is moulded to the outer shell, first inner shell 1 12 and lower shell 130 including by having a portion 134 that extends into the lower shell 130 between its opposed walls 131 , 132. Advantageously, the construction of the helmets 10, 1 10 according to embodiments of the present invention produces, for example, a helmet that meets the high performance equestrian standard for helmets, ARB HS 2012. Thus, for equestrian sports, these helmets have superior impact performance across a range of impact levels (with double the impact attenuation of conventional equestrian helmets), high strength, crush resistance and puncture resistance.

[047] One advantage of the helmet 1 10 of Figures 2A and 2B over the helmet 10 of Figure 1 is that it is lighter (yet still meets the same standard). However, the helmet 10 of Figure 1 is harder and therefore longer wearing.

[048] In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc.

[049] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.

[050] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.