CN107105808B

CN107105808B - Helmet strap attachment

Info

Publication number: CN107105808B
Application number: CN201580072583.1A
Authority: CN
Inventors: G.T.雅克布森
Original assignee: Bell Sports Inc
Current assignee: Bell Sports Inc
Priority date: 2014-11-13
Filing date: 2015-11-13
Publication date: 2021-11-09
Anticipated expiration: 2035-11-13
Also published as: EP3217827B1; EP3217827A1; CN107105808A; EP3217827A4

Abstract

An anchoring system for securing a strap to an in-molded helmet can include a strap anchor including an anchor housing and an in-molded flange coupled to the anchor housing. The anchoring system can include a bar tack clip sized to fit partially within the anchor housing, the bar tack clip including a cross-beam, an opening adjacent the cross-beam, and at least one clip coupled to the cross-beam and sized to mateably couple with the anchor housing. The anchoring system may also include a strap disposed through the opening in the bar tack clip and encircling the cross beam, the strap coupled to itself with a bar tack. The at least one clip of the bar tack clip may be disposed at an inner bound side of the bar tack clip, or may include two side clips.

Description

Helmet strap attachment

Related patent application

This application claims the benefit of U.S. provisional patent application 62/079,465 entitled "Helmet Strap Attachment Method and Device" (Helmet Strap Attachment Method and apparatus), filed 11, 13, 2014, the entire disclosure of which is incorporated herein by reference.

Technical Field

The present disclosure relates to headgear strap attachment methods and devices.

Background

Protective headgear and helmets have been used in a wide variety of applications and across a variety of industries, including use in athletic activities, athletics, construction, mining, military defense, and other fields to prevent damage to the head and brain of a user. The use of a helmet that prevents hard or sharp objects from directly contacting the user's head can avoid or reduce injury to the user. The use of helmets that absorb, disperse or otherwise manage impact energy also avoids or reduces injury to the user. Belts or webbing are commonly used to allow a user to releasably wear their helmet and to ensure that the helmet remains on the user's head during an impact.

When using straps or webbing to releasably couple the helmet to the head of a user, the helmet anchoring or attachment system typically includes a tie-down attachment point that couples one or more straps to the helmet. Like helmets and straps, the tie-down attachment points are subjected to large loading forces during impact, both during accidents and to test various safety standards. By ensuring that the helmet strap attachment point is secure and can withstand impact forces, the user is prevented from prematurely removing the webbing system during an accident.

The strap attachment or anchoring systems of helmets are generally of two different types: 1) in-mold molding the strap, and 2) post-molding the strap. In-molded straps are attached for in-molded helmets, where the protective shell is formed of a molded material, such as Expanded Polystyrene (EPS) foam or other material. The protective shell may be formed by injecting or expanding a material (such as plastic or foam beads) into a helmet mold under certain conditions (such as temperature) to allow the protective material to form within the mold. After molding is complete, the helmet or portions of the helmet can be removed from the mold to be completed and used. An in-molded strap is incorporated into the helmet and attached thereto during the molding process. The attachment strap or webbing may be provided within the helmet mold at the time of molding so that the strap is incorporated as part of the helmet. The temperature and other conditions of the molding process are controlled to ensure that the strap or webbing will not be damaged by the helmet molding process. As described below, the rear molded strap is attached after formation or molding of the helmet or protective shell.

For conventional post-mold attachment of straps, there are two common types of attachment: 1) riveting a strap or webbing to an outer shell of the helmet, such as an outer shell formed from (ABS), and 2) attaching the webbing to the in-mold mounting feature. The in-mold mounting features may be incorporated into and attached to the helmet during the molding process by being disposed within the helmet mold at the time of molding such that the in-mold mounting features are incorporated as part of the helmet. The strap or webbing may be coupled to an in-mold mounting feature, as shown and discussed below with respect to fig. 1 and 2A-2D.

A first method for coupling a strap or webbing to an in-mold mounting feature may be referred to as a snow or ski anchor method. An example of a conventional snow anchor is shown in fig. 1 below.

Fig. 1 shows a strap anchor, snow anchor, or ski-style strap anchor 10, typically used in-molded helmets (including ski helmets or other snow helmets) to couple the strap to the in-molded helmet. The strap anchor 10 can include two basic portions, i) a strap anchor body 14, which can include an opening 12; ii) webs, stiffening attachments, fins, umbrella systems, anchoring geometries, or stiffening attachment points 16 that couple the strap anchor 10 to the helmet or helmet body.

The opening 12 of the strap anchor 10 can receive a strap, which can be inserted through the opening to couple to the strap anchor 10. The strap can then connect the ski helmet to the user's head. When the strap anchor 10 is coupled to a helmet, the webs 16 of the strap anchor 10 may be disposed within an energy absorbing material or layer of the helmet, such as a layer of Expanded Polystyrene (EPS) foam or other suitable material. The webs 16 can be sufficiently large and include sufficient anchoring geometry to secure the strap anchor 10 to the helmet by securing the webs 16 within the energy absorbing material and remain securely coupled during impact. The rib plate 16 may be embedded within the helmet body when the ski anchor 10 is coupled to the helmet body.

The strap or webbing of the helmet can be coupled to the strap anchor 10 by forming a loop at one end of the strap and inserting a pin through the strap loop. The loop in the webbing may be formed by folding the end portion of the strap or webbing over itself, and securing the end portion of the strap to the central portion of the strap with a reinforcing hitch (i.e., stitching). The pin can then be disposed through a loop in the strap, and then the pin can be secured to the strap anchor body 14 by disposing the pin and a portion of the strap into the opening 12 in the lower portion of the strap anchor body 14 on the inside of the helmet. As used herein, the inside or medial side of the helmet refers to the side of the helmet that is adjacent to or in contact with the user's head, opposite the outside of the helmet, or both.

Thus, a conventional snow anchor, such as the strap anchor 10 shown in fig. 1, remains visible to the consumer after the helmet is formed. In addition, the attachment device of the helmet, i.e. the metal pin that secures the closed loop end of the webbing, is also visible. Since the strap anchor 10 is attached or coupled to the strap on the inside surface of the helmet, the plastic shell of the in-molded helmet that is typically present when in-molded does not need to be integrated, modified, or resized with the strap anchor 10 because the plastic shell and the strap anchor 10 are separated by the in-molded material.

Another method or apparatus that is commonly used is a shell-mounted anchor or housing 20, as shown in fig. 2A-2D. Shell-mounted anchor 20 may be similar in some respects to conventional strap anchor 10, but differs from conventional strap anchor 10 in that it is attached to a plastic shell, wherein shell-mounted anchor 20 may be simultaneously in-molded with plastic shell 22 to secure shell-mounted anchor 20 to a hole, opening, or punch in plastic shell 22. In some cases, shell-mounted anchors 20 are attached to shell 22 by snapping shell-mounted anchors 20 into punched holes in the shell, the holes being sized to fit and retain shell-mounted anchors 20 by friction. Accordingly, anchor 20 can be disposed within energy management material 23 of in-molded helmet 25.

Fig. 2A shows that only the bottom most portion of the shell-mounted anchor 20, such as the bottom portion of the strap anchor overmolded clip or overmolded snap-engagement feature 24, is visible to the user, and the strap anchor snap tabs, anchor engagements, fins or ribs 26 are hidden under the plastic shell 22. Fig. 2B, included below, shows a side view of an example of the entire shell-mounted anchor 20 outside of the shell 22 and helmet, such as before the shell-mounted anchor 20 is mounted to the shell 22 and inside the helmet.

Fig. 2B is labeled to indicate that the shell-mounted anchor clip 20 can be coupled to a webbing or strap 28, and can include a strap anchor overmold clip 24 and a cover 30. The strap anchor over-mold clip 24 can be formed with a plastic injection strap anchor over-mold clip 24 over the end of the webbing 28 that can be matingly inserted into the strap anchor snap tabs 26 after the helmet is molded. Insertion of the over-molded clip 24 into the strap anchor 26 can be a single stroke. In other words, once the overmolded clip 24 is inserted into the strap anchor 26, the overmolded clip 24 and the strap anchor 26 will be permanently and unreleasably coupled such that the overmolded clip 24 will not release unless the overmolded clip 24, the strap anchor 26, or both are broken. Among other things, shell-mounted anchors 20 and systems for using the same are desirable for their ornamental appearance.

Similar to fig. 2A, fig. 2C shows a close-up perspective view of the over-molded clip 24 coupled to the bottom-most portion of the shell-mounted anchor 20 (as shown in fig. 2B) and exposed from the plastic shell 22. Fig. 2C also provides additional detail of the webbing 28 coupled to the shell-mounted anchor and extending from the over-mold clip 24.

Fig. 2D shows a cross-sectional profile view of shell-mounted anchor 20 taken along section line 2D-2D shown in fig. 2B. The cross-sectional view of fig. 2D shows how the over-molded clip 24 engages the strap anchor snap tabs 26 within the shell-mounted anchor 20.

Disclosure of Invention

There is a need in the art for headgear strap attachments, and methods for providing headgear strap attachments. Accordingly, in one aspect, an anchoring system for securing a strap to an in-molded helmet can include a strap anchor including an anchor housing and an in-molded flange coupled to the anchor housing and sized to retain the strap anchor within the in-molded helmet. The anchoring system may include a bar tack clip sized to fit partially within the anchor housing, the bar tack clip may further include a cross-member, an opening adjacent the cross-member, and at least one clip coupled to the cross-member and sized to mateably couple with the anchor housing. The anchoring system may include a strap disposed through an opening in the bar tack clip and encircling the cross beam, the strap coupled to itself with the bar tack.

The anchoring system for coupling the strap to the in-molded helmet may further include at least one of the bar tack clips interlocking with the strap anchor to prevent the bar tack clip from being pulled out or away from the anchor housing. At least one of the bar tack clips may include two side clips. At least one clip of the bar tack clip may be arranged at an inner boundary side of the bar tack clip, which inner boundary side is perpendicular to a side face of the bar tack clip. The strap may be coupled to the bar tack clip without the over-molded band clip. The strap anchor, bar tack clip, and strap may be adapted to mount to an exterior side of the helmet, wherein the exterior side of the helmet is oriented away from the head of the user. A through hole may be formed at a lower edge of the bar tack clip and aligned with the cross beam, the through hole sized to receive a portion of the strap.

In another aspect, an anchoring system for securing a strap to an in-molded helmet can include a strap anchor, a bar tack clip sized to fit partially within an anchor housing, and a strap encircling a cross-beam and coupled to itself. The bar tack clip may include a cross beam and at least one clip coupled to the cross beam and sized to mateably couple with the strap anchor.

The anchoring system for securing the strap to the in-molded helmet may also include at least one of the bar tack clips having two side clips. At least one clip of the bar tack clip may be arranged at an inner boundary side of the bar tack clip, which inner boundary side is perpendicular to a side face of the bar tack clip. The strap may be coupled to the bar tack clip without a pin. The strap anchor can further include an in-molded flange including a mesh geometry including a solid outer perimeter and at least one inner open area surrounded by the solid outer perimeter. The strap anchor can be disposed within the energy management material of the in-molded helmet such that the bar tack clip, cross beam, and strap anchor are not visible to the user from the outside of the finished in-molded helmet. At least one of the bar tack clips may interlock with the strap anchor to prevent the bar tack clip from being pulled out or away from the strap anchor. The strap anchor, bar tack clip, and strap may be mounted to an exterior side of the helmet, wherein the exterior side of the helmet is oriented away from the head of the user.

In another aspect, a method of coupling a strap to an in-molded helmet can include in-molding a strap anchor into a protective helmet shell, wherein an opening in the strap anchor is exposed relative to the protective helmet shell; providing a reinforcement bar tack clip comprising a beam; looping a strap around the cross-beam and coupling the strap to itself; and inserting the bar tack clip into the opening of the strap anchor after the strap anchor has been in-molded into the protective helmet shell to couple the bar tack clip to the strap anchor.

The method of coupling the strap to the in-molded helmet can further include in-molding the strap anchor in the expanded foam energy management layer. The method may include coupling the strap to itself, further comprising sewing the ends of the strap to a central portion of the strap to form a reinforcement hitch. The method may further include coupling the bar tack clip to the strap anchor by interlocking a load bearing member disposed on a side of the strap anchor with a side clip of the bar tack clip. The method may further include coupling the bar tack clip to the strap anchor by interlocking a clip disposed at an inboard side of the bar tack clip with the strap anchor. The method may further include passing a strap through a through hole at a lower edge of the bar tack clip, the through hole aligned with the cross beam.

Drawings

Fig. 1 shows a view of a ski-type anchor device known from the prior art.

Fig. 2A-2D illustrate various views of an embodiment of a shell-mounted anchor.

Fig. 3 shows a perspective view of an embodiment of an anchoring system.

Fig. 4 shows a cross-sectional profile view of an embodiment of an anchoring system.

Fig. 5A-5I illustrate various views of a strap coupled to an embodiment of a bar tack clip.

Fig. 6A-6E show various views of another embodiment of a shell-mounted anchor.

Detailed Description

The present disclosure, aspects and implementations thereof are not limited to the specific helmet or material types or other system component examples or methods disclosed herein. Many additional components, manufacturing and assembly procedures consistent with helmet manufacture known in the art may be envisioned for use with particular implementations of the present disclosure. Thus, for example, although particular implementations have been disclosed, such implementations and implementation components may include any components, models, types, materials, versions, numbers, and/or the like known in the art for such systems and implementation components consistent with the intended operation.

The words "exemplary," "example," or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" or "exemplary" is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not intended to limit or restrict the disclosed subject matter or relevant portions of the present disclosure in any way. It should be understood that this document may present numerous additional or alternative examples with varying scope, but omitted for the sake of brevity.

While this disclosure is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

Apparatuses, devices, systems, and methods for providing protective headgear that can include an outer shell and an inner energy absorbing layer (such as foam). The protective helmet may be a cycling helmet for mountain biking or road biking, or may be used by skiers, skaters, hockey players, snowboarders, other snowboarders or water players, football players, baseball players, lacrosse players, polo players, climbers, car racers, motorcycle riders, cross-country motorcycle racers, high jump parachutists, or any other player participating in sports. Other industries also use protective headgear so that individuals employed in other industries or work, such as construction workers, soldiers, firefighters, pilots, or various types of work or activities may also use or require safety helmets, where similar techniques and methods are also available. Each of the sports, occupational, or activities listed above may employ a helmet comprising a single-impact or multi-impact grade protective material substrate, typically (although not always) covered on the outside by a decorative cover, and comprising a comfort material, typically in the form of a comfort pad, on at least some portion of the inside.

Generally, protective helmets, such as those listed above, can include an outer shell and an inner energy absorbing material. For convenience, protective helmets can be generally classified as either internally shaped helmets or hard shell helmets. An internally shaped helmet can comprise one or more layers, including a thin outer shell, an energy absorbing or impact resistant liner, and a comfort or conforming liner. Hard-shell helmets may include a hard outer shell, an impact resistant liner, and a comfort liner. The hard shell may be formed by injection molding and may comprise Acrylonitrile Butadiene Styrene (ABS) plastic or other similar or suitable material. The outer shell of hard-shell helmets is typically made hard enough to resist impact and puncture and meet the relevant safety test standards, while being flexible enough to deform slightly during an impact, absorbing energy through deformation, and thus aiding in energy management. Hard-shell helmets are useful as bucket skating helmets, motorcycle helmets, snow and water sports helmets, football helmets, baseball batter helmets, catcher's helmets, hockey sports helmets, and for BMX riding competitions. While various aspects and implementations presented in this disclosure are directed to embodiments including in-molded helmets, the present invention is also directed to and applicable to hard shell helmets.

Improvements to both the conventional strap anchor 10 and the shell-mounted anchor 20 are the subject of the present disclosure and may be referred to as a bar tack clip or as a bar tack clip strap anchor method for convenience. The methods and devices disclosed herein may provide a number of advantages relative to the strap anchor 10 and shell-mounted anchor 20, which are discussed in more detail below.

The methods and apparatus disclosed herein may take several forms, a number of non-limiting examples of which are provided below. As shown in the examples below, and as shown in fig. 3-5I, the bar tack clip includes a new, unobtrusive, and useful bar tack clip that can be coupled to a strap or a piece of webbing, which in turn can be coupled to a strap anchor or a strap anchor housing.

FIG. 3 illustrates a bar tack anchoring system 50 for securing webbing or straps to an in-molded helmet that includes a strap anchor 52. Strap anchor 52 may also include an anchor housing 54 and in-molded flanges, ribs, reinforcement attachments, fins, umbrella systems, anchoring geometries, or reinforcement attachment points 56. In-mold flange 56 may be formed as a web or web that includes openings or voids 58 that extend or are disposed away from anchor housing 54, as shown in fig. 3. Bar tack anchoring system 50 may also include a bar tack clip 60, an example of which is also shown in fig. 3. The strap or webbing may be coupled to the bar tack clip 60 by stitching or with a bar tack, as described in more detail below with respect to fig. 4 and 5A-5I.

In some embodiments, in-mold flange 56 can be integrally formed with anchor housing 54 and formed simultaneously with and from the same material as anchor housing 54. In-mold flange 56 and anchor housing 54 may be made of any suitable structural material, such as plastic, metal, ceramic, cellulose, textile, fiberglass, carbon fiber, other fibers, rubber, polymer, or other similar material. Possible plastics include thermoplastic elastomers (TPE), polyolefins, Polyethylene (PE), polyethylene terephthalate (PETE), polypropylene (PP), Polyetherimide (PET), and Polyethersulfone (PEs), polyvinyl chloride (PVC), Vinyl Nitrile (VN), melamine, nylon, acetal, styrene-ethylene-butylene-styrene (SEBS), isoprene copolymers, styrene, polycarbonate, or other similar materials. When the strap anchor 52 is coupled to a helmet or an in-molded helmet, the in-molded flange 56 of the strap anchor 52 and the anchor housing 54 can be disposed within an energy-absorbing material or layer of the helmet. The in-mold flange 56 can be sufficiently large and include sufficient anchoring geometry to secure the strap anchor 52 to the helmet by securing at least the in-mold flange 56 within the energy-absorbing material to maintain a secure coupling to the helmet during an impact. Accordingly, when the bar tack anchoring system 50 is coupled to the helmet body, the in-molded flange 56 and all or part of the anchor housing 54 can be embedded within the helmet body. Where the in-molded flange 56 is disposed within the helmet body, the in-molded flange 56 can be used to distribute the force applied to the strap anchor 52 (such as tension from the webbing 80) from the bar tack clip 60 to the surrounding helmet body. The strap anchor 52 can be disposed within an energy management material similar to or the same as the energy management material 23 of an in-molded helmet (similar to or the same as the in-molded helmet 25) such that the strap anchor 52, the bar tack clip 60, and the cross beam 62 are not visible to the user from the outside of the finished in-molded helmet. The energy management material 23 may be one or more layers of expanded polypropylene (EPP), Expanded Polystyrene (EPS), Expanded Polyolefin (EPO), or other similar or suitable material.

The anchor housing 54 of the strap anchor 52 shown in fig. 3 differs from the strap anchor body 14 and shell-mounted anchor 20 of the conventional strap anchor 10 in that it is configured to securely couple to the bar tack clip 60. Reinforcement hitch clip 60 may be formed from a material similar to or the same as the material forming anchor housing 54 and in-molded flange 56. The bar tack clip 60 may include a cross beam, top cross beam or stay 62 about which a webbing or strap 80 may be disposed, and a bar tack 82 may be stitched into the webbing 80 to form a loop of webbing 84. The bar tack clip 60 may also include clips, barbs, prongs, tines, engagement tabs, or interlocking engagement beams 64 that prevent the bar tack clip 60 from being inadvertently pulled out of or away from the anchor housing 54 after it has been inserted into the anchor housing 54. A clip 64, such as a bar tack clip 60 or the face of bar tack clip 60 surrounding clip 64, may be provided at the inner bound side of bar tack clip 60 that is perpendicular to the sides of the bar tack clip and oriented toward the interior of the helmet or toward an opening in the helmet for the head of a user.

The beam 62 and the clip 64 may include a horizontal orientation, wherein opposite ends of the beam 62 and opposite ends of the clip 64 are coupled to connecting members or vertical connecting members 66 disposed on opposite edges of the bar tack clip 60. Cross beam 62 and connecting member 66 can be rigidly and integrally coupled to provide a strong and robust structure that can be inserted into anchor housing 54. Clip 64 and connecting member 66 may also be integrally formed, and clip 64 may be coupled to connecting member 66 in such a manner as to provide a strong and secure connection, while also allowing clip 64 to flex and temporarily move or deform during insertion of anchor housing 54, and then clip 64 to return to a normal or rest position once inserted into anchor housing 54 to lock in place or mateably couple with anchor housing 54. One or more gaps, openings, or channels 68 formed along portions of the clip 64, such as between the clip 64 and the connecting member 66, may provide flexibility of the clip 64.

Thus, after the strap anchor 52 has been disposed within a helmet (such as the EPS foam layer of a helmet), the bar tack clip 60 can be disposed within an opening in the strap anchor 52 or anchor housing 54. Webbing or strap 80 may be used to hold the helmet to the user's head after insertion of bar tack clip 60 into strap anchor 52, and may also improve the overall aesthetic appearance of the helmet while maintaining functionality by having bar tack clip 60 and its cross beam 62, and strap anchor 52, disposed within the helmet so that they are not visible to the user from the outside of the finished helmet.

The present anchoring systems and devices may additionally include optional additional features. A first optional feature may be a rivet opening 70, which may be formed in the outer surface of the strap anchor 52. The rivet opening 70 can be configured to receive a decorative rivet 72, which can be disposed and coupled to the rivet opening 70 to be visible on the exterior surface of the in-molded helmet. The rivets 72 may provide structural support for securing the bar tack clip 60 to the strap anchor housing 54, or may not provide any structural support for securing the bar tack clip 60 to the strap anchor housing 54, but rather provide a desired aesthetic or appearance.

A second optional feature of the anchoring system 50 includes the anchoring system 50, or a portion thereof, mounted to the outside of the helmet, or to the side of the helmet that is oriented away from or does not contact the user's head. Thus, the strap anchor 52 of the anchoring system 50 can be different from conventional or conventional anchors, such as the strap anchor 10, where the primary mechanism of the strap anchor is located on the inside surface of the helmet. Similarly, the strap anchor 52 of the anchoring system 50 can also be different from the shell-mounted anchor 20, where the shell-mounted anchor 20 is exposed at the bottom of the plastic shell 22 and centered within the energy-absorbing material of the helmet. In contrast to conventional tethering methods from ski helmets, the bar tack anchoring system 50 may comprise a portion of the anchor housing 54 mounted or disposed on the outside of the helmet to provide a visual aesthetic similar to some shell type helmets in which the straps are mounted to the outside of the helmet while providing a secure connection between the in-molded flange 56 and the in-molded helmet.

Fig. 4 illustrates an embodiment in which an optional adhesive 90, such as tape or double-sided tape, may be attached to the underside or inner surface of the strap anchor 52 and the outer shell or cap 92 (similar to shell 22) of the in-molded helmet. The adhesive 90 may hold the strap anchor 52 in place relative to the outer helmet shell during the in-mold molding process. The adhesive 90 may be used in addition to or instead of using the rivet 72 and punch attachment. The adhesive 90 may also cover, protect, and prevent in-mold molding material, such as EPS foam or other material, from entering the first space or opening 94 and the second space or opening 96 in which the bar tack clip 60 is to be disposed. In some embodiments, the adhesive 90 may have a thickness in the range of 0.2-5.0 millimeters (mm), or about 1mm, and as used herein, the term "about" may refer to the stated value plus or minus up to 10%, 25%, or 50%.

The bar tack anchoring system 50 shown in fig. 3-5I, such as bar tack anchoring system 150 shown in fig. 6A-6E, illustrate that the present disclosure contemplates and encompasses numerous configurations and variations of the shapes, structures and forms of bar tack anchoring systems. For example, anchor housing 54 may have any desired shape or size configured to receive or be matingly compatible with a corresponding bar tack clip 60. Anchor housing 54 may include 6 sides or surfaces, or any number of sides or surfaces, including four and five sides or surfaces, such as the five-sided or 5-surfaced anchor housing 54 shown in fig. 4. Alternatively, anchor housing 54 of fig. 4 may also be considered a six-sided anchor housing having an open sixth or bottom side through which bar tack clip 64 will enter. The outer contour, shape, or cladding of anchor housing 54 may comprise a rectangular prism, frame, polygon, or any other solid or hollow shape. Accordingly, anchor housing 54 may be considered a hollow frame having one or more spaces or openings (such as first space 94 and second space 96) that may partially or completely pass through the volume or one or more surfaces of anchor housing 54.

As shown in fig. 4, the first space or opening 94 may extend partially, but not completely or completely, through the anchor housing 54 such that the first space 94 passes through a first surface 98 oriented toward the interior of the helmet and does not pass through a second surface 100 of the anchor housing 54 opposite the first surface 98, the second surface 100 being oriented toward the exterior of the helmet.

The second space or opening 96 may also extend partially, but not completely or completely, through the anchor housing 54. The second space 96 can extend from a third surface 102, the third surface 102 being oriented at the bottom edge of the helmet and in a direction away from the bottom of the helmet, and also being positioned or oriented in a direction that is perpendicular, transverse, or substantially perpendicular or transverse to the first surface 98, the second surface 100, or both. The second space 96 can extend into the anchor housing 54 without extending through a fourth surface 104, the fourth surface 104 being opposite the third surface 102, the fourth surface 104 also being positioned or oriented in a direction that is perpendicular, transverse, or substantially perpendicular or transverse to the first surface 98, the second surface 100, or both.

First and

second spaces

94, 96 may intersect one another to provide an opening, void, or interior space within anchor housing 54 to receive bar tack clip 60. Although the space for receiving bar tack clip 60 is described as the intersection of two separate spaces (first space 94 and second space 96) for convenience, the space for receiving bar tack clip 60 may also be described or considered as a single space or void having an intersection or opening through first surface 98 and third surface 102. In either case, bar tack clip 60 may be inserted into anchor housing 54 through first space 96, with clip 64 flexibly deforming to fit through first space 94. The clip 64 of the bar tack clip 60 may then return to the resting position to extend into or through the second space 96 to releasably or permanently couple the clip 64 with the second space 96. Thus, the bar tack clip 60 can be coupled within the strap anchor 52 to allow the bar tack anchoring system 50 to couple the webbing 80 to the helmet, and to allow the user to couple the helmet to the user's head.

As described above, the bar tack anchoring system 50 may couple the webbing 80 to the helmet by: the webbing 80 is coupled to the bar tack clip 60 by stitching or placing the bar tack 82 into the webbing 80 to form a loop of webbing 84 that is disposed around and coupled to the cross beam 62. Non-limiting examples of attaching the webbing 82 to the bar tack clip 60, such as by stitching, are described herein with respect to fig. 5A-5I.

Fig. 5A shows an example of a bar tack clip 60 that includes a clip 64 at a central region of the bar tack clip 60 and a cross beam 62 at a top or front edge of the bar tack clip 60, although in various embodiments the relative positions of the clip and cross beam may be moved relative to each other. The cross beam 62 of the bar tack clip 60 is shown oriented toward the webbing 80, with the end 81 of the webbing 80 offset from the bar tack clip 60, then passing through the top opening, gap or channel 69 in the bar tack clip 60 and around the cross beam 62.

As shown in fig. 5B, the end 81 of the webbing 80 may pass through the top opening 69 and around the cross member 62, the opening 69 being adjacent the cross member 62. In some cases, a side or portion of the cross beam 62 may define a side or portion of the opening 69. The cross member 62 and the opening 69 may each be sized to receive the webbing 80 such that a loop 84 of webbing 80 may be formed around the cross member 62. The opening 69 may be adjacent to the cross beam 62, and in some cases, a side or portion of the cross beam 62 may define a side or portion of the opening 69.

After inserting the webbing 80 through the opening 69, the webbing 80 may be folded back across the cross member 62. The webbing 80 may then be sewn or otherwise secured with a reinforcement knot to the sewing machine 110 (as shown in figure 5C) to form a loop of webbing 84 as shown in figure 5D. The loop of webbing 84 may be stitched with a reinforcing hitch 82 that passes through the webbing 80 near the end 81 of the webbing 80, and through a central portion of the webbing 80 located away from the end 81 of the webbing 80. Creating a loop of webbing 84 around the cross beam 62 to couple the webbing 80 to the bar tack clip 60 is less time consuming and less costly than in-molding a plastic clip geometry, such as the strap anchor overmold clip 24, to the end 81 of the webbing 80.

As shown in fig. 5E, after stitching the loop of webbing 84 around the cross member 62, the bar tack clip 60 may then be folded over the bar tack 82 and a portion of the webbing 80 such that the surface 65 of the bar tack clip 60 opposite the clip 64 may be adjacent to or in contact with a surface of the webbing 80. As shown in fig. 5F, a portion of the webbing 80 disposed above the cross member 62 may form a leading edge 86 of the webbing 80 that covers the top of the bar tack clip 60. While the relative movement of the bar tack clip 60 and webbing 80 may be described or considered in relation to moving the bar tack clip 60 relative to the webbing 80, the opposite may be true such that the webbing 80 moves relative to the bar tack clip 60. Thus, the webbing 80 may be moved relative to the bar tack clip 60 such that the webbing 80 and bar tack 82 may be folded and placed adjacent to or in contact with the surface 65 of the bar tack 60. In either case, movement of the webbing 80, the bar tack clip 60, or both may cause the tail or length 88 of the webbing 80 to follow the bar tack clip 60 tail or length 88Height H₁Disposed and extending away from the cross beam 62. The tail or length 88 of the webbing 80 can then be used to couple the helmet to the user's head.

Continuing from FIG. 5F, FIG. 5G shows the bar tack clip 60 ready for insertion into the strap anchor 52 or the strap anchor housing 54. The bar tack clip 60 and webbing 80 are shown aligned with the cross beam 62 of the bar tack clip 60 that is oriented toward and aligned with the opening 96 in the anchor housing 54. Clip 64 of bar tack clip 60 is also oriented such that bar tack clip 60 will mateably couple with opening 94.

Fig. 5H shows the bar tack clip 60 and webbing 80 coupled around the cross beam 62 inserted into the strap anchor housing 54 and releasably coupled to the strap anchor 52 after the bar tack clip 60 is aligned with the strap anchor 52 or the strap anchor housing 54. FIG. 5H shows the bar tack clip 60 partially inserted into the strap anchor 52.

FIG. 5I shows the bar tack clip 60 fully engaged with the strap anchor 52 such that the clip 64 of the bar tack clip 60 is disposed within the opening 94 of the bar tack clip 60. The clip 64 is in firm contact with the anchor housing 54 to prevent or impede removal of the bar tack clip 60 from the anchor housing 54 when tension is applied to the webbing or strap 80 to pull the webbing 80 and bar tack clip 60 away from the strap anchor 52, such as during an impact or bump in the event a user wears a helmet.

For clarity, fig. 5G-5I show a representation of the strap anchor 52 outside of the helmet including the in-molded flange 56. In actual use, however, the strap anchor 52 may be largely or completely hidden from view by being buried or embedded in a helmet, such as an EPS foam layer. In some cases, one or more strap anchors 52 will be disposed within the helmet at a side or lateral portion of the helmet, such as at the lower edge of the helmet, which may be the same or similar to the location of the shell-mounted anchor or shell 20 shown in fig. 2A. In any case, the method of coupling the webbing 80 to the in-molded helmet can include in-molding the strap anchor 52 into a protective helmet or helmet shell, wherein the opening 96 in the strap anchor 52 is exposed relative to the protective helmet shell or helmet. The method may further include providing a bar tack clip 60 including the cross beam 62, stitching the webbing 80 to or around the cross beam 62, and inserting the bar tack clip 60 into the opening 96 of the strap anchor 52 to permanently or releasably couple the bar tack clip 60 to the strap anchor 52.

By attaching webbing or strap 80 to bar tack clip 60 with stitched bar tack 82, webbing 80 and bar tack clip 60 can be coupled to and inserted into anchor housing 54 after anchor housing 54 is in-molded into the in-molded energy absorbing material of the in-molded helmet. Thus, the complexity of including the bar tack clip 60 and webbing 80 in the in-mold molding process, or attaching them to the strap anchor 52 or helmet during the in-mold molding process, can be avoided. Prior to in-molding the in-molded helmet, anchor housing 54 can be coupled to a mold or to a shell into which the in-molded helmet is to be formed, such as a polycarbonate vacuum formed shell that can be similar to plastic shell 22 shown in fig. 2A. In some embodiments, the strap anchor 52, including the in-molded flange 56, the anchor housing 54, or both, may be snapped into or perforated through a portion of the shell, such as a cut, void, hole, or opening in the shell. Alternatively, the strap anchor 52 may also be seated on a blade or post in an in-mold used to in-mold the energy-absorbing material (such as an EPS mold during an EPS forming process). While some variations of the strap anchor 52 will include rivets 72 and have portions of the strap anchor 52 exposed from the helmet, other variations or versions of the strap anchor may be formed without rivets 72 (including decorative rivets), and may be coupled to the shell prior to in-mold molding, and hidden from view after molding by being disposed within the in-molded helmet. In other embodiments, the rivet 72 shown in fig. 3 may be used to secure the strap anchor 52 to the shell prior to in-mold molding, and the rivet 72 may remain visible from the outside of the shell of the helmet.

Fig. 6A-6E include another embodiment of an anchoring system according to the present disclosure. FIG. 6A illustrates a non-limiting example of a bar tack anchoring system 150. The bar tack anchoring system 150 may include webbing or strap 80, strap anchor 152, anchor housing 154, in-molded flange 156, and bar tack clip 160, each of which may be formed of the same material, different materials, or similar materials, including one or more of any suitable structural materials, such as plastic, metal, ceramic, cellulose, textile, fiberglass, carbon fiber, other fibers, rubber, polymer, or other similar materials. Possible plastics include TPE, polyolefin, PE, PETE, PP, PET, PEs, PVC, VN, melamine, nylon, acetal, SEBS, isoprene copolymer, styrene, polycarbonate, or other similar materials.

The bar tack clip 160 may also include one or more side clips, barbs, prongs, tines, engagement tabs, or interlocking engagement 164. Side clip 164 may be a load bearing member coupled with or cooperatively engageable with strap anchor 152 to retain strap anchor 152 to bar tack clip 160 as part of bar tack anchoring system 150 for retaining the helmet to the wearer's head. The side clips 164 may differ from the clips 64 in both number and location. As shown in fig. 6A, bar tack clip 160 may include two side clips 164 that are disposed opposite one another at the sides or lateral regions of bar tack clip 160, rather than on the front or back of bar tack clip 160. In other words, the side clips 164 of the bar tack clip 160 may correspond to, be aligned with, or may be parallel or substantially parallel to the length or height of the webbing 80 or the edge 85 of the webbing 80. In addition, the strap anchor 152 can include a load bearing member or clip 159 that corresponds to, is coupled to, and is cooperatively sized with the side clip 164 of the bar tack clip 160. The load bearing member 159 can be separated or offset from the central portion 155 of the anchor housing 154 by an opening or channel 157. The load bearing member 159 may also be flexibly or hingedly coupled to the anchor housing 154 over or at the ends of the channel or opening 157. Thus, the load bearing member 159 may be supported and cantilevered from above, rather than from below, as is the case with the clip 64 shown in fig. 3.

Fig. 6B shows an enlarged view of the bar tack clip 160 separated from and not coupled to the strap anchor 152 and webbing 80. As shown in fig. 6B, the bar tack clip 160 may include a side clip 164 that aligns with an edge of the anchor housing 154 and the edge 85 of the webbing 80 coupled or attached to the bar tack clip 160, rather than with a major surface or face of the webbing 80 that is perpendicular to the edge 85. Thus, the side clips 164 may be perpendicular, transverse, or aligned at a 90 degree rotation relative to the clips 64 shown above in fig. 2A and 5. Fig. 6B also shows that the beam 162 is sized to receive the loop 84 of webbing 80 around the beam 162, the webbing 80 further being disposed through an opening 169 in the bar tack clip 160, the opening 169 being adjacent to the beam 162. In some cases, sides or portions of the beam 162 may define sides or portions of the opening 169.

Fig. 6C illustrates a bar tack clip 160 with the webbing 80 coupled to the bar tack clip 160, but not to the strap anchor 152, as shown in fig. 6A. As described above with respect to the webbing 80 coupled to the cross member 62 or the bar tack clip 60, the webbing 80 may be coupled to the cross member 162 of the bar tack clip 160, as shown in fig. 5A-5F. The bar tack clip 160 may optionally include an arcuate member or support 166 that forms a through hole or opening 166 for receiving a portion of the webbing 80 or allowing the portion to extend from a first side of the through hole 166 to a second side of the through hole 166 opposite the first side. Through-hole 166 may be disposed at a lower edge 170 of bar tack clip 160 and aligned with bow 166. Thus, a portion of the webbing 80 that is visible to the user may be neatly defined by a uniform portion of the lower edge 170 of the bar tack clip 160, such as a bead of plastic material. Conversely, and without the inclusion of the bow 166, the webbing 80 may be defined on less than all sides, such as on only one side or three sides by the bar tack clip 160. Fig. 6C shows a non-limiting example of a side clip 164 coupled to the cross beam 162 at or near the top of the bar tack clip 160, but in various embodiments, the side clip 164 may also be disposed at any lower point along an edge or side of the bar tack clip 160.

Figure 6D shows a cross-sectional perspective view of the bar tack clip 160 and webbing 80 and the webbing taken along line 1D shown in figure 6C. Fig. 6D also shows the path of the webbing 88 as it wraps around the cross member 162, is secured with the reinforcing hitch 82, and is disposed through the through-hole 168.

Figure 6E illustrates a close-up profile view of a portion of the bar tack anchoring system 150 shown as the left-hand central portion of the bar tack anchoring system 150 in figure 6A. Fig. 6E shows a bar tack clip 160 coupled to the strap 80 and disposed within the strap anchor housing 145. The left side clip 164 of the bar tack clip 160 is shown interlocking or matably coupled with the left side load bearing member 159. As the bar tack clip 160 is inserted into the strap anchor housing 154, the flexible load support arms 159 of the strap anchor 152 may be moved, pushed, or deformed by the side clips 164 of the bar tack clip 160. Alternatively, the flexible side clip 164 of the bar tack clip 160 may be moved, pushed, or deformed by the load bearing member 159 of the strap anchor 152 as the bar tack clip 160 is inserted into the strap anchor housing 154. In either case, the load bearing member 159 and the side clamp 164 can be engaged, mateably coupled, and locked in place after being advanced into the strap anchor 152.

For clarity, fig. 6A-6E show a representation of the strap anchor 152 including an in-molded flange 156 outside of the helmet. However, in actual use, the strap anchor 152 may be largely or completely hidden from view by being buried or embedded in the helmet, such as in an EPS foam layer. In some cases, one or more strap anchors 152 will be disposed within the helmet at a side or lateral portion of the helmet, such as at a lower edge of the helmet, which may be the same or similar to the location of the shell-mounted anchor or shell 20 shown in fig. 2A. In any case, the method of coupling the webbing 80 to the in-molded helmet can include in-molding the strap anchor 152 into a protective helmet or helmet shell, wherein the opening 168 in the strap anchor 152 is exposed relative to the protective helmet shell or helmet. The method may further include providing a bar tack clip 160 including a cross beam 162, stitching the webbing 80 to or around the cross beam 162, and inserting the bar tack clip 160 into the opening 168 of the strap anchor 152 to permanently or releasably couple the bar tack clip 160 to the strap anchor 152.

By attaching the webbing or strap 80 to the bar tack clip 160 with the stitched bar tack 82, the webbing 80 and bar tack clip 160 can be coupled to and inserted into the anchor housing 154 after the anchor housing 154 is in-molded into the in-molded energy absorbing material of the in-molded helmet. Thus, the complexity of including the bar tack clip 160 and webbing 80 in the in-mold molding process, or attaching them to the strap anchor 152 or helmet during the in-mold molding process, can be avoided. Prior to in-molding the in-molded helmet, the anchor housing 154 can be coupled to a mold or to a shell into which the in-molded helmet is to be formed, such as a polycarbonate vacuum formed shell that can be similar to the plastic shell 22 shown in fig. 2A. In some embodiments, the strap anchor 152, including the in-molded flange 156, the anchor housing 154, or both, can be snapped into or perforated through a portion of the shell, such as a cut, void, hole, or opening in the shell. Alternatively, the strap anchor 152 can also be seated on a blade or post in an in-mold used to in-mold the energy-absorbing material (such as an EPS mold during an EPS forming process). Some variations of the strap anchor 152 can also include rivets. The strap anchor 152 can be disposed within an energy management material similar to or the same as the energy management material 23 of an in-molded helmet (similar to or the same as the in-molded helmet 25) such that the strap anchor 152, the bar tack clip 160, and the cross beam 162 are not visible to the user from outside of the completed in-molded helmet.

Thus, while the particular shapes and configurations of the strap anchor and bar tack clip can vary, numerous variations can include common features. Such common features may include the form of the insertion geometry and the method of creating it. Methods of forming an insertion member (e.g., a bar tack clip) without the need to overmold a plastic component, such as the strap anchor overmold clip 24 of fig. 2A-2D. Additional common features may include a bar tack that is hidden within the body of the strap anchor once the clip is inserted into the strap anchor. In addition, each bar tack clip may include a beam opening over which a strap may be looped or passed. The strap anchor may have corresponding interlocking clips or engagement beams that may be matingly coupled to the clips of the bar tack clip.

Accordingly, the anchoring system described herein may provide advantages over conventional methods for installing the strap anchor 10 by allowing the webbing system to be installed outside the world rather than inside the world, or away from the inner surface of the helmet adjacent the wearer's head. The anchoring system may further allow for attachment of mounting features to in-molded polycarbonate shell caps, as found on bicycles and snow helmets. The anchoring system may further allow the use of decorative rivets to provide the appearance or "look" of a rivet attachment to a housing, such as a housing made of Acrylonitrile Butadiene Styrene (ABS) or other similar material. In addition, by forming the anchoring system as described herein, it is possible to insert the webbing reinforcement hitch clip after in-mold molding of the EPS, thereby avoiding the complexity of including the webbing assembly during in-mold molding.

For example, a difficulty with the anchor 20 installed using the shell of fig. 2A-2D may be the over-molded clip 24 formed over and around the end of the webbing 28. Overmolding the webbing 28 to form the overmolded clip 24 introduces a manufacturing process or step that requires additional time and expense. Further, housing the strap anchor overmold clip 24 with a void or opening in the shell-mounted anchor 20 generally includes using a cap 30 to prevent foam or in-mold molding material (such as expanded polystyrene beads) of the helmet from entering the void or opening in the shell-mounted anchor 20 and interfering with the engagement or interlocking of the strap anchor overmold clip 24 with the shell-mounted anchor 20. Thus, while useful, the inclusion of the cap 30 results in a more complex device and introduces another component or element that requires additional time and expense in manufacturing and assembly.

In the case of the above examples, embodiments, and specific implementation reference examples, it will be understood by those of ordinary skill in the art that other helmets and manufacturing equipment and examples may be mixed with or substituted for those provided. Where the above description relates to particular embodiments of helmets and customization methods, it should be apparent that many modifications can be made and these embodiments and implementations can also be applied to other helmet customization technologies without departing from the spirit of the invention. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the invention and within the knowledge of one of ordinary skill in the art.

Claims

1. An anchoring system for securing a strap to an in-molded helmet, comprising:

a strap anchor, the strap anchor comprising:

an anchor housing defining an interior space, an

An in-molded flange coupled to the anchor housing and sized to retain the strap anchor within the in-molded helmet, the in-molded flange comprising a mesh geometry comprising a solid outer perimeter and at least one inner open area surrounded by the solid outer perimeter;

a bar tack clip sized to fit partially within the anchor housing, the bar tack clip comprising:

a cross-beam coupled to the vertical connecting members of the bar tack clip,

an opening adjacent to the cross beam, an

At least one clip comprising a horizontal orientation and coupled to the vertical connection member of the bar tack clip and sized to mateably couple with the anchor housing;

wherein the strap anchor is disposed within an energy management material of an in-molded helmet such that the bar tack clip and strap anchor are not visible to a user from an outside of the completed in-molded helmet, and

a strap disposed through the opening in the bar tack clip and encircling the cross beam to form a leading edge of the strap, the strap coupled to itself with a bar tack such that at least the cross beam and the leading edge of the strap are received within the interior space of the anchor housing.

2. The anchoring system of claim 1, wherein the at least one clip of the bar tack clip interlocks with the strap anchor to prevent the bar tack clip from being pulled out of or away from the anchor housing.

3. The anchoring system of claim 2, wherein the at least one clip of the bar tack clip comprises two side clips.

4. The anchoring system of claim 2, wherein the at least one clip of the bar tack clip is disposed at an inboard side of the bar tack clip, the inboard side being perpendicular to a side of the bar tack clip.

5. The anchoring system of claim 1, wherein the strap is coupled to the bar tack clip without an overmolded webbing clip.

6. The anchoring system of claim 1, wherein the strap anchor, the bar tack clip, and the strap are adapted to be mounted to an ambient side of the helmet, wherein the ambient side of the helmet is oriented away from a user's head.

7. The anchoring system of claim 1, further comprising a through-hole at a lower edge of the bar tack clip and aligned with the cross beam, the through-hole sized to receive a portion of the strap.