EP1627575B1 - Full-face helmet and method of manufacturing same - Google Patents
Full-face helmet and method of manufacturing same Download PDFInfo
- Publication number
- EP1627575B1 EP1627575B1 EP05107246A EP05107246A EP1627575B1 EP 1627575 B1 EP1627575 B1 EP 1627575B1 EP 05107246 A EP05107246 A EP 05107246A EP 05107246 A EP05107246 A EP 05107246A EP 1627575 B1 EP1627575 B1 EP 1627575B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- bubble
- base portion
- band
- outer shell
- chin protector
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Not-in-force
Links
Images
Classifications
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
- A42C2/00—Manufacturing helmets by processes not otherwise provided for
- A42C2/002—In-mould forming
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/06—Impact-absorbing shells, e.g. of crash helmets
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/08—Chin straps or similar retention devices
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/10—Linings
- A42B3/12—Cushioning devices
- A42B3/125—Cushioning devices with a padded structure, e.g. foam
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/28—Ventilating arrangements
Definitions
- the inner band 20 has a pair of opposite holes 27, 28 close to its upper edge. These holes are formed alongside the holes 21, 22 of the outer shell and in such a way as to be substantially aligned with the latter. There are thus two radially aligned holes on each of the two opposite sides of the helmet. Into each of these pairs of aligned holes there is inserted, before the polystyrene is injected, one of the two attachment devices 23 for the straps 25, 26.
- a valve 29 is fitted in the air inlet hole 17 in the outer shell 11 so that the incoming air flow can be adjusted.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Helmets And Other Head Coverings (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Basic Packing Technique (AREA)
Abstract
Description
- The present invention relates to a full-face helmet suitable for motorcyclists, skiers and people engaged in various activities requiring a protective helmet. The invention also relates to a method of manufacturing this full-face helmet.
- Known full-face helmets comprise an outer shell (usually polycarbonate or glass fibre or Kevlar) which forms the bubble and the chin protector, while on the inner surface of the shell is spot-bonded a layer of expanded polystyrene which covers the inner surface of the bubble.
-
FR-A-2 340 066 US-A-4 710 984 ,US-B-6 711 751 andEP-A-0 370 696 . - It is an object of the invention to provide a full-face helmet capable of offering better protection against impact, especially but not exclusively against frontal impacts to the chin protector.
- It is another object of the invention to provide a full-face helmet that weighs less than the conventional full-face helmets mentioned above. It is another object of the invention to improve on the attachment of the straps which fasten under the user's chin to make the helmet fast.
- These and other objects and advantages which will be seen more clearly below, are achieved, according to the present invention, with a full-face helmet, and a method of manufacturing it, as defined in the appended claims.
- A preferred but not restrictive embodiment of the invention will now be described, referring to the attached drawings, in which:
- Figure 1 is a side view in vertical section of a helmet according to the invention;
- Figure 2 is a view in section on II-II as marked in Figure 1;
- Figure 3 is a front view of the helmet in the direction of arrow III as marked in Figure 1;
- Figure 4 is a view in horizontal section on IV-IV as marked in Figure 1; and
- Figure 5 is an enlarged view of a detail from Figure 2.
- Referring initially to Figure 1, a full-face helmet according to the present invention is marked 10 as a whole. The
helmet 10 comprises anouter shell 11 which forms abubble 12 with a lower orbase portion 12a and achin protector 13, an annular band orstrip 20 located within and at a distance from thebase portion 12a of the bubble and from thechin protector 13, and alayer 30 of expanded polystyrene injected onto the inner surface of the bubble or into the intermediate annular gap or space 14 (Figure 4) which is bounded on the inside by theannular band 20 and on the outside by thebase portion 12a of the bubble and by thechin protector 13. - In the present description and in the claims which follow, terms and expressions such as "radial", "inner", "outer", "upper" and "lower" should be interpreted with reference to the centre of the helmet and to the position of the helmet when worn on the head of a user.
- The principal steps in making the
helmet 10 are as follows. - Starting from a generally flat sheet of polycarbonate (or glass fibre or Kevlar), the
outer shell 11 as shown in the drawings is obtained by thermoforming or moulding. A number of holes are preferably formed in the shell 11: - a
front hole 15 in the chin protector, which will later take aplug 16 for attaching aflow deflector 19 for channelling the air over the outer surface of the visor (not shown); - a
hole 17 in the front-upper region of the bubble to create an air intake for internal ventilation of the helmet, as described in more detail below; - an
air outlet hole 18 in the rear region of the bubble; and - two
opposite side holes 21, 22 (Figure 2) for insertion of respectivetubular pieces 24 belonging to twoattachment devices 23 for thehelmet fastening straps - Thermoforming or injection moulding is used to form the
annular band 20, which is in the form of a closed, preferably continuous loop extending vertically to a limited height and following the (roughly oval) shape in plan view of the base of the helmet, and more precisely of the chin protector and the base of the bubble. As shown in Figure 1, the height of the front part of theannular band 20 is preferably comparable with that of thechin protector 13. However, theannular band 20 has radial dimensions significantly smaller than those of theouter shell 11, in such a way as to delimit with the latter theannular gap 14. - The
outer shell 11 and theinner band 20 are then placed in a mould (not shown) for the injection moulding of expanded polystyrene. In the mould theband 20 is positioned within and at a radial distance from the base of theshell 11, as shown in Figures 1 and 4, to define theannular gap 14. - The
inner band 20 has a pair ofopposite holes holes attachment devices 23 for thestraps - Also before the polystyrene is injected, a
valve 29 is fitted in theair inlet hole 17 in theouter shell 11 so that the incoming air flow can be adjusted. - The polystyrene is then injected to form the
layer 30 of expanded polystyrene, which covers the inner surface of thebubble 12 and fills theannular gap 14, making intimate contact with theinner band 20, with thebase portion 12a of the bubble, and with thechin protector 13. In this way thelayer 30, the inner band and theouter shell 11 are firmly held together as a single body. - In the event of a frontal impact to the chin protector, as indicated by the arrow A in Figure 4, the inner band, being connected to the outer shell, cooperates with the
chin protector 13 to withstand the impact and diffuse and dissipate the impact energy to the other parts of the helmet. - It is important to note that the helmet according to the invention exhibits better performance in impact absorption not only on the chin protector. Tests conducted by the Applicant demonstrate that, because of the connection between the outer shell and the polystyrene layer on the inside of the bubble, excellent results are also obtained in tests of impacts from above and against the sides of the bubble. The results of these tests have made it possible to reduce the thickness of the outer shell to approximately 1 mm (as against a thickness of 2 - 4 mm for the shells of conventional helmets). It has also been possible to use a less dense polystyrene than in conventional helmets, replacing a density of 80 - 90 kg/m3 to approximately 70 kg/m3. The result has been to produce a helmet weighing approximately 0.750 kg that offers greater safety and is far lighter than conventional helmets, which weigh on average about 1.250 kg. As will be appreciated, reducing the weight usually militates against safety.
- Another important advantage provided by the present invention has to do with the improved attachment of the straps. As illustrated in Figure 5, the
attachment devices 23 are embedded in the polystyrene when the latter is injected. Each of these devices comprises atubular distance piece 24 that extends from the outer shell to the inner band, and that is rigidly fixed to or formed integrally with anattachment piece 31 having an extended surface, in this case for example in the form of a wheel with anouter ring 32 connected to thetubular piece 24 by spokes orradial ribs 33. Anexpansion pin 35 is inserted into thetubular distance piece 24 from the inside, and sealed on the outside by aplug 36.Reference number 37 is a washer interposed between thetubular distance piece 24 and the enlarged part of theexpansion pin 35, while 38 is a stirrup to which thestrap 26 is connected. - Two factors contribute to the improved attachment compared with the conventional fixing system (which usually uses a rivet to fix the strap to the outer shell): the embedding of the
attachment device 23 in the polystyrene, and the distance apart of the two points of bearing contact between the fixing device and theholes - In the same polystyrene-injection step, two through
holes 37, 38 (Figure 1) are formed in thelayer 30 which extend from therespective holes layer 30 which covers the inside of the bubble, and a series of separate, essentiallyparallel grooves 39 are formed to carry the air from theadmission hole 17 to theoutlet hole 18. As illustrated in Figure 3, thegrooves 39 are distributed over the inner surface of thepolystyrene layer 30 to create a diffuse internal ventilation to prevent the stagnation of hot air and so increase the user's comfort. - It will be understood that the invention is not limited to the embodiment described and illustrated herein, which is to be considered as an illustrative embodiment of the helmet. Rather, the invention is capable of modifications to shapes, dimensions and arrangements of parts, constructional details and materials employed. For example, the attachment piece may differ in shape from the wheel shape illustrated in the figures (it may for example be shaped like a plate or like a solid disc).
Claims (5)
- A method of manufacturing a full-face helmet, comprising the following steps:a1) providing an outer shell (11) forming a bubble (12) with a base portion (12a) and a chin protector (13);a2) providing an annular band (20) having a peripheral surface with radial dimensions significantly smaller than those of the base portion (12a) of the bubble and of the chin protector (13) of the outer shell (11);b) placing the outer shell (11) and the inner band (20) in an expanded-polystyrene injection-moulding machine, positioning the inner band (20) within and at a radial distance from the base of the shell (11), so as to define an annular gap (14) bounded on the inside by the annular band (20) and on the outside by the base portion (12a) of the bubble and of the chin protector (13) of the shell (11);c) injecting expanded polystyrene onto the inner surface of the bubble (12) and into the annular gap (14) so as to produce a layer of expanded polystyrene (30) which- fills the annular gap (14), making intimate contact with the inner band (20), with the base portion (12a) of the bubble and with the chin protector (13) so as to connect the band (20) firmly to the shell (11), and- covers and makes intimate contact with the inner surface of the cranial part.
- The method of Claim 1, characterized in that
said step c) is preceded by the step of inserting between the outer shell (11) and the inner band (20), in opposite lateral positions, two devices (23) for attaching respective helmet fastening straps (25, 26), and in that
following the said injection step c), the attachment devices (23) remain embedded in the polystyrene layer (30). - The method of Claim 2, characterized in that said step a1) includes the step of forming, on each of the two opposite sides of the bubble (12), a respective hole (21, 22) for mounting the attachment devices (23).
- A full-face helmet of the type comprising
an outer shell (11) that forms a bubble (12) with a base portion (12a) and a chin protector (13), and
an expanded-polystyrene layer injection-moulded on the inner surfaces of the bubble (12), of the base portion (12a) and of the chin protector (13);
characterized in that
the helmet also includes an annular band (20) located within and at a distance from the base portion (12a) of the bubble and from the chin protector (13) and
in that the expanded-polystyrene layer (30) makes intimate contact with the inner surface of the bubble and at least partly fills a gap (14) bounded on the inside by the annular band (20) and on the outside by the base portion (12a) of the bubble and by the chin protector (13), in such a way as to make intimate contact with the inner band (20), with the base portion (12a) of the bubble and with the chin protector (13), so as to connect the band (20) firmly to the shell (11). - The helmet of Claim 4, characterized in that the gap (14) is an annular gap that runs around the inner periphery of the base of the outer shell (11) and is completely filled with expanded polystyrene (30) formed by injection.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP07110481A EP1839510B1 (en) | 2004-08-17 | 2005-08-05 | Attachment device for a helmet fastening strap |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IT000569A ITTO20040569A1 (en) | 2004-08-17 | 2004-08-17 | FULL FACE HELMET AND PROCEDURE FOR ITS MANUFACTURE |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07110481A Division EP1839510B1 (en) | 2004-08-17 | 2005-08-05 | Attachment device for a helmet fastening strap |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1627575A1 EP1627575A1 (en) | 2006-02-22 |
EP1627575B1 true EP1627575B1 (en) | 2007-10-24 |
Family
ID=35429377
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP05107246A Not-in-force EP1627575B1 (en) | 2004-08-17 | 2005-08-05 | Full-face helmet and method of manufacturing same |
EP07110481A Not-in-force EP1839510B1 (en) | 2004-08-17 | 2005-08-05 | Attachment device for a helmet fastening strap |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07110481A Not-in-force EP1839510B1 (en) | 2004-08-17 | 2005-08-05 | Attachment device for a helmet fastening strap |
Country Status (5)
Country | Link |
---|---|
EP (2) | EP1627575B1 (en) |
AT (2) | ATE427671T1 (en) |
DE (2) | DE602005013824D1 (en) |
ES (2) | ES2296082T3 (en) |
IT (1) | ITTO20040569A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2042048A2 (en) | 2007-09-25 | 2009-04-01 | CD DESIGN S.r.l. | A composite crash helmet |
Families Citing this family (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8117679B2 (en) * | 2006-03-22 | 2012-02-21 | Fox Head, Inc. | Molded articles and molding methods particularly for a protective helmet |
GB2445914A (en) * | 2007-01-24 | 2008-07-30 | Everitt William Vero | Moulded helmet |
ITTO20070936A1 (en) | 2007-12-21 | 2009-06-22 | Cd Design S R L | COMPOSITE HELMET AND PROCEDURE FOR ITS MANUFACTURING |
TW200927009A (en) * | 2007-12-25 | 2009-07-01 | Tze-Ping Wang | Integrally safety helmet and manufacturing method thereof |
ITGE20100119A1 (en) * | 2010-10-25 | 2012-04-26 | Jfm S R L | "PROTECTIVE HELMET WITH LOCKING BELT PINS" |
IT1402939B1 (en) * | 2010-11-18 | 2013-09-27 | Vemar Helmets S R L | SAFETY HELMET TERMINAL ELEMENT |
US9763488B2 (en) | 2011-09-09 | 2017-09-19 | Riddell, Inc. | Protective sports helmet |
US10159296B2 (en) | 2013-01-18 | 2018-12-25 | Riddell, Inc. | System and method for custom forming a protective helmet for a customer's head |
CN105636469B (en) | 2013-12-06 | 2021-01-26 | 贝尔运动股份有限公司 | Flexible multilayer helmet and method of making same |
WO2016069798A1 (en) | 2014-10-28 | 2016-05-06 | Bell Sports, Inc. | In-mold rotation helmet |
WO2016112987A1 (en) * | 2015-01-15 | 2016-07-21 | Cato Composite Innovations B.V. | Flexible sports helmet |
WO2018017867A1 (en) | 2016-07-20 | 2018-01-25 | Riddell, Inc. | System and methods for designing and manufacturing a bespoke protective sports helmet |
EP3733010B1 (en) * | 2017-12-26 | 2023-02-01 | VOG - Image Police Inc. | Safety helmet and manufacturing method therefor |
WO2020037279A1 (en) | 2018-08-16 | 2020-02-20 | Riddell, Inc. | System and method for designing and manufacturing a protective helmet |
WO2020107005A1 (en) | 2018-11-21 | 2020-05-28 | Riddell, Inc. | Protective recreational sports helmet with components additively manufactured to manage impact forces |
USD927084S1 (en) | 2018-11-22 | 2021-08-03 | Riddell, Inc. | Pad member of an internal padding assembly of a protective sports helmet |
ES1239399Y (en) * | 2019-11-04 | 2020-06-15 | Mat Product & Tech Slu | STRUCTURAL SHELL HELMET |
CN112056679A (en) * | 2020-09-04 | 2020-12-11 | 安徽润宏塑料制品有限公司 | Automatic cap assembling method |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2340066A1 (en) * | 1976-02-09 | 1977-09-02 | Sl France | Protective helmet of foamed polyurethane between two rigid shells - which are connected only by the plastic foam |
CH657760A5 (en) * | 1984-06-18 | 1986-09-30 | Battelle Memorial Institute | IMPACT PROTECTIVE HELMET AND MANUFACTURING METHOD THEREOF. |
US5119516A (en) * | 1988-11-21 | 1992-06-09 | Bell Sports, Inc. | Reinforced expanded plastic helmet construction |
SE9000922L (en) * | 1990-03-15 | 1991-09-16 | Rex Handels Ind Ab | DEVICE AT HELMET |
US6711751B1 (en) * | 2001-03-08 | 2004-03-30 | K-2 Corporation | Mounting system for helmets |
ITTO20020611A1 (en) * | 2002-07-15 | 2004-01-15 | Rem Line Srl | PROCEDURE FOR PRODUCING MOTORCYCLE HELMETS OBTAINED BY THAT PROCEDURE |
-
2004
- 2004-08-17 IT IT000569A patent/ITTO20040569A1/en unknown
-
2005
- 2005-08-05 DE DE602005013824T patent/DE602005013824D1/en active Active
- 2005-08-05 EP EP05107246A patent/EP1627575B1/en not_active Not-in-force
- 2005-08-05 AT AT07110481T patent/ATE427671T1/en not_active IP Right Cessation
- 2005-08-05 EP EP07110481A patent/EP1839510B1/en not_active Not-in-force
- 2005-08-05 AT AT05107246T patent/ATE376368T1/en not_active IP Right Cessation
- 2005-08-05 DE DE602005002988T patent/DE602005002988T2/en active Active
- 2005-08-05 ES ES05107246T patent/ES2296082T3/en active Active
- 2005-08-05 ES ES07110481T patent/ES2323390T3/en active Active
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2042048A2 (en) | 2007-09-25 | 2009-04-01 | CD DESIGN S.r.l. | A composite crash helmet |
Also Published As
Publication number | Publication date |
---|---|
ATE376368T1 (en) | 2007-11-15 |
DE602005002988D1 (en) | 2007-12-06 |
DE602005002988T2 (en) | 2008-08-14 |
EP1839510B1 (en) | 2009-04-08 |
EP1627575A1 (en) | 2006-02-22 |
ES2296082T3 (en) | 2008-04-16 |
ATE427671T1 (en) | 2009-04-15 |
ES2323390T3 (en) | 2009-07-14 |
EP1839510A1 (en) | 2007-10-03 |
ITTO20040569A1 (en) | 2004-11-17 |
DE602005013824D1 (en) | 2009-05-20 |
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