EP1894483A1 - Protective helmet and manufacturing method thereof - Google Patents

Abstract

The safety helmet (10), for sports activities, has an outer shell (11) and a thin inner padded hood (12). The shell is covered at least locally by a flexible fabric cover, bonded to the shell along its edges by a seamed line. The shell is fitted with ventilation openings (14-16).

Description

The invention relates to a protective helmet. It also relates to its manufacturing process.

For recreational sports such as skating, ice skating, biking, skiing, etc., it is becoming more common to wear a hard hat. These helmets generally comprise an outer shell made of a thin and rigid material, for example polycarbonate or ABS, and inside a damping cap for example made of polystyrene. These helmets are further equipped with a chinstrap and optionally an auxiliary restraint that passes on the back of the neck of the user. Most often they also have elements of comfort such as foam cushions, a textile trim, sometimes called a cap, on the inside of the cap or other.

To make the wearing of the helmet more pleasant there are also provided vents at the outer shell and the cap which form air ducts.

Two main techniques are used to make such helmets. According to a first technique, the shell and the cap are manufactured separately and subsequently assembled, for example, using glue, or any other appropriate means.

According to another technique, the shell is made and then placed in a mold to inject a material which will form the cap after expansion and hardening.

In both cases, the outer shell of the helmet is formed by the thin shell.

In the second case, the shell is constituted by a very thin sheet of a PVC type material whose thickness is such that when bare, this shell has the rigidity necessary to provide the protection expected by the helmet final. Generally, the cap is made of expanded polystyrene or an equivalent material. Since the assembly of the cap and the shell is done directly in the mold, during the polystyrene expansion phase, this helmet manufacturing technology is called "in-mold" technology.

Helmets are a protective accessory that does not directly affect the performance of the user in his sport practice. Also to make the helmet more attractive during its purchase and its use manufacturers have sought to improve its aesthetics. A first way was to work the shape of the outer shell of the helmet and its vents. Another way has been to add accessories, for example a visor. Another way has been to decorate the outer shell, for example by means of stickers, transfers, by a screen printing technique or by painting to directly print a pattern on the shell.

Another way has been to add a flexible material envelope to modify the external appearance of the hull. Patent applications FR2680305 , EP1256285 and 1358810 describe such devices.

These devices have in common the fact of being removable and where appropriate interchangeable. In return the aesthetic effect they produce is not completely satisfactory because the fastening systems do not allow to stretch the envelope over the entire covered area without having folds.

On the other hand, these devices can hardly be set up for helmets obtained by in-mold technology because the sheet of material which will constitute the outer skin of the helmet, that is to say the shell, is relatively fragile when not supported by the cap.

Given this state of the art, there is a need for a helmet and its manufacturing process that are improved in that the cladding with which the shell is coated has a better appearance, and in particular in that it does not present folds.

This object and other objects which will appear in the description which follows are achieved by the decoration method according to the invention and by the helmet obtained by the implementation of the method.

In particular, the object of the invention is achieved by providing a protective helmet comprising an outer shell and a damping cap disposed inside the shell, the shell being formed by a thin shell, the shell being covered at least locally by a yoke of a flexible material, said yoke being stretched against the shell and connected thereto by at least one seam line along one of its edges.

Preferably, the seam line is visible from the outside.

In a preferred embodiment of the invention the yoke comprises several widths and a seam line at the junction of two widths binds the yoke to the shell. Optionally, the widths have a different texture and / or color.

The yoke may also be attached to the shell by additional assembly means such as a strip of glue.

The shell may have openings to form vents, in which case the yoke has cuts coincident with said openings.

The flexible material may be a textile fabric, a leather band or any other flexible material.

• réalisation de la coque externe,
• préparation d'un empiècement en matière souple,
• liaison de la coque externe avec le dit empiècement au moyen d'au moins une ligne couture, et
• garniture de l'intérieur de la coque avec la calotte.

The object of the invention is also obtained by implementing the method of manufacturing a helmet having a thin outer shell and a damping inner cap and which comprises the following steps:

• realization of the outer shell,
• preparation of a yoke made of flexible material,
• binding the outer shell with said yoke by means of at least one sewing line, and
• trim the inside of the hull with the cap.

Preferably the cap is made by injection inside the shell already dressed by the yoke.

The protective helmet comprises an outer shell and a damping cap disposed inside the shell, the assembly defining a plane of symmetry, the shell being formed by a thin shell. The shell is covered at least locally by a yoke made of a flexible material, the yoke is stretched against the shell and is attached to the shell by at least one seam line along one of its edges.

According to the manufacturing method, the outer shell is produced, a yoke made of flexible material is prepared, the outer shell is bonded to the said yoke by means of at least one sewing line along one edge of the yoke, and then fill the inside of the shell with the cap.

The invention will be better understood by referring to the description below and attached drawings attached thereto.

Figure 1 shows the general construction of a helmet to which the invention applies.

Figure 2 shows a rear view of a helmet according to a first embodiment of the invention.

Figure 3 shows the helmet of Figure 2 seen from the side.

Figure 4 is a rear view of a helmet according to another embodiment of the invention.

Figure 5 shows the helmet of Figure 4 seen from the side.

Figures 6 to 9 schematically illustrate different mounting modes of the yoke in full surface on the hull.

Figures 10 to 14 illustrate different ways of assembling the widths of a yoke.

Figures 15 to 18 show different ways of mounting the yoke at an opening of the shell.

Figures 19 to 21 show different ways of mounting the yoke along an edge of the shell.

Figure 22 illustrates a phase of the manufacturing method of the invention.

Figure 23 relates to an alternative embodiment of the method.

FIG. 1 represents a helmet 10 which comprises an outer shell 11 and an inner cap 12.

The outer shell is formed by a shell made of a plastic material, and has a thin thickness of less than 1.5 millimeters. In particular, it can be obtained from a flat sheet of polycarbonate or PVC having a thickness of between 0.7 and 1.5 millimeters which has been cut and shaped by a thermoforming technique. The shell optionally has openings, such as the openings 14, 15, 16, and other openings where appropriate, as well as recessed or raised areas, possibly with edges of rupture of shape, in correspondence or not with the openings.

The inner cap 12 forms a cushioning layer which is provided to envelop and protect the user's head. It is for example made of expanded polystyrene. It is intended to internally fill the shell 11. The outer wall of the cap conforms to the inner shape of the shell. Preferably, it has openings coinciding with the openings of the shell so as to form overall vents to facilitate the circulation of air under the cap.

Overall, the shell and the cap have the shape of a symmetrical sphere portion relative to a median vertical plane that defines two hemispheres. This plane is parallel to the plane of FIGS. 3 and 5. In the following, the term "longitudinal" will designate a direction parallel to this plane and "transverse" will designate a direction perpendicular, that is to say which goes from a hemisphere to 'other.

The symmetry of the shell and the cap relative to the median plane makes it possible to produce helmets whose left part is identical, although inverted, to the right part. This is, of course, not a limiting feature of the invention and we can consider helmets according to the invention that do not have right-left symmetry.

The cap is made and assembled to the hull by any appropriate means. According to a first known technique, the shell and the cap are made separately and then assembled to each other for example by means of a glue or a single-sided or double-sided adhesive tape, or any other technical.

According to another known technique, the shell already cut and shaped is placed in a mold, then the material is injected into the mold so as to form the cap. For example, polystyrene balls and water vapor under pressure are injected into the mold in such a way as to cause the polystyrene to expand and to form the cap directly against the shell.

Other manufacturing techniques may also be suitable.

The helmet further comprises a retaining device on the user's head and, where appropriate, comfort elements. For example, these means comprise a chinstrap formed with portions of strap connected to the cap which are intended to be hooked together under the chin of the user. he there may also be an occipital restraint system associated or not with the jugular, as well as pads or pads made of foam or other material of hygiene or comfort. These devices are known and have not been shown in the figures.

Figures 2 and 3 show a helmet according to a first embodiment of the invention. This helmet has a shell 21 and a cap 22. The shell 21 is dressed externally by a yoke 23 which covers the rear part and the lower part of the shell 21. However, the openings 25, 26 which are in this area are disengaged. The yoke 23 is made here in two widths 23a, 23b which are assembled together so that the yoke follows the curvature of the hull in the covered area. The assembly means will be described later.

The yoke is made of a flexible material such as a skin, a film or a fabric based on natural or synthetic fibers. The material can be colored, embroidered or patterned. It can also be printed, screen printed or painted. The patterns of the yoke can be coordinated with the decoration of the hull. The widths can be of the same nature or of different nature in terms of texture or color. Preferably, the material has an extensible character so that it matches the rounded shape of the shell without wrinkling. For example the material is leather, or a leatherette which has the advantage of being flexible and compressible in the direction of the thickness, which gives a volume effect. Such material contrasts well with the appearance of the hull itself. Other materials are also suitable as a textile fabric, especially a jean cloth.

Other modes of construction are also suitable. In particular the yoke could cover the entire hull, or it could include more or less two widths. On the other hand, it could be expected that there are several inserts placed at different locations on the hull.

Figures 4 and 5 show a helmet 30 according to another embodiment of the invention. The shell 31 of the helmet is dressed with a yoke 33 which covers the upper part of the hull, leaving unobstructed the front part and the rear part.

The yoke is here formed of five widths whose widths 33a, 33b, 33c, 33d which are visible in the figures. As previously the widths are assembled so that the yoke matches the rounded shape of the shell without forming folds. The yoke is cut at the vents of the helmet so as not to impede the flow of air between the outside and the inside.

The material of the yoke is the same as that described for the previous helmet. As in the previous case, the yoke can cover the cap in a different way, and present a number of more or less important widths.

Overall a yoke comprises two transverse edges that extend from one hemisphere to the other of the shell, and connecting edges between these transverse edges.

According to a feature of the invention, the yoke is assembled to the shell by at least one seam which is made along an edge. Preferably, the edge in question is a transverse edge of the yoke. This edge is sewn to the hull in full surface or along one of its own edges. At the other transverse edge, also at the level of the vents the yoke can be sewn or glued to the shell, or the edge of the yoke can be folded on itself and sewn and then glued to the shell like this will be described later.

Other seams can also be made between the different widths of a yoke, by binding or without binding the shell and the yoke in this area.

As the shell has a thin thickness, the seams can be made simply, for example using a conventional sewing machine such as those used in the field of footwear. A material such as polycarbonate or ABS easily withstands a needle and is well suited for sewing.

The seams ensure a close fit of the yoke on the shell, they maintain a durable tension in the yoke that prevents the formation of creases. The seams guarantee an assembly that resists external aggression, including impacts or tears. In addition, the seams form lines on the surface of the shell and they print in the yoke a relief in relief that highlight its texture and contribute to make the aesthetics of the helmet more attractive. With the seam, the yoke is irremovable, that is to say it can not be disassembled without deterioration, except where appropriate by an experienced person.

There may be areas of the helmet where the wall of the shell forms a hollow. In these areas, the yoke tends to depart naturally from the hull wall. These areas can be glued prior to the application of the yoke on the shell and exert a support on the yoke so that it stretches locally and matches the shape of the shell in these areas of hollow.

Figures 6 to 21 illustrate different ways of mounting the connection between the yoke and the shell. They illustrate more particularly the mounting of the yoke 23 on the hull 21 of the first embodiment. To facilitate understanding of the invention the references of Figures 2 and 3 will be repeated in Figures 6 to 21 to designate the shell and the different widths of the yoke.

Figures 6 to 9 illustrate different mounting modes of the yoke in full surface of the hull.

According to Figure 6, the upper transverse edge of the width 23b forms a hem whose flap is sewn to the shell 22 by a seam line 40. The seam line is not visible in this case.

According to Figure 7, the edge of the width 23b forms a hem and the whole is sewn by a seam line 41.

According to Figure 8, the flap of the hem is sewn to the shell 22 by a first seam line 43, then the whole is sewn to the shell by a second line 44.

According to FIG. 9, a hem sewn by a seam line 45 is formed and then the whole is glued to the shell by means of a band of glue 46. In this case, the seam is visible, but it does not bind the seam. yoke to the hull. We then arrange for it to be the other transverse edge that is sewn to the hull.

Figures 10 to 14 illustrate the junction between the two widths 23a and 23b. According to Figure 10, the two widths are sewn edge to edge by a seam line 48 which is placed with the flaps on the side of the shell.

According to Figure 11 a hem is formed at the edge of the width 23b that is sewn to the width 23a by a seam line 49.

Figure 12 shows the same type of mounting, but the seam line 50 also binds the shell.

According to FIG. 13 both sides are sewn edge-to-edge by a sewing line 52, then each flap is sewn by a line 53, 54.

According to Figure 14, the two widths are sewn edge by edge by a line 55 and each edge of width is sewn to the shell by a seam line 56, 57 visible from the outside.

Figures 15 to 18 illustrate the mounting of the width 23a at the opening 26 of a vent.

According to Figure 15, the width is cut and the edges of the cut are folded through the opening 26, inside the shell. They are sewn by a seam 60.

According to FIG. 16, the edges of the blank are passed through the blank, they are glued inside the shell by a band of glue 61.

According to Figure 17, the edges of the cut are folded over the yoke itself and the assembly is sewn on the shell by a seam line 62.

According to FIG. 18, the yoke is cut away from the opening 26 and its edges are glued by an adhesive strip 63.

Figures 19 to 22 illustrate the mounting of an edge of the yoke along an edge of the shell 22.

According to FIG. 19, the flange of the yoke 23 is folded down and glued inside the shell 22 by an adhesive strip 64.

According to Figure 20, instead of being glued, the edge is sewn by a seam line 65 which passes through the assembly and which is visible from the outside.

According to Figure 21, the flap of the yoke 23 is folded between the yoke and the shell, and the assembly is sewn by a seam line 66.

These different modes of assembly make it possible to dress the shell with the yoke, and to stretch it without forming folds. The yoke is then integrated completely into the structure of the helmet in terms of aesthetics. The mounting mode is chosen according to the material used to make the yoke, the shape of the widths and also the desired aesthetic effect. Other mounting modes may also be suitable.

According to the manufacturing method of the invention, the shell of the helmet and the yoke is first made, these two elements are assembled, then the shell is filled with the cap according to one of the techniques mentioned above.

Figure 22 illustrates this process step. On one side is prepared a bare shell 68. The shell is cut and shaped by any appropriate technique, including thermoforming. It has its final shape, with the possible openings for vents and break edges for recessed or raised areas.

On the other hand is prepared the yoke 69, with the appropriate if its different widths joined together. The openings for the vents can be made before or after assembly of the yoke on the shell.

The yoke is then assembled to the shell along its different edges. Sewing is performed on at least one edge of the yoke. On the other edges, a seaming or gluing technique is used as described with reference to the preceding figures. At the level of openings it's the same thing.

Then fill the hull with the cap. According to a first technique, the cap is made apart and is assembled inside the shell by glue or adhesive, or any other appropriate hub.

According to a second technique, the shell is placed in an injection mold and material is injected into the mold to form the cap. In this technique the wall of the shell is pressed against the mold cavity, including in areas that are dressed by the yoke. This ensures application of the yoke against the shell, including in the recessed areas. Optionally, the assembly of the yoke can be provided to glue these areas to enhance the adhesion with the shell. One can also provide to place a hot melt glue film between the yoke and the shell at the time of assembly. At moment of injection, the glue film melts and contributes to the adhesion of the yoke on the shell. For the injection can be used the same press and the same mold for helmets whose shell is dressed and helmets whose shell is bare. Indeed, the presence of the yoke does not change the establishment of the hull in the mold significantly.

For the first filling technique, it can be provided to carry out these operations in a recovery press where the dressed shell of the yoke is compressed and optionally heated.

When the cap is put in place by injection inside the hull it traps all the flaps that are folded inside the hull, including in areas where the flaps were not linked to the hull.

Figure 23 illustrates another embodiment of the invention. Firstly, the yoke 70 is prepared, then it is assembled on the sheet 71 of thermoformable material from which the shell is made, for example with the aid of two seam lines 72 and 73 along each edge. cross section of the yoke. The other edges are glued, or they are intended to be folded inside the shell after shaping. Then, the sheet coated yoke is shaped and then cut to form the shell dressed. The heat necessary for the shaping of the sheet may be used for example to melt a film of glue between the yoke and the shell which enhances the adhesion between the shell and the yoke.

Naturally, the present description is given only as an indication and other embodiments of the invention could be adopted without departing from the scope thereof.

In particular the helmet may be equipped with a retainer and comfort elements.

Also the yoke could be made in two independent parts, or more.

Claims (12)

Protective helmet comprising an outer shell (11, 21, 31, 68) and a damping cap (12, 22, 32) disposed inside the shell, the shell being formed by a thin shell, characterized by the in that the shell is covered at least locally by a yoke (23, 33, 69) of a flexible material, which yoke is tightened against the shell and bonded to the shell by at least one seam line (40, 41, 44, 65, 66) along one of its edges. Protective helmet comprising an outer shell (11, 21, 31, 68) and a damping cap (12, 22, 32) disposed inside the shell, said shell being formed by a shell made from a sheet plane whose thickness is between 0.7 and 1.5 mm, characterized in that the shell is covered at least locally by a yoke (23, 33, 69) of a flexible material, that the yoke is stretched against the shell and bound to the shell by at least one seam line (40, 41, 44, 65, 66) along one of its edges. Helmet according to one of claims 1 or 2, characterized in that the seam line (41, 44, 65, 66) is visible from the outside. Helmet according to one of claims 1 or 2, characterized in that the yoke (23, 33) is formed by several widths (23a, 23b, 33a, 33b, 33c, 33d). Helmet according to claim 4, characterized in that a seam line (50, 56, 57) at the junction of two widths links the yoke to the shell. Helmet according to claim 4, characterized in that the widths (23a, 23b) have a different texture and / or color. Helmet according to one of claims 1 or 2, characterized in that at least one other edge of the yoke is joined to the shell by a seam line (40, 41, 44, 65, 66). Helmet according to one of claims 1 or 2, characterized in that at least one other edge of the yoke is assembled to the shell by an adhesive strip (46, 63, 64). Helmet according to one of claims 1 or 2, wherein the shell has openings (14, 15, 16, 25, 26) for forming vents, characterized in that the yoke has cutouts in coincidence with said openings. Helmet according to one of claims 1 or 2, characterized in that the flexible material is a textile fabric. A method for manufacturing a helmet having an outer shell (11, 21, 31, 68) of small thickness and an inner cap damping (12, 22, 32), characterized in that the outer shell is carried out, which prepares a yoke (23, 33, 69) of flexible material, which binds the outer shell with said yoke by means of at least one seam line (40, 41, 44, 65, 66) along one edge of the yoke, and then fill the inside of the shell with the cap. Process according to Claim 11, characterized in that the cap (12, 22, 32) is produced by injection inside the shell (11, 21, 31, 68) already dressed by the yoke (23, 33, 69).

Images