EP2156761B1 - Method for making a helmet and the helmet made thereby - Google Patents
Method for making a helmet and the helmet made thereby Download PDFInfo
- Publication number
- EP2156761B1 EP2156761B1 EP09010687A EP09010687A EP2156761B1 EP 2156761 B1 EP2156761 B1 EP 2156761B1 EP 09010687 A EP09010687 A EP 09010687A EP 09010687 A EP09010687 A EP 09010687A EP 2156761 B1 EP2156761 B1 EP 2156761B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- helmet
- fusion
- mould
- helmets
- pvc
- 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.)
- Active
Links
- 238000000034 method Methods 0.000 title claims description 8
- 230000004927 fusion Effects 0.000 claims description 9
- 229920005644 polyethylene terephthalate glycol copolymer Polymers 0.000 claims description 7
- 239000004794 expanded polystyrene Substances 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 239000004033 plastic Substances 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 3
- 238000005553 drilling Methods 0.000 claims description 2
- 238000003856 thermoforming Methods 0.000 claims 1
- 239000011257 shell material Substances 0.000 description 13
- 239000004417 polycarbonate Substances 0.000 description 4
- 229920000515 polycarbonate Polymers 0.000 description 4
- 230000035939 shock Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000009194 climbing Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
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
- A42B3/066—Impact-absorbing shells, e.g. of crash helmets specially adapted for cycling helmets, e.g. for soft shelled helmets
Definitions
- the invention relates to a method of manufacturing sports helmets and, in particular, to the method of manufacturing fusion in-mould helmets.
- sports helmets such as bicycle helmets, skate helmets, snow helmets, climbing helmets, and riding helmets
- a harder outer shell and a softer shock absorbing inner shell are more or less the same with a harder outer shell and a softer shock absorbing inner shell.
- higher-end helmets are integrally formed having a thin polycarbonate outer shell with the softer inner shell material injected into the outer shell so that the two parts are formed together. When impact occurs, the light harder shell and softer inner shell work together to absorb the shock.
- Such types of helmet are commonly called in-mould.
- outer helmets are usually made of costly polycarbonate.
- manufacturers are forced to consider cheaper materials instead.
- PVC, PET, and PETG are substitutes see for example US 5,833,796 , US 6,105,176 and US 2007/0277 296 .
- these cheaper substitutes cannot withstand high temperatures during the forming process.
- the forming process thus has to be done at lower temperatures. But using normal processes, when forming at lower temperatures, the outer shell and inner shell cannot bond together.
- an objective of the invention is to provide in-mould helmet formed using lower temperatures but still creating an integral bond between the two shell materials.
- Plastic shell material that cannot withstand high temperatures such as PVC, PET, PETG and others
- PVC, PET, PETG and others is first printed and then thermoformed. And then the vents and the edges are trimmed to form an outer helmet.
- the outer helmet is then pressed together with a pre-formed inner helmet in a molding machine. They are integrally formed into a sports helmet at lower pressure, lower temperature, and shorter time using the method of claim 1.
- the invention is implemented as follows. Outer shell material that cannot withstand high temperatures (e.g., 90°C or more), such PVC, PET, and PETG, is formed on thermo vacuuming machine. Afterwards, it is made into an outer helmet after printing, plastic removal, edge cutting, hole drilling, and so on.
- high temperatures e.g. 90°C or more
- the PVC, PET, or PETG outer helmet thus formed is pressed together with a pre-formed inner liner (normally made from expanded polystyrene (EPS) or similar materials) in a moulding machine. They are integrally formed into a sports helmet at lower pressure (0.5 ⁇ 0.1 bar), lower temperature (110 ⁇ 2 °C), and shorter time (168 ⁇ 5 sec).
- EPS expanded polystyrene
- the fusion in-mould helmet formed according to the above-mentioned method can have the same or similar appearance, functions, collision protection, and shock absorption as the conventional expensive polycarbonate outer helmet.
- the above-mentioned fusion in-mould helmet can prevent the problem of deformation due to direct sunlight as opposed to when the PVC, PET, or PETG outer shell is combined with the EPS inner helmet by glue or tape.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Helmets And Other Head Coverings (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Description
- The invention relates to a method of manufacturing sports helmets and, in particular, to the method of manufacturing fusion in-mould helmets.
- The structures of sports helmets, such as bicycle helmets, skate helmets, snow helmets, climbing helmets, and riding helmets, are more or less the same with a harder outer shell and a softer shock absorbing inner shell. However, higher-end helmets are integrally formed having a thin polycarbonate outer shell with the softer inner shell material injected into the outer shell so that the two parts are formed together. When impact occurs, the light harder shell and softer inner shell work together to absorb the shock. Such types of helmet are commonly called in-mould.
- The above-mentioned outer helmets are usually made of costly polycarbonate. In view of the high cost of polycarbonate, manufacturers are forced to consider cheaper materials instead. In this case, PVC, PET, and PETG are substitutes see for example
US 5,833,796 ,US 6,105,176 andUS 2007/0277 296 . Nevertheless, these cheaper substitutes cannot withstand high temperatures during the forming process. The forming process thus has to be done at lower temperatures. But using normal processes, when forming at lower temperatures, the outer shell and inner shell cannot bond together. - In view of the foregoing, an objective of the invention is to provide in-mould helmet formed using lower temperatures but still creating an integral bond between the two shell materials.. Plastic shell material that cannot withstand high temperatures (such as PVC, PET, PETG and others) is first printed and then thermoformed. And then the vents and the edges are trimmed to form an outer helmet. The outer helmet is then pressed together with a pre-formed inner helmet in a molding machine. They are integrally formed into a sports helmet at lower pressure, lower temperature, and shorter time using the method of claim 1.
- The invention will become more fully understood from the detailed description given herein below illustration only, and thus is not limitative of the present invention, and wherein:
- None.
- The present invention will be apparent from the following detailed description.
- The invention is implemented as follows. Outer shell material that cannot withstand high temperatures (e.g., 90°C or more), such PVC, PET, and PETG, is formed on thermo vacuuming machine. Afterwards, it is made into an outer helmet after printing, plastic removal, edge cutting, hole drilling, and so on.
- The PVC, PET, or PETG outer helmet thus formed is pressed together with a pre-formed inner liner (normally made from expanded polystyrene (EPS) or similar materials) in a moulding machine. They are integrally formed into a sports helmet at lower pressure (0.5±0.1 bar), lower temperature (110±2 °C), and shorter time (168±5 sec).
- The fusion in-mould helmet formed according to the above-mentioned method can have the same or similar appearance, functions, collision protection, and shock absorption as the conventional expensive polycarbonate outer helmet.
- According to the above-mentioned fusion in-mould helmet, there is no gap between the PVC, PET, or PETG outer helmet and the EPS inner helmet because they are integrally formed. This helps distributing the stress during a collision, thereby protecting the head.
- The above-mentioned fusion in-mould helmet can prevent the problem of deformation due to direct sunlight as opposed to when the PVC, PET, or PETG outer shell is combined with the EPS inner helmet by glue or tape.
- Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, contemplated that the appended claims will cover all modifications that fall within the true scope of the invention.
Claims (3)
- Method for producing a fusion in-mould helmet comprising
an outer helmet formed from a plastic plate, wherein the material of the outer helmet is PVC, or PET, or PETG. by printing, thermoforming, plastic removal, edge cutting, and hole drilling, characterised in that
the outer helmet and a pre-formed inner helmet are disposed together in a moulding machine to integrally form the in-mould helmet at lower pressure, lower temperature, and shorter time,
wherein the pressure for fusion is not more than 0.7+-0.1bar.
wherein the temperature for fusion is not more than 110+-2°C, and wherein the time for fusion is not more than 168+-5 sec. - The method of claim 1, wherein the material of the inner helmet is expanded polystyrene (EPS).
- A fusion in - mould helmet produced by a method according to claim 1 or 2.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
TW097131670A TW201008513A (en) | 2008-08-20 | 2008-08-20 | Cold fusion in-mold sports helmet |
Publications (3)
Publication Number | Publication Date |
---|---|
EP2156761A2 EP2156761A2 (en) | 2010-02-24 |
EP2156761A3 EP2156761A3 (en) | 2010-08-25 |
EP2156761B1 true EP2156761B1 (en) | 2012-10-31 |
Family
ID=41152167
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP09010687A Active EP2156761B1 (en) | 2008-08-20 | 2009-08-19 | Method for making a helmet and the helmet made thereby |
Country Status (3)
Country | Link |
---|---|
US (1) | US20100043127A1 (en) |
EP (1) | EP2156761B1 (en) |
TW (1) | TW201008513A (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9763488B2 (en) | 2011-09-09 | 2017-09-19 | Riddell, Inc. | Protective sports helmet |
US20130230836A1 (en) * | 2012-02-22 | 2013-09-05 | Marshall Street Entertainment, Inc. | Helmet with stage blood indicator to simulate head injury |
US20150223544A1 (en) * | 2012-02-22 | 2015-08-13 | Marshall Street Entertainment, Inc. | Helmet with stage blood indicator to simulate head injury |
EP2790540B1 (en) * | 2012-08-02 | 2017-03-15 | Strategic Sports Limited | Helmet with in-moulded memory foam member and process therefor |
US10159296B2 (en) | 2013-01-18 | 2018-12-25 | Riddell, Inc. | System and method for custom forming a protective helmet for a customer's head |
US10362829B2 (en) | 2013-12-06 | 2019-07-30 | Bell Sports, Inc. | Multi-layer helmet and method for making the same |
CN103919320A (en) * | 2014-04-24 | 2014-07-16 | 北京长信宏正丝印技术有限公司 | Manufacturing technology for inner-film integrated helmet |
CA3207551A1 (en) | 2014-10-28 | 2016-05-06 | Bell Sports, Inc. | In-mold rotation helmet |
WO2018017867A1 (en) | 2016-07-20 | 2018-01-25 | Riddell, Inc. | System and methods for designing and manufacturing a bespoke protective sports helmet |
US11399589B2 (en) | 2018-08-16 | 2022-08-02 | Riddell, Inc. | System and method for designing and manufacturing a protective helmet tailored to a selected group of helmet wearers |
CA3169309A1 (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 |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5376318A (en) * | 1993-05-24 | 1994-12-27 | Ho; Chang H. | Process for making helmets for cyclists |
US5450631A (en) * | 1993-09-17 | 1995-09-19 | Specialized Bicycle Components, Inc. | Bicycle helmet |
US5833796A (en) * | 1994-03-04 | 1998-11-10 | Armacel Pty Limited | Method and apparatus for forming structural articles |
KR970006438Y1 (en) * | 1995-09-05 | 1997-06-24 | 시몬인터내쇼날 주식회사 | Helmets |
US6055675A (en) * | 1997-01-09 | 2000-05-02 | Specialized Bicycle Components, Inc. | Protective bicycle helmet having a ventilated rear support structure |
US6425141B1 (en) * | 1998-07-30 | 2002-07-30 | Cerebrix | Protective helmet |
US6453476B1 (en) * | 2000-09-27 | 2002-09-24 | Team Wendy, Llc | Protective helmet |
GB0117140D0 (en) * | 2001-07-13 | 2001-09-05 | Protector Technologies Pty Ltd | Protective headgear |
ITMI20021941A1 (en) * | 2002-09-12 | 2004-03-13 | Roberto Cattaneo | PROTECTION HELMET AND RELATED METHOD OF REALIZATION. |
US7913325B2 (en) * | 2006-05-19 | 2011-03-29 | Specialized Bicycle Components, Inc. | Bicycle helmet with reinforcement structure |
US20070277294A1 (en) * | 2006-05-30 | 2007-12-06 | Green Lawrence J | Protective headgear system with filter protector |
FR2905235B1 (en) * | 2006-08-29 | 2009-03-13 | Salomon Sa | PROTECTIVE HELMET AND METHOD OF MANUFACTURING THE SAME |
-
2008
- 2008-08-20 TW TW097131670A patent/TW201008513A/en unknown
-
2009
- 2009-08-19 US US12/461,627 patent/US20100043127A1/en not_active Abandoned
- 2009-08-19 EP EP09010687A patent/EP2156761B1/en active Active
Also Published As
Publication number | Publication date |
---|---|
TWI372604B (en) | 2012-09-21 |
US20100043127A1 (en) | 2010-02-25 |
EP2156761A2 (en) | 2010-02-24 |
EP2156761A3 (en) | 2010-08-25 |
TW201008513A (en) | 2010-03-01 |
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