EP2156761B1 - Method for making a helmet and the helmet made thereby - Google Patents

Method for making a helmet and the helmet made thereby Download PDF

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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
Application number
EP09010687A
Other languages
German (de)
French (fr)
Other versions
EP2156761A2 (en
EP2156761A3 (en
Inventor
Tse-Ping Wang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP2156761A2 publication Critical patent/EP2156761A2/en
Publication of EP2156761A3 publication Critical patent/EP2156761A3/en
Application granted granted Critical
Publication of EP2156761B1 publication Critical patent/EP2156761B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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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

    BACKGROUND OF THE INVENTION Field of Invention
  • The invention relates to a method of manufacturing sports helmets and, in particular, to the method of manufacturing fusion in-mould helmets.
    • Related Art
  • 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 and US 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.
    • SUMMARY OF THE INVENTION
  • 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.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • 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.
    • DETAILED DESCRIPTION OF THE INVENTION
  • 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)

  1. 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.
  2. The method of claim 1, wherein the material of the inner helmet is expanded polystyrene (EPS).
  3. A fusion in - mould helmet produced by a method according to claim 1 or 2.
EP09010687A 2008-08-20 2009-08-19 Method for making a helmet and the helmet made thereby Active EP2156761B1 (en)

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)

* Cited by examiner, † Cited by third party
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)

* Cited by examiner, † Cited by third party
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

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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