EP2858523A1

EP2858523A1 - Helmet provided with a half-chinbar and corresponding method of production

Info

Publication number: EP2858523A1
Application number: EP13728179.6A
Authority: EP
Inventors: Lucio Zancai; Stephane Cohen
Original assignee: Bell Racing Europe SA
Current assignee: Bell Racing Europe SA
Priority date: 2012-06-11
Filing date: 2013-06-11
Publication date: 2015-04-15
Also published as: WO2013186190A1; ITUD20120109A1

Abstract

A helmet (10) provided with a half-chinbar comprises a protective shell (12) that has at least a front aperture (14) and a half-chinbar (13) that extends cantilevered from one side (17) of the front aperture (14) so as to have a free end (20) disposed in an intermediate position in said front aperture (14). The shell (12) and the half-chinbar (13) are two distinct components which are constrained in substantial correspondence of said side (17) of said front aperture (14) by means of a join region (18) configured as a hinge.

Description

"HELMET PROVIDED WITH A HALF-CHINBAR AND CORRESPONDING METHOD OF PRODUCTION"

FIELD OF THE INVENTION

The present invention concerns a protective helmet provided with a half- chinbar, and the corresponding method of production, used when driving automobiles or motor vehicles, in particular but not exclusively in the field of automobile races and sports competitions, specifically but not restrictively in the field of rallies. However, it is not to be excluded that the present invention can also be used in the field of sports motorcycling or in other fields which envisage the use of protective helmets.

BACKGROUND OF THE INVENTION

It is known for the driver and/or passengers to use a protective helmet in automobile races. Generally, a helmet of the type in question is provided with a protective cover or shell for the head, which has a lower aperture in which the head is inserted, and a front aperture of which at least one function is to allow the wearer of the helmet to see.

In so-called integral helmets, the front aperture is limited to a front band which substantially affects the zone around the eyes, while at the lower part there is a continuous chinbar on one side and the other of the cover, or shell, of the helmet, and integral therewith, which closes the lower front part of the shell to give greater protection to the user: the front and lower apertures are therefore distinct and separate from each other.

On the contrary, in the case of so-called open helmets, or jet helmets, the chinbar is not normally provided and the helmet is open at the front, with a single continuous aperture constituting the front and lower aperture. Such open or jet helmets on the one hand can protect the wearer to a lesser degree, but on the other hand they give greater comfort and freedom.

In particular, in rally races it is known to make a helmet in which there is a half-chinbar which does not extend from one side of the shell to the other, but is formed by an arm in a single piece with the shell, which extends cantilevered only partly on one side of the front aperture, and during use terminates substantially in correspondence with the user's mouth. The half-chinbar is normally used to position microphones in front of the mouth of the wearer, or in any case to facilitate their use. Generally, the driver and the passengers, for example the navigator, can communicate easily, using the microphones, even if there is a lot of environmental noise during the race. The half-chinbar is in any case advantageous since it allows a certain convenience compared with integral helmets, and this is often a sought-after and important feature in rally races, where the environmental conditions during the races can be very stressful.

At present, composite materials are used to produce the helmets in question, consisting of a matrix of thermosetting resin containing reinforcement fibers.

The use of composite materials is advantageous due to their characteristics of lightness, tenacity, rigidity and resilience, which can be combined variously as a function of the result to be obtained.

For the production of protective helmets that have to stand up to impacts, generally various layers of material are combined to obtain a rigid compound wall or sandwich, with a light core and rigid walls, in order to reduce the weight and increase the capacity of diffusing the impact energy into the system.

Composite materials with a thermosetting matrix may be obtained by impregnating a fabric formed by fibers with liquid thermosetting resins.

Otherwise the composite materials with a thermosetting matrix can be obtained using hot molding (from 120°C to 150°C), normally carried out in an autoclave, although with cycle times that can be longer compared to the wet layup systems. In this case, a pre-preg formed by reinforcement fibers incorporated in a thermosetting matrix is put in the autoclave, where the effect of temperature and pressure determines the desired final structure of the composite material.

One disadvantage of helmets provided with a half-chinbar is that, in the event of dangerous, unexpected or very quick maneuvers, or jolts, impacts, collisions or even accidents proper, the free end of the 'arm that makes up the half-chinbar can become accidentally attached or jammed, and therefore pulled and torn toward the outside, causing unnatural and dangerous torsions of the wearer's head. This is because the half-chinbar, since it is made in a single piece, and same continuous composite structure, with the shell of the helmet, transmits directly any stresses received, without any damping, and this therefore negatively affects at least the head and neck of the person wearing the helmet.

Document US-A-2009/031483 describes a helmet for motorcycles comprising a protective cap or shell made of plastic reinforced with drowned glass fiber (GRP), or thermoplastic materials like polycarbonate (PC), polyamide (PA) or acryl butadiene styrene (ABS). The helmet also comprises a chin piece formed by two sections of chin piece hinged to the protective shell by means of a flexible plate, glued, riveted or clamped to the external surface of the protective shell. Document US-A-5,963,990 describes a protective helmet for football or ice hockey that provides a front face mask formed by two separate sections, mounted elastically on the helmet. The sections of the face mask tend to open toward the outside if gripped, so as to facilitate the release of the grip itself whereas, if the grip continues, the section gripped detaches from the helmet.

Purpose of the present invention is to achieve a helmet provided with a half- chinbar, and to perfect a corresponding method of production, which guarantees greater safety even if the half-chinbar is undesirably attached or jammed and pulled toward the outside, without transmitting the stresses and torsions received onto the wearer's head.

The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

Unless otherwise defined, all the technical and scientific terms used here and hereafter have the same meaning as commonly understood by a person with ordinary experience in the field of the art to which the present invention belongs. Even if methods and materials similar or equivalent to those described here can be used in practice and in the trials of the present invention, the methods and materials are described hereafter as an example. In the event of conflict, the present application shall prevail, including its definitions. The materials, methods and examples have a purely illustrative purpose and shall not be understood restrictively.

SUMMARY OF THE INVENTION

The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the invention or variants to the main inventive idea.

In accordance with the above purpose, a helmet provided with a single half- chinbar according to the present invention comprises a protective cover or shell, which has at least a front aperture and a single half-chinbar which extends cantilevered from one side of the aperture so as to have a free end disposed in an intermediate position in said front aperture: in use, the free end is positioned in substantial correspondence with the mouth of the user who is wearing the helmet.

According to the present invention, the shell and the single half-chinbar are two distinct components, not in a single piece, and are constrained in substantial correspondence with the side of the front aperture by means of a joint region configured as a hinge.

In this way, the stresses exerted from the outside on the single half-chinbar, for example when it is attached or jammed and therefore torn or pulled toward the outside, do not affect and are not transmitted onto the shell of the helmet, protecting the wearer's head from dangerous torsions or stresses in general. This is because, as it deforms, the region configured as a hinge functions as a dissipator of the stresses acting on the half-chinbar, and this energy is absorbed and used to determine the desired hinge effect between the half-chinbar and the shell, and is not transmitted to the shell itself.

In some forms of embodiment, the shell and the single half-chinbar are formed of different materials, where a first material that constitutes the shell of the helmet is a rigid material, while a second material that constitutes the half- chinbar is a material with a great capacity of absorbing shocks without breaking, and an elastic elongation capacity. The difference in the mechanical behavior to stress between the first and second material determines the desired hinge effect when the half-chinbar is, for example, subjected to traction, tearing, bending or torsion toward the outside. Obviously, this effect, and the benefits connected to it, is also obtained when the half-chinbar is subjected to stresses, bending, thrusts or torsions toward the inside of the helmet.

One form of embodiment of the invention provides that the first material of the shell is a composite material consisting of a matrix of thermosetting resin containing reinforcement fibers.

One form of embodiment of the invention provides that the second material of the single half-chinbar is a composite material that comprises at least a laminate of thermoplastic resin and at least a pre-preg layer of reinforcement fibers incorporated in a thermosetting matrix.

In one form of embodiment, the single half-chinbar is connected to the shell in the hinge-type join region by means of a region of co-penetration and intimate stratification of the respective and possibly different materials that make up the shell and the half-chinbar; for this reason they are solid and amalgamated in correspondence with the hinge-type join region.

In this form of embodiment, the shell and the half-chinbar are made at the same time and in the same space, progressively constructing, by means of a step of compression and heat treatment, such as hot molding, the desired stratification and solidification of materials that make up the shell and the half-chinbar, in particular in correspondence with the desired hinge-type join region.

In variants of this form of embodiment, the region of co-penetration and stratification is made between pre-preg or impregnated fibers of the first material of the shell and pre-preg fibers of the second material of the half-chinbar amalgamated and stratified with each other.

This is obtained, in variant forms of embodiment, in the hot molding step, by disposing simultaneously, and according to the desired final geometry of the helmet, the at least one pre-preg formed by a pre-preg layer of reinforcement fibers incorporated in a thermosetting matrix, and the at least one laminate of thermoplastic resin which, once they have been subjected to suitable pressure and temperature, for example in an autoclave or in a high-pressure mold, will make up the half-chinbar, and also disposing the desired at least one pre-preg formed by a matrix of thermosetting resin containing reinforcement fibers, which, once it has been subjected to pressure and temperature at the same time as the first material of the half-chinbar, will make up the shell.

In another form of embodiment, the single half-chinbar is connected to the shell in the hinge-type join region by means of an at least partial incorporation of a constrained end, opposite the free end, in the material that makes up the cover.

In this other form of embodiment, the half-chinbar is made in a separate finished piece and is subsequently associated as an insert with the cover of the helmet in the course of the production of the molded shell itself, for example using liquid resins techniques, or with a technique that uses a pre-preg formed by a matrix of thermosetting resin containing reinforcement fibers and subsequently a treatment at a suitable pressure and temperature, generally for example in an autoclave, or in a high-pressure mold.

In variant forms of embodiment of this other form of embodiment, the second constrained end, incorporated in the material that makes up the molded shell, has retaining flaps on the periphery. In the finished product, these are surrounded by the material of the cover, increasing the mechanical attachment of the half- chinbar to the cover.

As we said, therefore, according to the possible two variants, the single half- chinbar is made with a technique using a pre-preg and subsequently a treatment at a suitable pressure and temperature, generally in an autoclave, or a separate finished piece which is subsequently associated as an insert with the shell of the helmet in the course of the production of the cover, for example using liquid resins.

To make the composite material of the half-chinbar, the laminate and the pre- preg are separate from each other at the beginning, and are able to be hot molded in a single operation.

According to the invention, after molding, the laminate and the pre-preg form a structure having at least a zone of transition from a rigid section to a flexible section.

According to a variant, the laminate of thermoplastic resin is an open-cell polyolefm foam.

According to another variant, the laminate of thermoplastic resin consists of a polyethylene laminate or expanded polypropylene.

According to one form of embodiment of the present invention, the matrix of thermosetting resin of the material of the half-chinbar consists of epoxy resin and said reinforcement fibers are glass or carbon fibers.

In some forms of embodiment, the single half-chinbar is obtained by pre- cutting the materials that make it up, according to the development of the final shape required, which will subsequently be subjected to hot compression in a mold, so as to achieve in a single step the polymerization of the components and the molding of the thermoplastic laminate. As we said, this can be obtained separately from the cover, and then part of the single half-chinbar can be incorporated as an insert in the cover, or said pre-cut materials are combined with the pre-preg used to make the shell and the half- chinbar can be obtained at the same time as the cover, with suitable conditions of pressure and temperature, for example in an autoclave or in a high-pressure mold, polymerizing the resin and gradually constructing the progressive stratification of the two different materials and obtain, in particular, the regions of co-penetration of fibers in the hinge-type join region of the helmet.

In other forms of embodiment, it is possible to achieve a magnetic clamping unit configured to define a selective clamping of the half-chinbar and shell.

In variant forms of embodiment, the magnetic clamping unit is obtained by a first magnet comprised in the half-chinbar and a second magnet comprised in the shell. In possible implementations, the second magnet is provided in the side of the shell where the half-chinbar is provided.

According to some forms of embodiment, it is possible to make a housing seating on the shell, which is configured to receive a part of the half-chinbar. In possible implementations, the housing seating is made on the side of the shell where the half-chinbar is provided.

In possible variant forms of embodiment, it is possible to attach the half- chinbar to the shell by means of anchoring members.

Moreover, in possible variant forms of embodiment it is possible to make a reduced thickness zone of the half-chinbar that defines the hinge-type joining region. In possible implementations, the reduced thickness zone is obtained by means of a localized compression during the molding of the material that forms the half-chinbar.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics of the present invention will become apparent from the following description of a preferential form of embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

- fig. 1 is a first three-dimensional view of a helmet according to the present invention;

- fig. 2 is a second three-dimensional view of the helmet in fig. 1 ;

- fig. 3 is a three-dimensional view of some forms of embodiment of the helmet according to the present invention;

- fig. 4 is an enlarged detail of fig. 3;

- fig. 5 is a partial section of the enlarged detail in fig. 4;

- fig. 6 is a three-dimensional view of some forms of embodiment of the helmet according to the present invention;

- fig. 7 is a view of a part of the helmet in fig. 6;

- fig. 8 is a top plan view of fig. 6;

- fig. 9 is a section from IX to IX of fig. 8;

- fig. 10 is a section of the helmet in fig. 6;

- fig. 1 1 is an enlarged detail of fig. 10;

- fig. 12 is an enlarged section of part of fig. 1 1 ;

- fig. 13 is a first three-dimensional view of a helmet according to the present invention subjected to deformation stress toward the outside of the half-chinbar;

- fig. 14 is a second three-dimensional view of the helmet in fig. 13;

- fig. 15 is a three-dimensional view in separate parts of some forms of embodiment of the helmet according to the present invention;

- fig. 16 is a three-dimensional view of some forms of embodiment of the helmet according to the present invention;

- fig. 17 is a three-dimensional view of a helmet according to the present invention subjected to deformation stress toward the outside of the half-chinbar.

To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one form of embodiment can conveniently be incorporated into other forms of embodiment without further clarifications.

DETAILED DESCRIPTION OF SOME FORMS OF EMBODIMENT

We shall now refer in detail to the various forms of embodiment of the present invention, of which one or more examples are shown in the attached drawings. Each example is provided by way of illustration of the invention and shall not be understood as a limitation thereof. For example, the characteristics shown or described as part of one form of embodiment may be adopted on or in association with other forms of embodiment to produce another form of embodiment. It is understood that the present invention includes all such modifications and variants.

With reference to the attached drawings, we shall now describe some forms of embodiment of a helmet 10 according to the present invention, which can be used for example, but not restrictively, in sports races and automobile competitions, typically in rallies. Basically, the helmet 10 in question is the open type, or jet helmet, but is provided with a half-chinbar.

The helmet 10 comprises a protective shell 12 which has a front aperture 14, through which the user can see, and a lower aperture 15 into which the head is inserted; due to the open nature of the helmet, the apertures 14, 15 are a single whole area in front of the shell 12.

In some forms of embodiment, which can be combined with all the forms of embodiment described here, the front aperture 14 is typically delimited laterally by two lateral lobes 17, or sides, of the shell 12.

The helmet 10 comprises a single half-chinbar 13 which is constrained to the shell 12 in substantial correspondence with one side of the front aperture 14 by means of a join region 18 configured as a hinge (figs. 1 and 2). With reference for example to forms of embodiment described using figs. 1-4, 6 and 10, the single half-chinbar 13 is shown by way of example on the left side of the helmet 10.

In particular, in possible implementations, the single half-chinbar 13 can be formed for example by an arm 16 constrained only to one of the two lateral lobes 17 of the shell 12, which extends cantilevered partly toward the inside of the front aperture 14. In this case, the arm 16 can have for example a first free end 20, in an intermediate position in the front aperture 14, so that during use it is substantially in correspondence with the mouth of the user of the helmet. Furthermore, for example the arm 16 can have a second end 22 constrained to the lateral lobe 17 of the shell 12 in correspondence with the join region 18 configured as a hinge.

In some forms of embodiment, which can be combined with all the forms of embodiment described here, the shell 12 and the half-chinbar 13 can be formed by different materials, of which a first material that constitutes the shell 12 of the helmet 10 can typically be a rigid material, while a second material that constitutes the half-chinbar 13 can typically be a material with a great capacity of absorbing shocks and deformations without breaking, and an elastic elongation capacity.

In some forms of embodiment of the invention, which can be combined with all the forms of embodiment described here, the first material of the shell 12 can be a composite material consisting of a matrix of thermosetting resin containing reinforcement fibers.

According to some forms of embodiment of the invention, instead, the second material of the half-chinbar 13 can be a composite material that comprises at least a laminate of thermoplastic resin and at least a pre-preg layer of reinforcement fibers incorporated in a thermosetting matrix.

In some forms of embodiment of the invention, which can be combined with all the forms of embodiment described here, the laminate of thermoplastic resin of the second material that forms the half-chinbar 13 can consist of open-cell polyolefin foam, preferably polyethylene or expanded polypropylene. The matrix can normally consist of epoxy resin, phenolic resin, polyester, etc. The reinforcement fibers are normally glass or carbon fibers, Kevlar or suchlike.

The thermoplastic laminate and the reinforced thermosetting can constitute a sandwich type structure, which is completed with a supporting layer of synthetic rubber. The component layers keep their individuality even after hot molding, which is carried out in a single operation.

Naturally, the layers of thermoplastic laminate and of pre-preg fibers with thermosetting resin can be combined in numerous and various ways. It is possible to have a thermoplastic core, for example of polyethylene foam, between two layers of pre-preg and with a thermoplastic laminate surface coating. Or it is possible to simply have a thermoplastic core, for example of polyolefin foam, between two layers of pre-preg. Or again, it is possible to have for example a pre- preg core between two layers of thermoplastic laminate.

It is very easy to work the second material to make the half-chinbar 13. Indeed, the material can be pre-cut, for example in a punch cutter press, according to the development of the final shape of the half-chinbar 13. Subsequently, it can be for example hot molded, which produces a uniform pressure inside a rigid mold, allowing to work even on vertical or inclined walls, thus advantageously compensating for the limit of composite materials with only one thermosetting matrix which do not have a sufficient cold flow that allows the necessary pressure to be applied so as to obtain possible vertical or very inclined surfaces.

The hot molding of the materials of the half-chinbar 13, in a first step, causes the resins to compact, by means of penetration of the liquid thermosetting resin into the open cells of the thermoplastic foam.

Subsequently, the different resins of the half-chinbar 13 are welded definitively to each other during the polymerization of the thermosetting resin. During this step, the thermoplastic resin melts and fills the available space. The melting temperature can typically be raised (for example from 140°C to 180°C approximately) due to the effect of the exothermic reaction of the thermosetting resin. The molding cycle can take place for example in about 1 minute, correctly adapting the temperature and pressure to the type of article to be obtained. In some forms of embodiment, which can be combined with all the forms of embodiment described here, the structure of the half-chinbar 13 obtained has a zone of transition between a rigid pre-preg zone and a flexible zone formed by thermoplastic polymer and synthetic rubber.

Consequently, the second material that forms the half-chinbar 13 has a viscous-elastic behavior: its peculiar characteristics of lightness, tenacity and resilience are much higher than those of a traditional composite material, only thermosetting or only thermoplastic.

This makes it particularly suitable for the purposes of the present invention since, combined with the first material, more rigid, of the shell 12, it can physically constitute a differentiation of the material, more or less progressive according to the variants, which defines the join region 18 configured as a hinge. Advantageously, the sandwich of the second material of the half-chinbar 13 is formed by external walls, or skins, with strong elastic elongation and high tenacity, thus preventing, during flexion, maximum elongations from being reached which can be critical: it therefore has a good capacity for absorbing impacts and stresses without breaking.

In particular, with reference to forms of embodiment described in figs. 13 and 14 and which can be combined with all the forms of embodiment described here, it can be seen how the half-chinbar 13, if subjected to stresses such as traction, bending, tearing or torsion toward the outside, can deform, rotating as shown by the arrow F around the hinge-type join region 18, thanks to the different mechanical behavior of the first material of the shell 12 and the second material of the half-chinbar 13, without the stress having an unwanted and dangerous effect on the shell 12.

Figs. 3-5 are used to describe forms of embodiment of the helmet 10, in which the half-chinbar 13 is connected to the shell 12 in the hinge-type join region 18 by means of a region of co-penetration and intimate stratification 24 (shown more emphasized in fig. 3, to facilitate comprehension) of the respective different materials that make up the shell 12 and the half-chinbar 13. In particular, the pre- preg fibers of the second material of the half-chinbar 13 are stratified and diffusely amalgamated with the impregnated or pre-preg fibers of the first material of the shell 12.

These forms of embodiment are for example obtainable using a technique with a pre-preg to make the shell 12, for example in an autoclave or high-pressure mold. In particular, the first composite material of the half-chinbar 13, suitably shaped, is put in the autoclave or the high-pressure mold at the same time as the pre-preg of the first material of the shell 12, according to the final conformation and geometry desired for the helmet 10. Everything is then subjected to adequate pressure and temperature, obtaining the polymerization of the resins and progressively constructing the subsequent stratification, in the join region 18, of the two different materials.

Figs. 6-12 are used to show other forms of embodiment, in which the half- chinbar 13 is made as a separate finished piece by hot molding as described above and is subsequently connected as an insert to the shell 12 in the hinge-type join region 18 by means of at least partial incorporation of the second constrained end 22, opposite the first free end 20, in the material that makes up the shell 12. In these forms of embodiment, the half-chinbar 13 is coupled as a finished insert with the shell 12 of the helmet 10 in the course of making the molded shell itself, which may provide for example to use a liquid resin technique, or a technique that uses a pre-preg and subsequently a treatment at suitable pressure and temperature, generally for example in an autoclave or in a high-pressure mold. In the forms of embodiment described by way of example with reference to figs. 6-12, the second end 22 of the arm 16 of the half-chinbar 13 that is incorporated in the material that makes up the shell 12 has retaining flaps 26 (see for example figs. 6-9) on its periphery: at the end of the production process, these are surrounded by the material of the shell 12 (see for example figs. 10-12). In particular, with reference for example to fig. 12, the first material of the shell 12 formed by layers 28 of fibers with thermosetting resin effectively incorporates the retaining flaps 26 of the half-chinbar 13.

Figs. 15-17 are used to describe other forms of embodiment, in which the half- chinbar 13 is positioned adjacent to the shell 12, for example essentially above the lateral lobe 17, that is, it may be overlapping at least part of the lateral lobe 17, and can be distanced by means of rotation toward the outside. In these forms of embodiment, as well as providing that the half-chinbar 13 is hinged to the shell 12 by the join region 18 configured as a hinge, a magnetic clamping unit 30 may also be provided (see for example figs. 16 and 17), configured to constrain the half-chinbar 13 to the shell 12, in particular to a lateral lobe 17, in a selectively releasable manner.

In this way, a traction of the half-chinbar 13 toward the outside, when the force of traction overcomes the magnetic retention, causes the rotation toward the outside of the half-chinbar 13 around said join region 18 configured as a hinge, distancing itself for example from the lateral lobe 17. As described for example with reference to figs. 16 and 17, this can be advantageous since possible torsions, tears, bending or traction applied toward the outside on the half-chinbar 13, see for example arrow F, do not meet any considerable resistance in the half- chinbar 13 itself, they do not affect the shell 12 and therefore they are not transmitted to the head and neck of the user wearing the helmet 10.

On the contrary, with reference to thrusts or other stresses toward the inside of the helmet 10, according to forms of embodiment described using figs. 15-17, the half-chinbar 13 is configured to provide a robust behavior, with suitable rigidity, in response to frontal impacts. In particular, for example, when receiving a frontal impact, the half-chinbar 13 can in turn discharge the stress onto the part of the shell 12 adjacent to it, for example the lateral lobe 17 to which it is connected and which it overlaps, which also gives the desired resistance and robustness against impacts. Consequently, some forms of embodiment described here make available a half-chinbar 13 which is configured to robustly resist frontal impacts, which tend to thrust the half-chinbar 13 toward the inside, whereas, in the case of traction toward the outside, the half-chinbar 13 behaves as described above, protecting the health of the user wearing the helmet 10.

In possible implementations, the magnetic clamping unit 30 comprises a first magnet 32 inserted in the half-chinbar 13 and a second magnet 34 inserted into the shell 12 on the side where the half-chinbar 13 is hinged, in particular at the side of the front aperture 14, for example in the lateral lobe 17.

For example, the first magnet 32 and the second magnet 34 can be magnets based on boron and neodymium. In possible implementations, the first magnet 32 and the second magnet 34 can be configured to provide a magnetic closing force that can be comprised between 100 N and 400 N, in particular between 150 N and 300 N, more particularly between 180 N and 250 N, for example 200 N. In possible forms of embodiment, the first magnet 32 and/or the second magnet 34 can be incorporated, drowned or embedded partly or completely respectively in the half-chinbar 13 or the shell 12. For example, the first magnet 32 can be provided on the inner side of the half-chinbar 13 and, in a coordinated manner, the second magnet 34 can be provided on the outer side of the shell 12. In possible implementations, the first magnet 32 or the second magnet 34 can also include a mechanical holding element, like a bulb, a protrusion or similar element, which can be provided to consolidate the constraint, or a fastening device such as Velcro®.

In possible implementations, the shell 12 can comprise a housing seating 36, which is configured to receive part of the half-chinbar 13, for example the second constrained end 22 of the half-chinbar 13. For example, part of the half-chinbar 13 can be inserted into the housing seating 36, while still remaining free toward the outside, so as not to have obstacles against the outward rotation. For example, the housing seating 36 can be made lowered in the shell 12, for example at the side of the front aperture 14 on the side where the half-chinbar 13 is provided, typically on the lateral lobe 17 to which the latter is connected. In this way, by inserting the half-chinbar 13 into the housing seating 36, it overlaps at least part of the lateral lobe 17. For example, the depth of the housing seating 36 can be essentially equal to the thickness of the part of the half-chinbar 13 positioned inside it, so that the half-chinbar 13 is flush with the surface of the shell 12. This can be advantageous in aerodynamic terms.

With reference to the forms of embodiment described using figs. 15-17, the housing seating 36 also defines a support and abutment for the half-chinbar 13, essentially preventing it from rotating toward the inside of the helmet 10. Consequently, the half-chinbar 13 can rotate, if suitably stressed, only toward the outside of the helmet 10, as described above.

In possible forms of embodiment, which can be combined with other forms of embodiment described here, the half-chinbar 13 can be constrained to the shell 12 using anchoring members 38, such as anchoring screws or similar anchoring or attachment components, such as rivets, blocks, pins, pegs. For example, threaded holes 40 can be provided in the shell 12 to receive the anchoring members 38 and mating holes 41 in the half-chinbar 13, for the passage of said anchoring members 38. The threaded holes 40 can for example be made at the side of the front aperture 14, typically in the lateral lobe 17 to which the half-chinbar 13 is connected. In possible implementations, the threaded holes 40 are provided inside the housing seating 36.

In possible forms of embodiment described for example with reference to figs. 15-17, and which can be combined with all the other forms of embodiment described here, the join region 18 configured as a hinge of the half-chinbar 13 can be defined by a reduced thickness zone 42 of the half-chinbar 13 itself, typically provided in the second end 22. The reduced thickness zone 42 can be configured to define the axis of hinging around which the half-chinbar 13 can rotate toward the outside. The reduced thickness zone 42 can for example be made so that the corresponding axis of hinging is defined parallel to the main polar axis of the helmet 10.

In particular, the reduced thickness zone 42 can define a weakening in the material of the half-chinbar 13 that allows the desired hinging. In particular, the reduced thickness zone 42 consequently divides the half-chinbar 13 into two hinging portions, of which a first hinging portion 44 constrained to the shell 12 and a second hinging portion 46 that can rotate toward the outside. For example, the first hinging portion 44 can be constrained by the anchoring members 38, or other attachment components. The first magnet 32 of the half-chinbar 13 can for example be provided in or on the second hinging portion 46, in particular on the side of the latter that faces toward the inside of the shell 12.

In possible implementations, the external conformation of the reduced thickness zone 42, that is, facing toward the outside with respect to the shell 12, can define a thin groove, with a very limited width. On the contrary, the internal conformation of the reduced thickness zone 42, that is, facing toward the inside with respect to the shell 12, can define a wider groove, for example with a flared cross section, for example essentially V-shaped, where the angle of the V can be between 30° and 60°, for example about 45°. This conformation of the reduced thickness zone 42 can facilitate the rotation of the half-chinbar 13 toward the outside.

For example, according to possible forms of embodiment, the reduced thickness zone 42 can be obtained during the step of molding the half-chinbar 13 itself, according to the above description. In particular, a localized compression of the material that is molded on the fibers can be provided, until the desired reduction in thickness is obtained, thus conferring the necessary flexibility on the material. In substance, the molded material is "squeezed" during the molding itself, when the material is therefore still workable and deformable, as far as the level of the drowned fibers. The fibers can be fibers of a flexible fabric, for example Kevlar®, which is drowned in the molding material. Depending on how the material is compressed during molding, it is possible to define the desired internal and external conformation of the reduced thickness zone 42.

Claims

1. Helmet provided with a half-chinbar comprising a protective shell (12) that has at least a front aperture (14) and a single half-chinbar (13) that extends cantilevered from one side (17) of said front aperture (14) so as to have a free end (20) disposed in an intermediate position in said front aperture (14), characterized in that the shell (12) and the half-chinbar (13) are two distinct components which are constrained one each other in substantial correspondence of said side (17) of said front aperture (14) by means of a join region (18) configured as a hinge.

2. Helmet as in claim 1, characterized in that the shell (12) and the half-chinbar (13) are formed by different materials, of which a first material that constitutes the shell (12) is a rigid material, while a second material that constitutes the half- chinbar (13) is a material with a great capacity of absorbing shocks and deformations without breaking, and an elastic elongation capacity.

3. Helmet as in claim 2, characterized in that the first material of the shell (12) is a composite material consisting of a matrix of thermosetting resin containing reinforcement fibers.

4. Helmet as in claim 2 or 3, characterized in that the second material of the half-chinbar (13) is a composite material that comprises at least a laminate of thermoplastic resin and at least a pre-preg layer of reinforcement fibers incorporated in a thermosetting resin.

5. Helmet as in any claim hereinbefore, characterized in that it comprises a magnetic clamping unit (30) configured to define a selective clamping of the half-chinbar (13) and shell (12).

6. Helmet as in claim 5, characterized in that characterized in that the magnetic clamping unit (30) comprises a first magnet (32) comprised in the half- chinbar (13) and a second magnet (34) comprised in the shell (12).

7. Helmet as in claim 6, characterized in that the second magnet (34) is provided in the side (17) of the shell (12) where the half-chinbar (13) is provided.

8. Helmet as in any claim hereinbefore, characterized in that the shell (12) comprises a housing seating (36) configured to receive a part of the half-chinbar (13).

9. Helmet as in claim 8, characterized in that the housing seating (36) is provided on the side (17) of the shell (12) where the half-chinbar (13) is provided.

10. Helmet as in any claim hereinbefore, characterized in that the half-chinbar (13) is attached to the shell (12) by anchoring members (38).

1 1. Helmet as in any claim hereinbefore, characterized in that the hinge-type join region (18) is defined by a reduced thickness zone (42) of the half-chinbar (13).

12. Helmet as in any claim from 1 to 4, characterized in that the half-chinbar (13) is connected to the shell (12) in the hinge-type join region (18) by means of a region of co-penetration and stratification (24) of the respective materials that make up the shell (12) and the half-chinbar (13).

13. Helmet as in claim 12, characterized in that said region of co-penetration and stratification (24) is made between pre-preg or impregnated fibers of the first material of the shell (12) and pre-preg fibers of the second material of the half- chinbar (13).

14. Helmet as in any claim from 1 to 4, characterized in that the half-chinbar

(13) is connected to the shell (12) in the hinge-type join region (18) by means of at least partial incorporation or embedment of a constrained end (22), opposite the free end (20), in the material that makes up the molded shell (12).

15. Helmet as in claim 14, characterized in that said constrained end (22) has retaining flaps (26) on its periphery.

16. Method to make a helmet provided with a single half-chinbar comprising a protective shell (12) that has at least a front aperture (14) and a single half- chinbar (13) that extends from one side (17) of said front aperture (14) so as to have a free end (20) disposed in an intermediate position in said front aperture

(14) , characterized in that it provides to constrain, in substantial correspondence with said side (17) of said front aperture (14), the shell (12) and the half-chinbar (13) each other, achieving a hinge-type join region (18) between the shell (12) and the half-chinbar (13).

17. Method as in claim 16, characterized in that it provides to achieve the join region (18) between the half-chinbar (13) and the shell (12) by a step of compression and heat treatment, progressively constructing a co-penetration and stratification of the respective materials that make up the shell (12) and the half- chinbar (13).

18. Method as in claim 17, characterized in that the shell (12) and the half- chinbar (13) are made simultaneously, in terms of space and time, progressively constructing the desired stratification of materials, in correspondence with the desired hinge-type join region (18) to be obtained.

19. Method as in claim 18, characterized in that the compression and heat treatment to achieve the shell (12) and the half-chinbar (13) is a hot molding step.

20. Method as in claim 19, characterized in that the hot molding provides to position simultaneously, according to the desired final geometry of the helmet (10), both a desired at least one pre-preg layer of reinforcement fibers incorporated in a thermosetting matrix, and at least one laminate of thermoplastic resin which, once they have been subjected to pressure and temperature, make up the composite material of the half-chinbar (13), and also at least one desired pre- preg formed by a matrix of thermosetting resin containing reinforcement fibers which, once it has been subjected to pressure and temperature at the same time as the material of the half-chinbar (13), makes up the composite material of the molded shell (12).

21. Method as in claim 16, characterized in that it provides to achieve separately the half-chinbar (13) as a finished component and to achieve the join region (18) between the half-chinbar (13) and the shell (12) incorporating or embedding at least partly a constrained end (22), opposite the free end (20), of the half-chinbar (13) as an insert in the material that makes up the molded shell (12) during a step of making the shell (12).

22. Method as in claim 21, characterized in that the step of making the shell (12), during which the half-chinbar (13) is associated as an insert, provides to use a technique with liquid resins, or a technique that uses a pre-preg and subsequently a treatment with adequate pressure and temperature.

23. Method as in claim 16, characterized in that it provides to make a magnetic clamping unit (30) configured to define a selective clamping of the half-chinbar ( 13) and shell (12).

24. Method as in claim 23, characterized in that the magnetic clamping unit (30) is made of a first magnet (32) comprised in the half-chinbar (13) and a second magnet (34) comprised in the shell (12).

25. Method as in claim 24, characterized in that the second magnet (34) is provided in the side (17) of the shell (12) where the half-chinbar (13) is provided.

26. Method as in claim 16, or in any claim from 23 to 25, characterized in that it provides to make on the shell (12) a housing seating (36) configured to receive a part of the half-chinbar (13).

27. Method as in claim 26, characterized in that it provides to make the housing seating (36) on the side (17) of the shell (12) where the half-chinbar (13) is provided.

28. Method as in claim 16, or in any of claims 23 to 27, characterized in that it provides to attach the half-chinbar (13) to the shell (12) using anchoring members (38).

29. Method as in claim 16, or in any of claims 23 to 28, characterized in that it provides to make a reduced thickness zone (42) of the half-chinbar (13) that defines the hinge-type join region (18).

30. Method as in claim 29, characterized in that the reduced thickness zone (42) is made by means of a localized compression during the molding of the material that forms the half-chinbar (13).