EP3544459B1 - Outer shell for a safety helmet - Google Patents

Description

The invention relates to an outer shell for a protective helmet with the features of the preamble of claim 1, a protective helmet with such an outer shell and a method for producing an outer shell for a protective helmet with the features of the preamble of claim 1.

It is known from the prior art that protective helmets and in particular motorcycle protective helmets have an outer shell for distributing impact forces. Such outer shells are used for areal distribution of the impact forces along the outer shell. An inner layer regularly arranged inside the outer shell then serves to dampen the impact forces distributed in this way. In addition to the primary protective aspect of such protective helmets, the digital communication of protective helmet wearers and in particular of motorcycle helmet wearers is becoming increasingly important. Essential components of the corresponding communication devices can be arranged on the protective helmet or on the motorcycle helmet.

the U.S. 2013/176183 A1 shows a substantially linear dipole antenna for protective helmets with two conductive branches arranged to be electrically connected at one of their ends to the respective radio alignment, the two conductive branches being arranged substantially aligned and having a length which is substantially ¼ of the expected operating wavelength of the radio equipment.

From the state of the art and specifically from the American patent specification U.S. 8,667,617 it is known to dispose an antenna for wireless communication on the inner layer so that it is supported by the inner layer. This can be done in particular by the antenna extending over the outer surface of the inner layer. The disadvantage of this approach is that with such an arrangement, the antenna cannot easily be fixed. Gluing the antenna or a similar measure is usually required. It is also disadvantageous that, depending on the design of the antenna, such an antenna made of a material that is harder than the inner layer over the long term can damage the inner layer. However, such damage is not easy to discover and therefore regularly remains undetected.

the DE 30 42 159 , from which the present invention comes closest, shows a protective helmet with a loudspeaker, a microphone and an operating unit that are connected to a radio, the radio with supply unit, antenna or the like being integrated into the protective helmet. A niche-like container, which has a lockable cover, is provided on the outer shell to accommodate the radio device including the supply unit, antenna or the like.

EP 1 836 913 discloses a method for producing an outer shell for a protective helmet from fiber material and matrix material.

Proceeding from this prior art, the object of the invention is to provide a possibility for arranging an antenna on a protective helmet, which avoids the disadvantages mentioned above.

This object is achieved in relation to an outer shell for a protective helmet having the features of the preamble of claim 1 by the features of the characterizing part of claim 1. In relation to a protective helmet with such an outer shell, this object is achieved by the features of the characterizing part of claim 9 and in relation to a method for producing an outer shell for a protective helmet with the features of the preamble of claim 13, this object is achieved by the features of the characterizing part solved by claim 13.

Essential to the invention is the knowledge that the outer shell itself can be used to fix the antenna, specifically by forming a cover for receiving the antenna between the cover and one side of the outer shell. Because of its intended function, the outer shell already has the material properties required for such a fixation and accommodation. The hard and durable material of the outer shell can therefore be used to separate the antenna from the softer inner layer. This also avoids arranging the antenna on the outside of the outer shell.

The proposed outer shell is for a protective helmet, which can in particular be a motorcycle shelter, and is used for distribution of impact forces. The outer shell according to the invention has an outer shell material and is characterized in that on one side with the outer shell material of the outer shell the outer shell has a cover for receiving an antenna between the cover and the side, the cover having the outer shell material. It is therefore a side of the outer shell which side has the outer shell material. The term "cover" is to be understood as meaning a structure that is at least partially spaced from a base area of the side and thus forms an opening, in which the received structure - in this case the antenna - is located between a flat cover side of the cover and a flat base area below the cover is arranged and is preferably fixed by the arrangement between this top side and this base. This base area is a partial area of the upper side of the outer shell. This top side essentially overlaps this base area. Alternatively, it could also be stated that the antenna is received in an opening formed between the cover and the side of the outer shell.

According to a first preferred embodiment of the proposed outer shell, the side is an inside of the outer shell. The inside of the outer shell is the concave side of the outer shell. According to a second preferred embodiment of the proposed outer shell, the side is an outside of the outer shell. Correspondingly, the outside of the outer shell is the convex side of the outer shell. Of course, this means the respective side of the outer shell apart from the cover itself.

A preferred embodiment of the proposed outer shell is characterized in that the outer shell material has a matrix material for a fiber composite material. Such a matrix material serves to bind fiber material of the fiber composite material to the matrix material by means of adhesive or cohesive forces. The matrix material surrounds the fiber material of the fiber composite material. The above bonding through adhesive or cohesive forces regularly results from curing or crosslinking of the matrix material, which process can also be referred to as compounding. In principle, the outer shell material can also have other materials in addition to the matrix material. However, it can also be that the outer shell material consists essentially of the matrix material. It can also be the case that the outer shell material has the fiber material or essentially consists of it.

In particular, it can be that the outer shell material has a fiber-reinforced plastic with the plastic as matrix material and a fiber material or even essentially consists of this fiber-reinforced plastic. The fiber material preferably has glass fibers. Correspondingly, the outer shell material then has a glass fiber reinforced plastic or essentially consists of such. The fiber material can also be a number of different fiber materials.

A further preferred embodiment of the proposed outer shell is characterized in that the outer shell material and preferably the matrix material has a duroplast. It can also be the case that the matrix material essentially consists of the duroplast. Preferably, the thermoset is one or more of vinyl ester resin (VE resin), epoxy acrylate, polyester resin (UP resin), epoxy resin, phenolic resin (PF resin), PVB-modified phenolic resin, and styrene-free resin, inclusive of derivatives of these substances and of these substances with additives.

According to a preferred embodiment of the proposed outer shell, it is provided that the outer shell material and preferably the matrix material have a thermoplastic. It can also be the case that the matrix material essentially consists of the thermoplastic. Preferably, the thermoplastic is one or more of acrylonitrile butadiene styrene (ABS), polyethylene (including HDPE and LDPE), polypropylene (PP), polycarbonate, polycarbonate with acrylonitrile butadiene styrene (PC+ ABS), polycarbonate with acrylonitrile styrene acrylate (PC+ASA), polycarbonate with polyamide (PA) and polyetheretherketone (PEEK). The group also includes derivatives of these substances and these substances with additives.

The cover can be designed in one piece with the rest of the outer shell. Likewise, the cover can be integrally connected to the rest of the outer shell.

The outer shell is characterized in that the cover has an extent which essentially corresponds to the extent of the antenna. The extent of the cover here preferably corresponds to the extent of the cavity formed by the cover, specifically between the cover and the base area below the cover. In this way the placement of the antenna between the cover and the page is essentially fixed by the cover. It is further preferred that the cover is set up to accommodate the antenna essentially completely between the cover and the side. Thus, when essentially no part of the antenna is outside the area of the cover, the separation between the antenna and in particular an inner shell is essentially complete, which minimizes the risk of dislocation of the antenna or mutual damage. According to a first preferred variant, the cover may be open on two, in particular opposite, sides. Accordingly, it is preferred that the cover forms a passage between the cover and the side. The result is a tunnel-like structure for accommodating the antenna.

An alternative and equally preferred variant provides that the cover forms a pocket. In other words, the cover forms a bag-like closure for accommodating the antenna. A corresponding preferred embodiment of the proposed outer shell is characterized in that the pocket is open in an opening direction - starting from the inside of the pocket - for inserting the antenna and is closed in a direction opposite to the opening direction. Consequently, the antenna can then only be inserted into the pocket in one direction of movement--this time starting from outside the pocket--and can only be removed from the pocket by moving in the opposite direction to this direction of movement. A passage through the bag is therefore not possible. This embodiment further improves the fixation of the antenna in the pocket. It is further preferred that the pocket is closed on the inside of the outer shell in the two transverse directions perpendicular to the opening direction. Leading in or out in such a transverse direction is then also ruled out. In particular, it may be that one Longitudinal extent of the pocket along the opening direction exceeds a transverse extent of the pocket along the transverse directions. In this case, the pocket has an elongate shape, which is particularly advantageous when the antenna has one alignment and is also to be arranged in a specific alignment with respect to the outer shell.

It is proposed that the cover extends essentially along a surface of the side of the outer shell. In this way, the cover "follows" the course of the surface of the page, particularly in its curvature. Therefore, it is preferred that the cover substantially follows a surface curvature of the surface of the page. In particular, it can be the case here that the cover is set up to deform the received antenna in accordance with the surface curvature and to fix it under the cover as a result of the deformation.

The proposed protective helmet, which is in particular a motorcycle protective helmet, has a proposed outer shell and is characterized in that it has an antenna accommodated between the cover and the side for preferably digital communication. The antenna can be set up in particular for Bluetooth communication.

It is preferred that the antenna is held by a force fit between the cover and the side. This frictional connection can in particular be a frictional connection which is based on friction between the antenna and the cover. Here it can also be the case that the antenna is accommodated without a material bond between the cover and the side. Consequently, the antenna is not glued or similarly fixed between the cover and the side. A comparatively complex processing step for producing such a material connection can accordingly be omitted.

It is not necessary that the above friction is caused by direct contact between the antenna and the cover. Rather, it may be the case that, for example, a foil or other structure is arranged between the cover and the antenna and between the side and the antenna. This foil or this other structure can be a shaping means or a mold core, which is used during production of the outer shell is used to form the cover in the manner described in more detail below and which remains wholly or partially between the cover and the side after manufacture.

A preferred embodiment of the protective helmet according to the proposal is characterized in that the antenna has a metallic antenna body and a plastic housing for preferably substantially completely accommodating the antenna body. Furthermore, it may be that the antenna has an elongate shape, specifically both with regard to its antenna body and with regard to its plastic housing.

A further preferred embodiment of the proposed protective helmet is characterized in that the antenna is accommodated between the cover and the side in such a way that it can be pulled out, in particular in the opening direction.

According to a preferred embodiment of the proposed protective helmet, it is provided that the protective helmet has an inner layer accommodated by the outer shell to absorb impact forces, that the protective helmet has an antenna feed line coupled to the antenna for connecting the antenna, and that the antenna feed line is at least partially between the outer shell and the Inner layer is arranged. The antenna feed line is not used to send or receive radio signals, so it is not part of the antenna itself, but merely creates an electrical connection with the device that uses the antenna for sending and/or receiving. In principle, this device using the antenna can be any device that is preferably either permanently or detachably connected to the protective helmet.

It is preferred that this device is a communication device. A preferred embodiment of the protective helmet according to the proposal is then characterized in that the protective helmet has a contact arrangement for the electrical connection to a communication device and that the antenna feed line is routed to the contact arrangement for connecting the antenna.

Further preferred embodiments and features of the proposed protective helmet correspond to preferred embodiments and features of the proposed outer shell.

In the proposed method for producing an outer shell for a protective helmet, the outer shell has an outer shell material.

The proposed method is characterized in that a cover layer with a second fiber material is arranged on one side of a preform with a first fiber material. In principle, these can be different fiber materials, but it is preferred that the first fiber material is identical to the second fiber material. Then the first fiber material and the second fiber material can simply be referred to as fiber material.

The proposed method is further characterized in that a mold core is arranged between the side and the cover layer, that a matrix material surrounding the first fiber material of the preform and the second fiber material of the cover layer is cured to form the outer shell, so that the outer shell is covered on the side formed with the outer shell material for receiving an antenna between the cover and the side. The outer shell material can comprise the matrix material, the first fiber material or the second fiber material or consist essentially of one or more of these materials. Specifically, the outer shell material can therefore include the matrix material as well as the first fiber material and the second fiber material. With regard to the sequence of the proposed method steps, the mold core can also be arranged on the preform before the cover layer is arranged on the side of the preform.

In particular, if the mandrel is hollow or the like, it can remain in the place where it was placed. However, it is preferred that the mandrel is completely or partially removed after curing.

With regard to the preform, it is preferably provided that this essentially forms the rest of the outer shell—that is, without the cover. In other words, an expansion of the preform essentially corresponds to an expansion of the—then finally produced—outer shell.

According to a first preferred variant of the proposed method, it is provided that the preform is a prepreg preform comprising the matrix material and that--alternatively or additionally--the cover layer is a prepreg cover layer comprising the matrix material. In this case, it may be that the preform or the cover layer has already been partially compounded or cured, preferably before the cover layer is arranged on the side. In the case of the preform, the first fiber material and/or the second fiber material in the case of the top layer is therefore preferably—particularly only—partially bonded to the matrix material or the respective matrix material is only partially cured.

In principle, the matrix material can be further cured in any desired manner. However, it is preferred that the matrix material is preferably substantially completely cured by hot pressing. In particular, complete compounding preferably takes place during the hot pressing, so that the fiber material of the preform and/or the cover layer is essentially completely bonded to the matrix material only with the hot pressing. Likewise, there is preferably an integral connection between the first fiber material of the preform and the second fiber material of the cover layer by means of the matrix material through the curing of the matrix material.

According to a further preferred variant of the proposed method, it is provided that the matrix material is introduced as liquid matrix material into the preform and into the cover layer after the cover layer has been arranged on the inside of the preform, so that the curing of the matrix material creates a material connection between the cover layer and the preform is produced. According to this variant, the liquid matrix material can be a synthetic resin. The matrix material is preferably introduced into the preform and into the cover sheet essentially simultaneously. In this way, the matrix material can impregnate both the preform and the cover sheet and also flow between these two structures during this process. This ensures a reliable material connection between the cover layer and the preform during curing.

The fiber-reinforced plastic can in particular be a glass-fiber-reinforced plastic. Correspondingly, the first fiber material and/or the second fiber material each has glass fibers.

A preferred embodiment of the proposed method is characterized in that the mold core is glued to the side of the preform before the top layer is arranged.

A further preferred embodiment of the proposed method is characterized in that after the mold core has been removed, the antenna is inserted into the pocket. Alternatively, the mandrel can remain between the cover and the side and then in particular the antenna can be inserted into the mandrel.

Further preferred embodiments and features of the proposed method correspond to preferred embodiments or features of the proposed outer shell and the proposed protective helmet and vice versa. It should be noted here that the side of the preform corresponds to the side of the outer shell and therefore the statements regarding the side of the outer shell apply analogously to the side of the preform.

Fig. 1

eine Teil-Schnittansicht eines Schutzhelms mit einem Ausführungsbeispiel einer vorschlagsgemäßen Außenschale und

Fig. 2

eine weitere Teil-Schnittansicht des Schutzhelms der Fig. 1 aus einer anderen Perspektive.

Further details, features, aims and advantages of the present invention are explained below with reference to the drawing of a preferred exemplary embodiment. In the drawing shows

1

a partial sectional view of a protective helmet with an embodiment of a proposed outer shell and

2

another partial sectional view of the protective helmet 1 from a different perspective.

The proposed outer shell of the 1 and 2 is part of a protective helmet 1, which is a motorcycle protective helmet. The outer shell consists of an outer shell material 2, which is specifically a glass fiber reinforced plastic. On one side 3 of the outer shell—in this case specifically on an inside of the outer shell This a cover 4, which consists of the outer shell material 2 and which forms a pocket. In turn, an antenna 5 is arranged in this pocket in such a way that it is completely covered by the cover 4 and is thus completely accommodated by the pocket. This antenna 5 is an antenna 5 for digital communication and specifically an antenna 5 for Bluetooth communication.

The pocket is only open in one direction, which is in the 2 shown opening direction 6. In both transverse directions 7a, b and counter to the opening direction 6 - thus in three directions - the pocket is closed. The elongated configuration of the cover 4 and thus also of the pocket can be recognized by the fact that the longitudinal extent 8 of the cover 4 exceeds its transverse extent 9 . The cover 4 extends along the surface of the side 3 and also follows the surface curvature of the surface of the side 3 caused by the rounding of the outer shell. The corresponding deformation of the antenna 5 by diffraction increases the friction between the antenna 5 and the cover 4, which in turn, the corresponding frictional connection for holding the antenna 5 under the cover 4 is reinforced.

Furthermore, the protective helmet 1 has an inner layer 10 which, due to its material properties, serves to dampen impact forces. Electrically connected to the antenna 5 and so far connected is one in the 1 and 2 recognizable antenna feed line 11 of the protective helmet 1, which runs between the outer shell and the inner layer 10 in the illustrated embodiment. The antenna feed line 11 is - as in the 1 shown - guided to a contact arrangement 12, which contact arrangement 12 produces an electrical connection with a communication device 13. In the present case, this communication device 13 is a Bluetooth module for Bluetooth communication.

The outer shell of the in the 1 and 2 shown protective helmet was made by a top layer 14 - which in the 1 shown - made of glass fibers on side 3 of a preform - also made of glass fibers - which preform corresponds to the outer shell without the above cover layer 14. Side 3 of the preform, which in turn is the inside of the preform corresponds, also forms the corresponding side 3 of the then finished outer shell otherwise, i.e. apart from the cover 4.

A mandrel—not shown here—was arranged between the preform and the cover layer 14 , the dimensions of which essentially correspond to those of the antenna 5 . In a mold in which the preform, the cover sheet 14 and the mandrel were placed, a resin material was charged as a liquid matrix material so that this matrix material surrounded the glass fibers of the preform and the cover sheet 14 . Curing of the matrix material brought about a material connection between the glass fibers of the cover layer 14 and the glass fibers of the preform, these glass fibers then forming the outer shell material 2 of the outer shell with the matrix material. The mold core was then removed and the antenna 5 was placed between the resulting cover 4 and the side 3.

Claims (15)

1. Outer shell for a safety helmet (1), in particular, for a motorcycle safety helmet, for distributing impact forces having an outer shell material (2), wherein, on a side (3) having the outer shell material (2) of the outer shell, the outer shell has a cover (4) in order to hold an antenna (5) between the cover (4) and the side (3), characterized in that the cover (4) comprises the outer shell material (2) and that the cover (4) essentially extends along a surface of the side (3) of the outer shell.
2. Outer shell according to Claim 1, characterized in that the side (3) is an inner side of the outer shell or that the side (3) is an outer side of the outer shell.
3. Outer shell according to Claim 1 or 2, characterized in that the outer shell material (2) comprises a matrix material for a fibre composite material, in particular, a fibre-reinforced plastic having the plastic as a matrix material and a fibrous material, preferably, that the fibrous material comprises a glass fibre material.
4. Outer shell according to one of the Claims 1 to 3, characterized in that the outer shell material (2), preferably, the matrix material, comprises a thermoset, preferably that the matrix material is essentially made of a thermoset.
5. Outer shell according to one of the Claims 1 to 4, characterized in that the outer shell material (2), preferably the matrix material, comprises a thermoplastic, preferably that the matrix material is essentially made of a thermoplastic.
6. Outer shell according to one of the Claims 1 to 5, characterized in that the cover (4) has an extension, which essentially corresponds to the extension of the antenna (5), preferably, that the cover (4) is set up to essentially completely hold the antenna (5) between the cover (4) and the side (3).
7. Outer shell according to one of the Claims 1 to 6, characterized in that the cover (4) forms a bag, which is open in an opening direction (6) for inserting an antenna (5) and is closed in a direction opposing the opening direction (6), preferably, that the bag is closed on the side (3) of the outer shell in the two transverse directions (7a, b) aligned perpendicular to the opening direction (6), in particular, that a longitudinal extension (8) of the bag along the opening direction (6) exceeds an transverse extension (9) of the bag along the transverse directions (7a, b).
8. Outer shell according one of the Claims 1 to 7, characterized in that the cover (4) essentially follows a surface curvature of the surface of the side (3), in particular, that the cover (4) is set up to deform the held antenna (5) according to the surface curvature and to fix it under the cover (4) by means of the deformation.
9. Safety helmet, in particular a motorcycle safety helmet, with an outer shell according to one of the Claims 1 to 8, characterized in that the safety helmet (1) has an antenna held between the cover (4) and the side (3), preferably for digital communication, in particular, for Bluetooth communication, being furthermore preferred, that the antenna (5) is held by a frictional connection between the cover (4) and the side (3), being furthermore preferred that the antenna (5) is held between the cover (4) and the side (3) in an adhesive-bond-free manner.
10. Safety helmet according to Claim 9, characterized in that the antenna (5) is held between the cover (4) and the side (3) in such a way that it can be pulled out in the insertion direction (6) in particular.
11. Safety helmet according to Claim 9 or 10, characterized in that the safety helmet (1) has an inner layer (10) held by the outer shell for dampening impact forces, that the safety helmet (1) has an antenna feed line (11) coupled with the antenna (5) for connecting the antenna (5), and that the antenna feed line (11) is at least partially arranged between the outer shell and the inner layer (10).
12. Safety helmet according to Claim 11, characterized in that the safety helmet (1) has a contact assembly (12) for the electrical connection to a communication device (13) and that the antenna feed line (11) is guided onto the contact assembly (12) to connect the antenna (5).
13. Method for producing an outer shell for a safety helmet (1), wherein the outer shell has an outer shell material (2), characterized in that, on one side (3) of a preform comprising a first fibrous material, a cover layer (14) comprising a second fibrous material is arranged, that, between the side (3) and the cover layer (14), a mould core is arranged, that a matrix material surrounding the first fibrous material of the preform and the second fibrous material of the cover layer (14) is cured in order to form the outer shell so that, on the side (3), a cover (4) of the outer shell comprising the outer shell material (2) is formed to hold an antenna (5) between the cover (4) and the side (3).
14. Method according to Claim 13, characterized in that the preform is a prepreg preform has the matrix material and/or that the cover layer (14) is a prepreg cover layer comprising the matrix material, preferably that the matrix material is cured by means of hot pressing.
15. Method according to Claim 13 or 14, characterized in that the matrix material is introduced as a liquid matrix material after arranging the cover layer (14) on the side (3) of the preform, preferably essentially simultaneously, into the preform and into the cover layer (14) so that a substance-to-substance connection between the cover layer (14) and the preform is established.

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