EP4719116A1

EP4719116A1 - Safety device, manufacturing method and airbag

Info

Publication number: EP4719116A1
Application number: EP24728551.3A
Authority: EP
Inventors: Jonas Svantesson
Original assignee: Autoliv Development AB
Current assignee: Autoliv Development AB
Priority date: 2023-05-24
Filing date: 2024-05-21
Publication date: 2026-04-08
Also published as: CN121311134A; WO2024240749A1; KR20250174086A; DE102023113645B4; DE102023113645A1

Abstract

The invention relates to a safety device (10) for the head of a human comprising a helmet element (11) having an inner surface (12) and an outer surface (13) and comprising an airbag (20) having an inflatable part (21), said airbag (20) being connected to the helmet element (11), wherein the inflatable part (21) is located on the outer surface (13). In order to provide improved fixation of the airbag (20) to the helmet element (11), it is suggested that the airbag (20) further comprises a flap (22), and the helmet element (11) comprises a through-hole (14) through which the flap (22) extends, such that a connection section (23) of the flap (22) extends along the inner surface (12) of the helmet element (11), said connection section (23) of the flap (22) being connected to the helmet element (11). Thus, a beneficially lean and space- saving attachment solution for the airbag (20) is provided and a reliable and secure fastening are ensured. The invention furthermore relates to an associated method of manufacturing such a safety device (10) as well as to an airbag (20) for such a safety device (10).

Description

Safety device, manufacturing method and airbag

Description

The invention relates to a safety device for the head of a human according to claim 1 . Furthermore, the invention relates to a method of manufacturing such a safety device as well as to an airbag for such a safety device.

Safety devices for the head of a human have constantly gained in importance with a raising safety awareness in society. A very common example for protection devices are helmets, which are well-developed and widespread. Helmets are mainly used for human locomotion under exposed conditions such as by urban cyclists or motorcyclists, or for accident-prone sporting activities as skiing, skating, riding or climbing.

Nevertheless, efforts are made to provide enhanced head protection articles for improved physical safety, especially in case of a critical event as an accident. Thus, the invention relates to a safety device for the head of a human comprising a helmet element having an inner surface and an outer surface, wherein the safety device further comprises an airbag comprising an inflatable part, said airbag being connected to the helmet element, wherein the inflatable part is located on the outer surface. When inflated, the inflatable part provides a protective barrier for the head of the human additionally to the helmet element.

Usually, the airbag is inserted into associated recesses in the helmet. For instance, WO 2021/160817 A1 discloses a full-face helmet with a cap to be fitted around the head of a user, wherein the cap comprises an external shell and at least one housing seat housing an inflatable airbag.

The combination of a helmet with an inflatable airbag significantly raises the protective effect of the safety device since the airbag increases and reinforces the protective barrier between the head of the human and the environment. At the same time, the airbag is configured to deploy only in case of a critical event such that the safety device does not affect the human’s comfort wearing the safety device during normal use.

Still, conventional helmets do not provide much space for the arrangement and the attachment of an airbag. Furthermore, it is essential to reliably secure the airbag to the helmet such that impacts, e.g. caused by a crash, do not lead to an unintended separation of the airbag from the helmet. These requirements lead to an increased challenge for attachment concepts regarding safety devices of the described kind.

Hence, it is an object of the invention to provide a safety device with improved fixation of the airbag to the helmet element. Further objects of the invention comprise the provision of an associated manufacturing method and a suitable airbag for such a safety device.

The above-mentioned objects are achieved by a safety device as defined in claim 1 , by a manufacturing method as defined in claim 1 and by an airbag as defined in claim 24. Advantageous embodiments are disclosed in the dependent claims, the description and the drawings.

According to a first aspect of the invention referring to the safety device described above, the airbag further comprises a flap, and the helmet element comprises a mounting feature comprising a through-hole through which the flap extends, such that a connection section of the flap extends along the inner surface of the helmet element, said connection section of the flap being connected to the helmet element.

By the use of a flap being guided through the helmet element and fixed on the opposite side of the outer surface on which the inflatable part extends, a beneficially lean and space-saving attachment solution for the airbag is provided. Furthermore, the deflection of the flap being guided from the outer surface to the inner surface of the helmet element in combination with the surrounding helmet element structure enhances the grip and support of the airbag being connected to the helmet element, thus leading to an improved and reliable fastening. In conclusion, a safety device with improved fixation of the airbag to the helmet element is provided. For instance, the flap may be a substantially flat strip-like tab or protrusion. The connection section of the flap may be a flap surface intended to flatly fit to the inner surface of the helmet element. The flap may be an integral part of the airbag or attached to it by a seam or other suitable fastening, e.g. an adhesive connection. The connection section may comprise a connection structure suitable to fix the flap to the helmet element directly or by means of an integrated or separate connection element.

The inner surface of the helmet element is intended to face the human’s head and the outer surface faces the environment when the safety device is put on.

According to an advantageous embodiment, the helmet element comprises a main body made from a foamed plastic material. For instance, the foamed plastic material may be expanded polystyrene (EPS). The main body made from a foamed plastic material provides beneficial shock-absorbing characteristics as well as a relatively soft material to which the flap can be easily connected.

According to a refined embodiment, the safety device further comprises a shell covering at least a section of the main body, said shell having a first surface pointing towards the main body and a second surface pointing away from the main body. The shell provides additional cover protection to the main body. The shell may be thinner than the main body. Preferably, the shell is rigid and made of a hard material like polycarbonate or a fiber reinforced plastic material. According to a preferable embodiment, the shell comprises set break-lines or expansion joints in order to allow the covered airbag to deploy when the inflatable part is inflated. In some embodiments, at least one shell part remains attached to the deploying airbag when the inflatable part is inflated such that the airbag is still protected by the shell part even if the shell breaks or expands. For instance, the shell may comprise adhesion points by which it is selectively fixed to the airbag.

In the just described case, the shell forms a cover for a sub-assembly comprising the helmet element and the airbag. By providing a sub-assembly comprising the helmet element and the airbag, the safety device production is accelerated and facilitated and the shell may be easily placed on the sub-assembly in order to cover it. For instance, the sub-assembly may be prepared by providing the helmet element and the airbag, by guiding a flap of the airbag through a through-hole of the helmet element and by connecting the connection section of the flap to the inner surface of the helmet element.

In accordance with another embodiment, the shell forms a part of the helmet element such that the second surface of the shell forms the outer surface of the helmet element. In other words, the shell and the main body form a combined helmet element. Both the shell and the main body may comprise a merging through-hole through which the flap extends. For instance, the flap is connected to the helmet element on the inner surface of the main body and the inflatable part is located on the outer surface of the shell. According to the embodiment, the inflatable part of the airbag is positioned on the outside of the helmet element such that the inflatable part may deploy in a rapid and unimpeded manner.

The aforementioned embodiment can be further improved by additionally providing a cover element, said cover element covering at least a section of the inflatable part. By means of the cover element, the inflatable part is at least partially protected towards the environment. Furthermore, the appearance and the aerodynamics of the safety device are enhanced by the cover element. In case of an airbag inflation, the cover element may be configured to remain at least partially on the inflatable part in order to protect the surface of the inflatable part from impact-induced damages.

According to an advantageous embodiment, the connection section of the flap is connected to the main body by means of a mounting element extending through a hole in the connection section and into the main body. The additional mounting element beneficially secures the connection section of the flap to the main body such that a reliable fastening between the flap and the main body is provided. For instance, the mounting element may be a T-shaped or nail-shaped element or clip which is inserted through the hole in the connection section and driven into the main body. Preferably, the mounting element is made of a light material as plastic in order to maintain a low total weight of the safety device. Nevertheless, other suitable mounting elements as e.g. screws or fleece tapes may be used to connect the connection section of the flap to the main body. According to a preferable embodiment, the through-hole is slit-shaped. The slit-shape minimizes the structural weakening of the helmet element and promotes a defined orientation as well as a strong hold of the flap guided through the through-hole. The slit through which the flap extends, is also referred to as first slit.

In a preferred embodiment, a second slit extends substantially parallel to the first slit such that an airbag distal section of the flap can be stored in this second slit. This makes it possible to use a rather long flap without which might ease the mounting process.

In accordance with an advantageous embodiment, the airbag comprises a plurality of flaps and the helmet element comprises a plurality of mounting features. The use of a plurality of flaps each extending through an assigned through-hole allows for a more even and secure attachment of the airbag to the helmet element. It is further advantageous if more through-holes than flaps are provided in order to enable various fixation schemes according to predefined criteria or according to different airbag designs.

In one embodiment, at least a section of the inflatable part of the airbag has an oblong shape with a first edge and a second edge extending substantially parallel to the first edge, wherein at least one first flap extends from the first edge and at least one second flap extends from the second edge, and wherein the oblong section of the inflatable part is folded along an even number of folding lines being parallel to one another. The oblong shape may for instance form a center cell traversing the top of the helmet or alternatively a side cell of the airbag surrounding at least partially a circumferential region of the helmet element, as e.g. the rear, front and/or lateral regions. Depending on a selected fixation scheme, the first flap and the second flap may be arranged directly opposite to each other or located in offset positions, e.g. alternating along the first and second edges in order to provide evenly distributed fixation points.

According to the aforementioned embodiment and according to a further independent inventive aspect of the presented invention, a section of the inflatable part is folded along an even number of folding lines being parallel to one another. The even number may be two, four or other multiples of two. The folding lines are preferably substantially parallel to the first and second edge of the oblong shape such that the section is transversally folded across its cross section. According to an example, the folded section may be Z-shaped with two folding lines. With at least one folded section, the inflatable part may be packed and stowed on the helmet element in a compact manner without affecting the deployment of the inflatable part upon inflation. By folding the section along an even number of folding lines it is achieved that the first flap and the second flap still extend in opposite directions in the folded state of the section such that fixation of the airbag to the helmet element is still possible using opposed flaps. In the inflated state, the inflatable part is unfolded and extended to its maximum size. For instance, the inflatable part may form a hose-shaped protective barrier when inflated.

According to an advantageous embodiment, the inflatable part of the airbag forms an elongated center cell traversing the top of the helmet element and an elongated side cell surrounding at least partially a circumferential region of the helmet element. This embodiment provides beneficial protective coverage of the human’s head, especially with regard to critical head parts. The circumferential region is represented by the rear, front and the lateral regions of the helmet element. The top of the helmet comprises the center region of the helmet element and adjoins the circumferential region. The center cell may have a broadening in the center of the top for providing extended protection in this region.

According to a further improved embodiment and according to a further independent inventive aspect of the presented invention, at least one flap connecting the side cell to the helmet element is located at a side cell bottom facing a bottom edge of the helmet element. Preferably, the side cell is only connected to the helmet element by means of flaps located at the side cell bottom only, meaning that the other edge of the side cell is not connected to the helmet element. The bottom edge of the helmet element is pointing towards the neck and shoulders of the human when the safety device is put on. In other words, the side cell part of the airbag is fixed to the helmet element in a lower region of the side cell, wherein the side cell top remains unconnected in order to freely deploy upwards upon inflation. The airbag expansion is thus facilitated and accelerated. According to an advantageous embodiment and according to a further independent inventive aspect of the presented invention, the safety device further comprises an inflator positioned horizontally in the inflatable part adjacent to a neck region of the helmet element. Inflators may be pyrotechnics or compressed gas devices which generate or release inflation gas at a high volumetric flow rate, such that the inflatable part is rapidly inflated upon inflator activation. The neck region of the helmet element corresponds to a rear region of the helmet directed to the back of the neck of a human wearing the safety device. The horizontal position refers to the longest axis of the inflator which runs substantially parallel to the ground when the human wearing the safety device is standing on the ground. If the side cell has an open design with ends, the ends of the side cell may each point towards the inflator. The inflator may have a substantially cylindrical shape. With an inflator positioned horizontally in the inflatable part adjacent to the neck region of the helmet element, the safety device is improved regarding space utilization and weight distribution so that the wearer’s comfort is not affected.

It is advantageous if the safety device further comprises a detection unit for detecting a critical event and a triggering unit for inflator activation. For instance, the detection unit comprises an acceleration sensor. Upon detecting a predetermined acceleration being equal to or greater than a defined threshold value based on a signal from the acceleration sensor, the triggering unit supplies electrical energy to the inflator in order to activate the inflation process. The detection unit and the triggering unit may be placed anywhere in the safety device, wherein a preferable position may be adjacent to the inflator for short signal distances.

In accordance with a refined embodiment, the inflator comprises radial inflation gas outlet holes. The inflation gas outlet holes are configured to release inflation gas from the inflator in a substantially radial direction. Thus, a thrust neutral inflator is provided that ensures high system safety for the human wearing the safety device.

According to a further improved embodiment, the inflatable part of the airbag has an L-shaped inflator holding section. The L-shaped inflator holding section takes into consideration that the inflator provides a radial inflation gas flow. The L-shaped inflator holding section allows the inflation gas to directly enter the inflatable part (long L leg), e.g. the center cell, without initial deflection at cell walls, wherein the inflator is securely arranged in the bent section of the inflatable part (short L leg). The inflator holding section comprises an opening allowing for lateral insertion of the inflator. The inflator may be fixed and secured in the inflator holding section by means of a hose clamp or other suitable fixation means.

According to a second aspect of the invention, a method of manufacturing a safety device is provided which comprises:

- providing a helmet element having an inner surface, an outer surface and at least one through-hole between the inner surface and the outer surface;

- providing an airbag comprising an inflatable part and further comprising at least one flap with a connection section;

- arranging the inflatable part of the airbag on the outer surface of the helmet element;

- guiding the at least one flap through one of the at least one through-holes such that the connection section of the flap extends along the inner surface of the helmet element; and

- connecting the connection section of the flap to the inner surface of the helmet element.

The described method allows to implement a beneficially lean and space-saving attachment solution for fastening an airbag to a helmet element. Furthermore, the presented manufacturing method is particularly easy to realize and cost-efficient. Already with a small number of method steps, a reliable and secure connection between the airbag and the helmet element is achieved. It is not required to provide many or complex tools for the implementation of the method.

According to an advantageous embodiment, the method further comprises a subsequent step of arranging a shell or a cover element on the inflatable part. Thus, a further improved safety device may be manufactured as the inflatable part is at least partially protected towards the environment by means of the shell or the cover element. Furthermore, the appearance and the aerodynamics of the safety device are enhanced by the shell or cover element. In accordance with preferred embodiments, the method of manufacturing a safety device comprises manufacturing a safety device according to the characteristics described above in relation to the first aspect of the invention.

According to a third aspect of the invention, an airbag for a safety device for the head of a human is provided, wherein the airbag has a substantially T-shaped base form with at least one flap protruding from an edge of the base form and wherein the at least one flap is configured to be guided through a through-hole of a helmet element of the safety device and to be connected to an inner surface of the helmet element. The presented airbag may be beneficially used for a safety device as described in relation with the first aspect of the invention. The described airbag can be fastened to a helmet element in a beneficially lean and space-saving manner. The airbag may comprise further characteristics as described in relation with the first aspect of the invention. For instance, the airbag may comprise an inflatable part and a plurality of flaps. The flap may comprise a connection section. In the connection section, a connection means as e.g. a hole may be provided through which a mounting element can be inserted. At least a section of the inflatable part may have an oblong shape with a first edge and a second edge extending substantially parallel to the first edge, wherein at least one first flap extends from the first edge and at least one second flap extends from the second edge. The first flap and the second flap may be arranged directly opposite to each other or located in offset positions. The airbag may be partially folded, e.g. the oblong section of the inflatable part may be folded along an even number of folding lines being parallel to one another. The inflatable part of the airbag may form an elongated center cell and an elongated side cell. Substantially in the middle of the center cell a cell broadening may be provided. The airbag may comprise an L-shaped inflator holding section.

The presented safety device, manufacturing method and airbag provide reliable, simple and cost-efficient attachment solutions for the fixation of airbags to helmet elements.

Conceivable applications of the safety device comprise traffic and sport implementations. The safety device is especially suited for accident-prone activities. In the following, the invention is described by means of example embodiments in conjunction with the accompanying schematic drawings. Functionally similar elements illustrated in the drawings are denoted by the same or similar reference numerals, and the description thereof is not repeated.

Fig. 1 a is a perspective side view of a safety device according to an embodiment.

Fig. 1 b provides a front view of the safety device according to the embodiment.

Fig. 1 c illustrates a sectional side view of the safety device along the section line A-A indicated in Fig. 1 b.

Fig. 1 d is a perspective rear view of the safety device according to the embodiment.

Fig. 1 e provides a side view of the safety device according to the embodiment.

Fig. 2 is a perspective detail view of an airbag attachment region of the safety device according to the embodiment.

Fig. 2a a view from direction R in Fig. 2.

Fig. 3 a variation to what is shown in Figure 2.

Fig. 4 illustrates a two-dimensional schematic view of a suitable airbag for the safety device according to the embodiment.

Figs. 1 a to 1 e provide front, side, rear and sectional views the inventive safety device

10. The safety device 10 is intended to be used with accident-prone activities and is configured to be worn on the head of a human (not shown). The safety device 10 mainly comprises a helmet element 1 1 and an inflatable airbag 20 configured to deploy upon the detection of a critical event. The combination of the helmet element 1 1 and the inflatable airbag 20 provide beneficial physical protection to the human from impacts.

As for instance depicted in Fig. 1 b, the helmet element 1 1 comprises an inner surface 12 pointing towards the human’s head and an outer surface 13 pointing towards the environment when the safety device 10 is put on. The airbag 20 comprises an inflatable part 21 which is arranged on the outer surface 13 of the helmet element 1 1. Upon inflation, the inflatable part 21 provides a protective barrier for the head of the human additionally to the helmet element 1 1 .

The airbag 20 needs to be securely connected to the helmet element 1 1 in order to prevent unintended separation of the airbag 20 e.g. following a crash impact. At the same time, the helmet element 11 does not provide much space for extensive attachment concepts. Therefore, it is suggested that the airbag 20 further comprises a flap 22 and the helmet element 1 1 further comprises a mounting feature with a through-hole in form of a first slit 14a through which the flap 22 is guided from the outer surface 13 to the inner surface 12. In the embodiments shown, the mounting feature additionally comprises a second slit 14b extending parallel to the first slit 14. A connection section 23b of the flap 22 thus extends along the inner surface 12. The connection section 23b of the flap 22 is connected to the helmet element 1 1 on this inner surface 12. By this, a beneficially lean and space-saving attachment solution for the airbag 20 is provided. Furthermore, a secure and reliable fastening is ensured.

According to the depicted embodiment and as possibly best illustrated in Figs. 1 a and 1 d, the airbag 20 comprises several flaps 22. The flaps 22 are flat strip-like tabs and provide a suitable connection surface that flatly fits to the inner surface 12 of the helmet element 1 1 . As for instance can be taken from the detail views in Figs. 2 and 4, the flaps 22 each comprise a hole 24 through which a mounting element 25 is insertable into the helmet element 11 in order to fix the flap 22 to the helmet element 1 1 . For instance, the mounting element 25 may be a T-shaped or nail-shaped plastic element for providing a light and secure fastening. According to other embodiments, the connection section 23 of the flap 22 may already provide an integrated connection element as e.g. a fleece tape or a clip.

The illustrated safety device 10 represents an example embodiment in which the helmet element 1 1 represents a main body 15 made from a foamed plastic material as EPS. The main body 15 provides advantageous shock-absorbing features as well as a relatively thick and soft material, such that the mounting element 25 is easily insertable into the main body 15. Although not shown, a rigid shell may be placed on the sub-assembly formed by the helmet element 1 1 and the airbag 20 for providing a cover at least to the inflatable part 21 of the airbag 20. Alternatively, the helmet element 1 1 can be a combined main body and shell element such that the inflatable part 21 of the airbag 20 is placed on the outer surface 13 of the helmet element 1 1 and optionally covered by an additional cover element.

According to the depicted embodiment, for instance as illustrated in Figs. 1 a and 1 c, the helmet element 1 1 comprises several mounting features, each comprising a first slit 14a and a second slit 14b. The slit shape of the first slits 14a assists in maintaining the structural stability of the helmet element 1 1 and provides a defined orientation of the flap 22 guided through the first slit 14a. The second slit can accommodate an airbag distal section 23b of the flap such that it does not come into contact with the head of the user which might be uncomfortable. Using a rather long flap (meaning a flap that extends beyond the hole 24 eases the assembly process, but once assembled, the airbag distal section of the flap should be stowed away (Fig. 3).

As can be taken from Figs. 1 a to 1 e, the inflatable part 21 of the airbag 20 forms an elongated center cell 29 traversing the top 16 of the helmet element 1 1 and providing a hose-shaped protective barrier when inflated. In the embodiment shown, two transverse cells 42 extend from the center cell 29. The inflatable part 21 further forms an elongated side cell 30 surrounding a circumferential region 17 of the helmet element 1 1 . By this, the front, rear and lateral sides of the human’s head are beneficially protected. As for instance depicted in Fig. 1 d, the side cell 30 has an open configuration with two side cell ends pointing towards each other close to a neck region 19 of the helmet element 1 1 . The side cell 30 provides a hose-shaped protective barrier when inflated. As for instance illustrated in Figs. 1 a and 1d, the flaps 22 connecting the side cell 30 to the helmet element 1 1 are located at a side cell bottom 31 facing a bottom edge 18 of the helmet element 1 1. The side cell top opposite the side cell bottom 31 is not connected to the helmet element 1 1 according to the illustrated embodiment. Thus, the airbag 20 may perform easy and fast expansion, since the inflatable side cell 30 can freely deploy upwards upon inflation.

Fig. 2 and Fig. 2a provide a detail view of an attachment region of the safety device 10. As depicted, the helmet element 1 1 , represented by the main body 15, comprises two slits 14a, 14b extending substantially parallel to each other. The flap 22 of the airbag 20 extends through the lower first slit 14a and is deflected at the end of the through-hole 14 such that the connection section 23b extends along the inner surface 12 of the helmet element 1 1 . The connection section 23b comprises a hole 24 through which the nail-shaped mounting element 25 is inserted into the inner surface 12 of the helmet element 1 1. Thus, an easy and secure fastening of the airbag 20 is provided. As can be seen from Figure 3 and has already been briefly described, an airbag distal section 23c of the flap 22 can be inserted into the second slit 14b.

Fig. 4 provides a two-dimensional schematic view of a suitable airbag 20 for a safety device 10 according to the invention. The airbag 20 can be connected to the helmet element 1 1 in accordance with the disclosure of this application. Some of the aspects described above may become clearer upon consideration of Fig. 4. As depicted, the airbag 20 has a substantially T-shaped base form with strip-like flaps 22 protruding from the edges of the base form. For clarity reasons, not all of the plurality of flaps 22 shown in the figure are indicated by reference numerals. The flaps 22 are configured to be guided through the above-mentioned first slits 14a of the helmet element 1 1 for connection to the helmet element 11 by means of connection sections 23b. Each connection section 23b comprises an above-mentioned hole 24 for insertion of a mounting element 25. The airbag 20 has an inflatable part 21 configured to form an elongated center cell 29 with two transverse cell 42 extending from the same and an elongated side cell 30. The side cell 30 forms an oblong section 26 with a first edge 27a and a second edge 27b extending substantially parallel to the first edge 27a. In this embodiment, first flaps 22a extend from the first edge 27a and second flaps 22b extend from the second edge 27b. Although the second flaps 22b are shown as positioned opposite to first flaps 22a, other configurations as e.g. alternating positioning may be conceivable.

As schematically indicated, the oblong side cell 30 is intended to be Z-folded along three folding lines upon attachment to the helmet element 1 1 . The folding promotes a compact packaging of the inflatable part 21 on the helmet element 1 1. The Z-folding comprises folding the inflatable part 21 along an even number of folding lines 28 parallel to each other and parallel to the first edge 27a and the second edge 27b, such that the first flaps 22a and the second flaps 22b still extend in opposite directions in the folded state of the inflatable part 21 .

Fig. 4 as well as Fig. 1 c further depict an inflator 40 to be positioned in the inflatable part 21 of the airbag 20. When the airbag 20 is attached to the helmet element 1 1 , the inflator 40 is oriented horizontally and arranged next to a neck region 19 of the helmet element 1 1 . The inflator 40 shown has a substantially cylindrical shape and radial inflation gas outlet holes 41 for releasing inflation gas into the inflatable part 21 in order to inflate the inflatable part 21 . By means of radial inflation gas outlet holes 41 , a thrust neutral inflator 40 is provided.

The inflatable part 21 of the airbag 20 has an L-shaped inflator holding section 32 into which the inflator 40 is laterally inserted via an opening of the inflator holding section 32 and fastened to the airbag 20, e.g. by means of a hose clamp. The L-shaped inflator holding section 32 allows the inflation gas to directly enter the inflatable part 21 without initial deflection at cell walls.

Although not depicted, the safety device 10 preferably further comprises a detection unit with an acceleration sensor or other suitable detector for detecting a critical event and a triggering unit for inflator activation.

Although not depicted in single method steps, an associated manufacturing method for the described safety device 10 can be derived from Figs. 1 a to 1 e and Figs. 2 to 4 comprising the steps: - providing a helmet element 11 having an inner surface 12, an outer surface 13 and at least one through-hole 14 between the inner surface 12 and the outer surface 13;

- providing an airbag 20 comprising an inflatable part 21 and further comprising at least one flap 22 with a connection section 23;

- arranging the inflatable part 21 of the airbag 20 on the outer surface 13 of the helmet element 11 ;

- guiding the at least one flap 22 through one of the at least one through-holes 14 such that the connection section 23 of the flap 22 extends along the inner surface 12 of the helmet element 11 ; and

- connecting the connection section 23 of the flap 22 to the inner surface 12 of the helmet element 11 .

In accordance with the described embodiments, a beneficially lean and space-saving as well as reliable and secure attachment solution is provided for safety devices 10 comprising a helmet element 11 and an airbag 20.

Claims

1 . Safety device (10) for the head of a human comprising:

- a helmet element (11 ) having an inner surface (12) and an outer surface (13),

- an airbag (20) comprising an inflatable part (21 ), said airbag (20) being connected to the helmet element (1 1 ), wherein the inflatable part (21 ) is located on the outer surface (13), characterized in that the airbag (20) further comprises at least one flap (22), and the helmet element (11 ) comprises at least one mounting feature comprising a through-hole through which the flap (22, 22a, 22b) extends, such that a connection section (23b) of the flap (22, 22a, 22b) extends along the inner surface (12) of the helmet element (11 ), said connection section (23b) of the flap (22, 22a, 22b) being connected to the helmet element (1 1 ).

2. The safety device (10) according to claim 1 , characterized in that the helmet element (1 1 ) comprises a main body (15) made from a foamed plastic material.

3. The safety device (10) according to claim 2, characterized in that it further comprises a shell covering at least a section of the main body (15), said shell having a first surface pointing towards the main body (15) and a second surface pointing away from the main body (15).

4. The safety device (10) according to claim 3, characterized in that the shell forms a part of the helmet element (1 1 ) such that the second surface of the shell forms the outer surface (13) of the helmet element (1 1 ).

5. The safety device (10) according to claim 4, characterized in that additionally a cover element is provided, said cover element covering at least a section of the inflatable part (21 ).

6. The safety device (10) according to claim 3, characterized in that the shell forms a cover for a sub-assembly comprising the helmet element (11 ) and the airbag (20).

7. The safety device (10) according to any one of claims 2 to 6, characterized in that the connection section (23b) of the flap (22, 22a, 22b) is connected to the main body (15) by means of a mounting element (25) extending through a hole (24) in the connection section (23) and into the main body (15).

8. The safety device (10) according to any one of the preceding claims, characterized in that the through-hole (14) of the mounting feature is slitshaped, such that it forms a first slit (14a).

9. The safety device according to claim 8, characterized in that the mounting feature further comprises a second slit (14b), preferably extending parallel to the first slit (14a).

10. The safety device of claim 9, characterized in that an airbag distal section (23c) of the flap (22, 22a, 22b) extends into the second slit (14b)

1 1. The safety device (10) according to any one of the preceding claims, characterized in that the airbag (20) comprises a plurality of flaps (22, 22a, 22b) and the helmet element (1 1 ) comprises a plurality of mounting features.

12. The safety device (10) according to any one of the preceding claims, characterized in that the inflatable part (21 ) of the airbag (20) comprises at least one oblong section with a first edge (27a) and a second edge (27b) extending substantially parallel to the first edge (27a), wherein at least one first flap (22a) extends from the first edge (27a).

13. The safety device (10) of claim 12, characterized in that at least one second flap (22b) extends from the second edge (27b).

14. The safety device of claim 13, characterized in that the oblong section of the inflatable part (21 ) is folded along an even number of folding lines (28) being parallel to one another.

15. The safety device (10) according to any one of the claims 12 to 14, characterized in that the inflatable part (21 ) of the airbag (20) comprises at least two oblong sections, namely an elongated center cell (29) traversing the top (16) of the helmet element (1 1 ) and an elongated side cell (30) surrounding at least partially a circumferential region (17) of the helmet element (1 1 ).

16. The safety device (10) according to claim 15, characterized in that two transverse cells (42) extend from the center cell (29).

17. The safety device (10) according to claim 15 or 16, characterized in that at least one flap (22) connecting the side cell (30) to the helmet element (11 ) is located at a side cell bottom (31 ) facing a bottom edge (18) of the helmet element (11 ).

18. The safety device (10) according to any one of the preceding claims, characterized in that it further comprises an inflator (40) extending horizontally into the inflatable part (21 ) adjacent to a neck region (19) of the helmet element (1 1 ).

19. The safety device (10) according to claim 18, characterized in that the inflator (40) comprises radial inflation gas outlet holes (41 ).

20. The safety device (10) according to claim 19, characterized in that the inflatable part (21 ) of the airbag (20) has an L-shaped inflator holding section (32).

21 . Method of manufacturing a safety device (10), comprising:

- providing a helmet element (1 1 ) having an inner surface (12), an outer surface (13) and at least one through-hole between the inner surface (12) and the outer surface (13);

- providing an airbag (20) comprising an inflatable part (21 ) and further comprising at least one flap (22. 22a, 22b) with a connection section (23); - arranging the inflatable part (21 ) of the airbag (20) on the outer surface (13) of the helmet element (1 1 );

- guiding at least a section of the at least one flap (22) through one of the at least one through-holes such that the connection section (23b) of the flap (22) extends along the inner surface (12) of the helmet element (1 1 ); and

- connecting the connection section (23b) of the flap (22) to the inner surface (12) of the helmet element (1 1 ).

22. The method according to claim 21 , wherein the method further comprises:

- arranging a shell or a cover element on the inflatable part (21 ).

23. The method according to claim 21 or 22, wherein the safety device (10) is a safety device (10) according to any one of claims 1 to 19.

24. Airbag (20) for a safety device (10) for the head of a human comprising an inflatable part and at least one flap (22, 22a, 22b) protruding from an edge (27a, 27b) of the inflatable part, wherein the at least one flap (22, 22a, 22b) is configured to be guided through a through-hole of a helmet element (1 1 ) of the safety device (1 1 ) and to be connected to an inner surface (12) of the helmet element (1 1 ).