Field of the invention
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The present invention refers to a padding arrangement for helmet.
Background of the invention
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As is known, the use of a helmet is required or necessary for performing numerous activities in a civil, industrial, military or sporting context.
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Modern helmets are generally characterized by their high capacity to absorb the energy produced by radial impacts, i.e., impacts in which the impulsive force applied to the helmet is directed substantially perpendicularly to the outer surface of said helmet. In recent years, in order to further improve the protection offered to the user, helmets have been developed that are capable of effectively absorbing the energy produced by oblique impacts, i.e., impacts in which the impulsive force applied to the helmet has a significant component directed tangentially to the outer surface of the helmet.
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Some known helmets include a protective shell comprising rigid parts capable of moving in relation to one another in the case in which the helmet is subjected to tangential impulsive forces. The movement of one part of the protective shell in relation to the other allows partial absorption of the kinetic energy transmitted to the helmet in the case of oblique impact.
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Other helmets use solutions of an entirely different type, substantially consisting of applying a padding to the protective shell, which is capable of deforming so as to dissipate the kinetic energy transmitted to the helmet in the case of an oblique impact. Examples of helmets of this kind are described in the patent documents
US2018/0303187A1 ,
US10271604B2 ,
EP244082A1 and
WO2011/139224A1 .
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Although satisfying the purposes for which they have been designed, currently available helmets of this latter type include paddings that are structurally complex and/or costly to manufacture on an industrial scale. Moreover, in many cases the paddings used are not particularly comfortable for the user and of difficult practical use.
Summary of the invention
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The main aim of the present invention is to provide a padding arrangement for helmet that allows the drawbacks of the prior art to be solved.
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Within this aim, an object of the present invention is to provide a padding arrangement that allows the user's protection to be significantly improved, in particular when the helmet is subjected to oblique impacts.
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Another object of the present invention is to provide a padding arrangement that ensures a high level of comfort for the user.
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Another object of the present invention is to provide a padding arrangement that is simple to mount and rapid and economical to produce on an industrial scale.
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This aim and these objects, together with other objects that will be apparent from the description below and from the accompanying drawings, are achieved according to the invention by a padding arrangement for helmet according to claim 1 set forth below.
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The padding arrangement according to the invention is able to cover, at least partially, the user's head during use of the helmet.
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The padding arrangement according to the invention comprises layers superimposed and joined together. In particular, the padding arrangement according to the invention comprises:
- a first layer having a first surface and a second surface opposite each other;
- a second layer having a third surface and a fourth surface opposite each other.
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The aforesaid first and second layers are superimposed so that the second surface of said first layer and the third surface of said second layer face each other.
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The padding arrangement according to the invention further comprises a first structure made of thermoplastic material joined to said first layer and a second structure made of thermoplastic material joined to said second layer.
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The first structure made of thermoplastic material protrudes from the second surface of said first layer while the second structure made of thermoplastic material protrudes from the third surface of said second layer.
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At least one of said first and second structures made of thermoplastic material is elastically deformable.
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According to the invention, the aforesaid first and second structures made of thermoplastic material respectively comprise first connection portions and second connection portions, coupled together. These coupled connection portions join the aforesaid first and second structures made of thermoplastic material together so as to join said first and second layers to each other.
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According to some embodiments, the first and second connection portions of said first and second structures made of thermoplastic material are coupled together in a removable manner, for example with a snap-fit type connection.
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According to other embodiments, the first and second connection portions of said first and second structures made of thermoplastic material are coupled together in a permanent manner, for example by gluing or welding.
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According to some embodiments, the aforesaid first and second structures made of thermoplastic material are both elastically deformable.
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Preferably, the aforesaid first structure made of thermoplastic material comprises first formations made of thermoplastic material spaced apart from each other along the second surface of said first layer. Each first formation made of thermoplastic material comprises a first support portion, joined to the second surface of said first layer, and a first connection portion, joined to said first support portion.
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Said first connection portion is intended to be coupled with a corresponding second connection portion of said second structure made of thermoplastic material, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the aforesaid first structure made of thermoplastic material comprises first bridge portions that connect the aforesaid first formations made of thermoplastic material.
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Preferably, the aforesaid first structure made of thermoplastic material comprises first comb formations made of thermoplastic material. Each first comb formation comprises first elastically deformable teeth joined to the second surface of said first layer and facing the third surface of said second layer, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the aforesaid first elastically deformable teeth have free ends in contact with the third surface of said second layer, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the aforesaid second structure made of thermoplastic material comprises second formations made of thermoplastic material spaced apart from each other along the third surface of said second layer. Each second formation made of thermoplastic material comprises a second support portion, joined to the third surface of said second layer, and a second connection portion, joined to said second support portion.
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Said second connection portion is intended to be coupled with a corresponding first connection portion of said first structure made of thermoplastic material, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the aforesaid second structure made of thermoplastic material comprises second bridge portions made of thermoplastic material which connect the aforesaid second formations made of thermoplastic material.
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Preferably, the aforesaid second structure made of thermoplastic material comprises second comb formations made of thermoplastic material. Each second comb formation comprises second elastically deformable teeth joined to the third surface of said second layer and facing the second surface of said first layer, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the aforesaid second elastically deformable teeth have free ends in contact with the second surface of said first layer, when said first and second structures made of thermoplastic material are coupled together.
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Preferably, the first surface of said first layer faces the user's head, during use of said padding arrangement.
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Preferably, the fourth surface of said second layer faces an internal surface of a protective shell of said helmet, when said padding arrangement is coupled with said protective shell.
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Preferably, the padding arrangement comprises, at the fourth surface of said second layer, first fixing means couplable in a removable manner with corresponding second fixing means arranged at the internal surface of the protective shell of said helmet.
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According to some embodiments of the invention, the aforesaid first and second fixing means comprise a plurality of fixing elements or surfaces of Velcro™ type (hook and loop connections), couplable together.
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According to other embodiments of the invention, the aforesaid first and second fixing means comprise a plurality of snap-fit elements, couplable together.
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In a further aspect thereof, the present invention refers to a method for manufacturing a padding arrangement for helmet according to claim 17 and the related dependent claims.
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The method according to the invention comprises the following steps:
- providing a first semi-finished product arranged so as to form a first layer of said padding arrangement, wherein said first layer has a first surface and a second surface opposite each other;
- providing a second semi-finished product arranged so as to form a second layer of said padding arrangement, wherein said second layer has a third surface and a fourth surface opposite each other;
- depositing a first thermoplastic material on said first semi-finished product and forming a first structure made of thermoplastic material joined to said first layer and protruding from the second surface of said first layer;
- depositing a second thermoplastic material on said second semi-finished product and forming a second structure made of thermoplastic material joined to said second layer and protruding from the third surface of said second layer;
- superimposing said first and second semi-finished products on each other so that said first and second layers are superimposed on each other and that the second surface of said first layer and the third surface of said second layer are facing each other;
- coupling together the first connection portions of said first structure made of thermoplastic material and the second connection portions of said second structure made of thermoplastic material so as to join said first structure made of thermoplastic material and said second structure made of thermoplastic material together.
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At least one between the aforesaid first structure and second structure made of thermoplastic material is elastically deformable.
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According to some embodiments of the invention, both the structures made of thermoplastic material are elastically deformable. However, embodiments of the invention in which only one of the structures made of thermoplastic material is elastically deformable are also possible.
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According to some embodiments of the invention, the first and second connection portions of said first and second structures made of thermoplastic material are coupled together in a removable manner with a snap-fit type connection.
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According to other embodiments of the invention, the first and second connection portions of said first and second structures made of thermoplastic material are coupled together by gluing, welding, press-fitting, or interlocking.
Description of the figures
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Further features and advantages of the method according to the invention can be better understood by referring to the description provided below and to the accompanying figures, provided purely for non-limiting illustrative purposes, wherein:
- Fig. 1 schematically illustrates a helmet including the padding arrangement according to the invention;
- Fig. 2 schematically illustrates a portion of the helmet of Fig. 1;
- Figs. 3-14 schematically illustrate some embodiments of the padding arrangement according to the invention;
- Fig. 15 schematically illustrates some steps of a method for manufacturing the padding arrangement according to the invention.
Detailed description of the invention
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With reference to the aforesaid figures, the present invention refers to a padding arrangement 1 for helmet.
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Fig. 1 schematically illustrates a helmet 100 comprising the padding arrangement 1 according to the invention, while Fig. 2 schematically illustrates a portion of the helmet of Fig. 1.
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In principle, the helmet 100 can be of any type and have any use in a civil, industrial, military and sporting context.
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In general terms, the helmet 100 comprises a protective shell having at least one stiff external layer 101, for example made of ABS, PC, PP or a composite material, and at least one internal covering layer 102 made of a relatively flexible, light and strong material, capable of effectively absorbing impact energy, for example EPS or EPP.
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The helmet 100 can further comprise fastening means of known type (not illustrated) for fastening the helmet to the user's head.
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The internal covering layer 102 of the protective shell comprises an internal surface 103 facing the user's head, during use of the helmet.
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The helmet 100 comprises the padding arrangement 1 fixed, in a removable manner, to the aforesaid internal surface 103 of the protective shell.
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The padding arrangement 1 is able to cover, at least partially, the user's head during use of the helmet.
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The padding arrangement 1 comprises a plurality of superimposed layers 11, 12 joined to each other. It is formed by a multilayer structure, pliable and soft to the touch, capable of bending to follow the profile of the internal surface 103 of the protective shell, when fixed thereto.
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This multilayer structure will now be described in detail with particular reference also to Figs. 3-4.
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For evident reasons of clarity, it is specified that terms such as "superimposed", "upper", "lower" "internal", "external" and any other terms referring to the relative positioning of parts of the padding arrangement, are to be understood with reference to the normal position thereof, when fixed to the protective shell, as illustrated in the aforesaid figures.
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Fig. 3 schematically illustrates an exploded view of the padding arrangement 1 according to an embodiment of the invention.
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According to the invention, the padding arrangement 1 comprises a first layer 11, having a first surface 111 and a second surface 112 opposite each other, and a second layer 12, having a third surface 123 and a fourth surface 124 opposite each other.
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The second layer 12 is superimposed on the first layer 11 so that the third surface 123 of the second layer 12 is facing the second surface 112 of the first layer 11.
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Preferably, the first surface 111 of the first layer 11 is intended to come into contact with the user's head, during use of the helmet, while the fourth surface 124 of the second layer 12 is facing the internal surface 103 of the protective shell of the helmet, when the padding arrangement is coupled with the protective shell (Figs. 1-2).
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Preferably, each of the layers 11, 12 of the padding arrangement can be made of a material selected from: a fabric, a nonwoven, a polymeric material, or a combination of these materials. According to some embodiments, the fourth surface 124 of the second layer 12 can comprise portions of surface with hook and loop fixing systems of Velcro™ type.
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Preferably, at least the first layer 11 is made, at least partially, of a breathable material to ensure improved comfort for the user.
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According to the invention, the padding arrangement 1 comprises a first structure 13 made of thermoplastic material, joined to the first layer 11, and a second structure 14 made of thermoplastic material, joined to the second layer 12.
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The first structure 13 made of thermoplastic material is arranged so as to protrude from the second surface 112 of the first layer 11 while the second structure 14 made of thermoplastic material is arranged so as to protrude from the third surface 123 of the second layer 12.
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According to the embodiments illustrated in the aforesaid figures, the structures made of thermoplastic material 13, 14 are joined to respective layers 11, 12 at the surfaces 112, 123 thereof and protrude from these surfaces.
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However, embodiments (not illustrated) in which the structures made of thermoplastic material 13, 14 are joined to respective layers 11, 12 at both the surfaces 111, 112 or 123, 124 of each layer even if they protrude from the surfaces 112, 123 of the layers 11, 12 are also possible.
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According to the invention, at least one of the first structure 13 and the second structure 14 made of thermoplastic material is elastically deformable upon application of a force also when this force is directed predominantly in a direction parallel to the surface of the second layer 12, as can occur when the helmet is subjected to an oblique impact.
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According to some embodiments of the invention (Figs. 5-7, 9-11, 13-14), both the structures 13, 14 made of thermoplastic material are elastically deformable. However, embodiments of the invention (Figs. 8, 12) in which only one of the structures 13, 14 made of thermoplastic material is elastically deformable are also possible.
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A particularly important aspect of the invention consists in the fact that the first structure made of thermoplastic material 13 and the second structure made of thermoplastic material 14 are coupled together. Advantageously, they respectively comprise first connection portions 130b and second connection portions 140b coupled together.
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According to some embodiments of the invention, the first connection portions 130b and second connection portions 140b of the first structure 13 and second structure 14 made of thermoplastic material are coupled together in a removable manner, for example with a snap-fit type connection.
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According to other embodiments of the invention, the first and second connection portions 130b, 140b of the aforesaid first and second structures made of thermoplastic material are coupled together in a permanent manner, for example by gluing or welding.
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The solution proposed by the present invention, as illustrated above, offers significant advantages.
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Thanks to coupling between the structures 13, 14 made of thermoplastic material, the padding arrangement is provided with an elastically deformable and structurally complex internal protector. This protector is very effective in reducing the effects of an oblique impact to which the helmet can be subjected. In particular, it can be designed to re-distribute the impulsive forces following an impact and reduce their effects on the head of the user.
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Simultaneously, industrial manufacture of the padding arrangement is greatly facilitated. The aforesaid structures made of thermoplastic material 13, 14 can be formed separately at the respective support layers 11, 12 and subsequently coupled together, in a permanent or removable manner, when the padding arrangement is assembled and the support layers 11, 12 are superimposed on each other.
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In general, the structures 13, 14 made of thermoplastic material can be made according to a wide range of variants of embodiment, as a function of the required performance. This allows the performance of the padding arrangement to be adapted to the type of helmet on which it is to be mounted. Naturally, this flexibility of use is made possible by the fact that the structures 13, 14 made of thermoplastic material are produced separately and subsequently coupled together during assembly of the padding arrangement.
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Figs. 5-10, 12-14 illustrate the first structure 13 made of thermoplastic material according to some possible variants of embodiment of the invention.
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In general, the first structure 13 made of thermoplastic material preferably comprises first formations 130 made of thermoplastic material spaced apart from each other along the second surface 112 of the first layer 11.
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Each first formation 130 comprises a first support portion 130a, joined to the first layer 11, and a first connection portion 130b joined to the first support portion 130a.
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In the embodiments of Fig. 5-7 and 9-10, the first support portion 130a consists of a plurality of elastically deformable curved legs. Each curved leg has a first end fixed to the second surface 112 of the first layer 11 and a second end raised from the surface 112 of the first layer 11.
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According to some variants (not illustrated), the first support portion 130a can also comprise a reinforcing base (for example a ring) fixed to the surface 112 of the first layer 11 and joined to the first end of the curved legs.
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In the embodiments of Fig. 5-7 and 9-14, the first connection portion 130b consists of a ring (Fig. 6) or disc (Fig. 7) at the end of the aforesaid curved legs in distal position from the surface 112 of the first layer 11.
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In the embodiment of Fig. 8, the first support portion 130a consists of a base (for example disk shaped) fixed to the first layer 11 while the first connection portion 130b consists of a protrusion protruding from the aforesaid base and facing the third surface 123 of the second layer 12.
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According to the embodiments described above, the first connection portion 130b of each first formation 130 is couplable with a corresponding second connection portion 140b of a second formation 140 of the second structure 14 made of thermoplastic material (Figs. 6-7).
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In the case in which the first structure 13 made of thermoplastic material is removably couplable with the second structure made of thermoplastic material, the first connection portion 130b is advantageously provided with first removable connection means 130d couplable with second removable connection means 140d of a corresponding second connection portion 140b of a second formation 140 of the second structure 14 made of thermoplastic material.
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In the embodiment of Fig. 6, the first removable connection means 130d consists of a connection hole able to accommodate a pair of deformable tabs 140d of a corresponding second connection portion 140b of a second formation 140 of the second structure 14 made of thermoplastic material.
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In the embodiment of Fig. 7, the removable connection means 130d consist of a pair of deformable tabs able to be inserted into a connection hole 140d of a corresponding second connection portion 140b of a second formation 140 of the second structure 14 made of thermoplastic material.
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According to the embodiments of Figs. 5-8, 12, the first structure 13 made of thermoplastic material comprises first bridge portions 130c made of thermoplastic material (preferably elastically deformable) that connect the first formations 130 arranged along the second surface 112 of the first layer 11.
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Naturally, embodiments in which the first formations 130 are structurally separated from each other are also possible.
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According to the embodiment of Figs. 9-10 illustrated above, the first structure 13 made of thermoplastic material comprises first comb formations 135 made of thermoplastic material, each of which is preferably arranged at the separation space between two first formations 130 arranged adjacent along the second surface 112 of the first layer 11.
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Each comb formation 135 comprises first elastically deformable teeth 135a joined to the second surface 112 of the first layer 11. The first elastically deformable teeth 135a protrude from the second surface 112 of the first layer 11 and face the third surface 123 of the second layer 12, when the aforesaid first and second structures 13, 14 made of thermoplastic material are coupled together (Fig. 10).
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Preferably, the first elastically deformable teeth 135a have free ends in contact with the third surface 123 of the second layer 12, when the aforesaid first and second structures 13, 14 made of thermoplastic material are coupled together.
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Based on the above, it is evident how, according to the embodiments of Figs. 5-7, 9-14, the first structure 13 made of thermoplastic material is elastically deformable.
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Instead, according to the embodiment of Fig. 8, the first structure 13 made of thermoplastic material is not elastically deformable or can only deform to a very limited extent.
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As is evident to the person skilled in the art, the first structure 13 made of thermoplastic material can be produced according to further variants of embodiment, optionally obtained by suitably combining the variants of embodiment illustrated above with each other. These embodiments of the padding arrangement are not illustrated in detail herein for evident reasons of brevity of exposition.
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Figs. 6-14 illustrate the second structure 14 made of thermoplastic material according to some possible variants of embodiment of the invention.
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In general, the second structure 14 made of thermoplastic material preferably comprises second formations 140 made of thermoplastic material spaced apart from each other along the third surface 123 of the second layer 12.
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Preferably, each second formation 140 comprises a second support portion 140a, joined to the second layer 12, and a second connection portion 140b joined to the second support portion 140a.
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In the embodiments of Fig. 6-11 and 13-14, the second support portion 140a consists of a plurality of elastically deformable curved legs. Each curved leg has a first end fixed to the second surface 123 of the second layer 12 and a second end raised from the surface 123 of the second layer 12. According to some variants (not illustrated), the second support portion 140a can also comprise a base (for example a ring) fixed to the surface 123 of the second layer 12 and joined to the first end of the curved legs.
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In the embodiments of Figs. 6-11 and 13-14, the second connection portion 140b consists of a shaped ring (Fig. 6) or shaped disc (Fig. 7) joined to the end of the aforesaid curved legs in distal position from the surface 123 of the second layer 12.
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In the embodiment of Fig. 12, the second support portion 140a consists of a base fixed to the second layer 12, while the second connection portion 140b consists of a protrusion protruding from the base and facing the second surface 112 of the first layer 11.
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According to the embodiments described above, the second connection portion 140b of each second formation 140 is couplable with a corresponding first connection portion 130b of a first formation 130 of the first structure 13 made of thermoplastic material.
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In the case in which the second structure 14 made of thermoplastic material is couplable in a removable manner with the first structure 13 made of thermoplastic material, the second connection portion 140b is advantageously provided with second removable connection means 140d couplable with first removable connection means 130d of a corresponding first connection portion 130b of a first formation 130 of the first structure 13 made of thermoplastic material.
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In the embodiment of Fig. 6, the second removable connection means 140d consist of a pair of deformable tabs able to be inserted into a connection hole 130d of a corresponding first connection portion 130b of a first formation 130 of the first structure 13 made of thermoplastic material.
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In the embodiment of Fig. 7, the second removable connection means 140d consist of a connection hole able to accommodate a pair of deformable tabs 130d of a corresponding first connection portion 130b of a first formation 130 of the first structure 13 made of thermoplastic material.
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According to the embodiments 6-8 and 11-12, the second structure 14 made of thermoplastic material comprises second bridge portions 140c made of thermoplastic material (preferably elastically deformable) connecting the second formations 140 arranged along the third surface 123 of the second layer 12.
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Naturally, embodiments in which the second formations 140 are structurally separate from each other are also possible.
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According to the embodiment of Figs. 13-14 illustrated above, the second structure 14 made of thermoplastic material comprises second comb formations 145 made of thermoplastic material, each of which is preferably arranged at the separation space between two second formations 140 arranged adjacent along the second surface 123 of the second layer 12.
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Each comb formation 145 comprises second elastically deformable teeth 145a joined to the second surface 123 of the second layer 12. The second elastically deformable teeth 145a protrude from the second surface 123 of the second layer 12 and face the second surface 112 of the first layer 11, when the aforesaid first and second structures 13, 14 made of thermoplastic material are coupled together (Fig. 14).
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Preferably, the second elastically deformable teeth 145a have free ends in contact with the second surface 112 of the first layer 11, when the aforesaid first and second structures 13, 14 made of thermoplastic material are coupled together (Fig. 14).
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Based on the above, it is evident how, according to the embodiments of Figs. 6-11, 13-14, the second structure 14 made of thermoplastic material is elastically deformable.
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Instead, according to the embodiment of Fig. 11, the second structure 14 made of thermoplastic material is not elastically deformable or can only deform to a very limited extent.
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As is evident to the person skilled in the art, the second structure 14 made of thermoplastic material can be produced according to further variants of embodiment, optionally obtained by suitably combining the variants of embodiment illustrated above. These embodiments of the padding arrangement are not illustrated herein in detail for evident reasons of brevity of exposition.
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As mentioned above, the padding arrangement 1 is intended to be fixed, in a removable manner, to the aforesaid internal surface 103 of the protective shell.
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With reference to Figs. 1-2, the padding arrangement 1 comprises first fixing means 15 at the fourth surface 124 of the second layer 12. The first fixing means 15 are removably couplable with corresponding second fixing means 104 arranged at the internal surface 103 of the protective shell of the helmet 100.
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According to some embodiments of the invention (Figs. 1-2), the first and second fixing means 15, 104 comprise a plurality of fixing elements or surfaces of Velcro™ type (hook and loop connections) couplable with each other.
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According to other embodiments of the invention (Figs. 1-2), the first and second fixing means 15, 104 comprise a plurality of snap-fit type fixing elements couplable with each other.
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As may be easily understood by a person skilled in the art, further variants of embodiment of the padding arrangement are possible by suitably combining the solutions described above. These embodiments of the padding arrangement are not described in detail herein for evident reasons of brevity of exposition.
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In a further aspect thereof, the present invention refers to a method 50 for industrially manufacturing the padding arrangement 1 (Fig. 15).
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For simplicity of exposition, the method 50 according to the invention will be described with particular reference to the embodiment of Figs. 3-4.
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The method 50 comprises the step of providing a first semi-finished product 51 arranged so as to form a first layer 11 of the padding arrangement.
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As mentioned above, the first layer 11 comprises a first surface 111 and a second surface 112 opposite each other.
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The semi-finished product 51 preferably consists of a sheet of a soft material, for example selected from: a fabric, a nonwoven, a polymeric material, or a combination of these materials. To form the first layer 11, the first semi-finished product 51 can be subjected to preliminary processing operations of known type. These processing operations are not described in detail herein for evident reasons of brevity.
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The method 50 comprises the step of providing a second semi-finished product 52 arranged so as to form a second layer 12 of the padding arrangement.
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The second layer 12 has a third surface 123 and a fourth surface 124 opposite each other. The second semi-finished product 52 preferably consists of a sheet of a material selected from: a fabric, a nonwoven, a polymeric material, or a combination of these materials.
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To form the second layer 12, the second semi-finished product 52 can b subjected to preliminary processing operations of known type. These processing operations are not described in detail herein for evident reasons of brevity.
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The method 50 comprises the step of depositing a first thermoplastic material on the first semi-finished product 51 so as to form the first structure 13 made of thermoplastic materials joined to the first layer 11 and arranged so as to protrude from the first surface 112 thereof.
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Preferably, the first thermoplastic material consists of TPE, TPU, PVC, HDPE, LDPE or similar materials.
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Advantageously, the first thermoplastic material can be deposited on the first semi-finished product 51 by a process selected from: injection moulding, additive printing, gluing, stitching, heat-sealing and pouring. Preferably, the first thermoplastic material is deposited on the first semi-finished product 51 by an injection moulding procedure.
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The method 50 comprises the step of depositing a second thermoplastic material on the second semi-finished product 52 so as to form the second structure 14 made of thermoplastic material joined to the second layer 12 and arranged so as to protrude from the first surface 112 thereof. Preferably, the second thermoplastic material consists of TPE, TPU, PVC, HDPE, LDPE or similar materials.
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Advantageously, the second thermoplastic material can be deposited on the second semi-finished product 51 by a process selected from: injection moulding, additive printing, gluing, stitching, heat-sealing and pouring. Preferably, the second thermoplastic material is deposited on the second semi-finished product 52 by an injection moulding procedure.
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The method 50 comprises the step of superimposing the first semi-finished product 51 and the second semi-finished product 52 so that the first layer 11 and the second layer 12 are superimposed on each other and so that the third surface 123 of the second layer 12 faces the second surface 112 of the first layer 11.
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The method 50 comprises the step of coupling together the first connection portions 130b of said first structure 13 made of thermoplastic material and the second connection portions 140b of the second structure 14 made of thermoplastic material.
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According to some embodiments of the invention, the first and second connection portions 130a, 140a of the aforesaid first and second structures made of thermoplastic material are mutually coupled, in a removable manner, for example with a snap-fit type connection.
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According to other embodiments of the invention, the first and second connection portions 130a, 140a of the aforesaid first and second structures made of thermoplastic material are mutually coupled in a permanent manner, for example by gluing or welding.
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At least one of the first structure 13 and the second structure 14 made of thermoplastic material is elastically deformable.
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According to some embodiments of the invention (Figs. 5-7, 9-11, 13-14), both the structures 13, 14 made of thermoplastic material are elastically deformable. However, embodiments of the invention (Figs. 8, 12) in which only one of the structures 13, 14 made of thermoplastic material is elastically deformable are also possible.
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As may be easily understood by a person skilled in the art, the method 50 according to the invention can include further processing steps to those described. These further processing steps can be of known type and are not illustrated herein for evident reasons of brevity of exposition. The padding arrangement according to the invention has considerable advantageous relative to the prior art.
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The padding arrangement is produced so that its layers, in particular the layers 11, 12, can move slidably on each other when the helmet is subjected to an oblique impact. This allows the impulsive forces, to which the user's head is subjected following any impact on the helmet, to be effectively reduced and redistributed.
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The padding arrangement includes an internal protector 13, 14 consisting of the first and second structures 13, 14 made of thermoplastic material coupled together. This internal protector is elastically deformable both in perpendicular direction and in a direction parallel to the respective support layers 11, 12.
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The internal protector 13, 14 can thus effectively adapt to the shape of the head for increased comfort. Simultaneously, being elastically deformable in tangential direction (to the support layers 11, 12), it allows the impulsive forces of the user during the impact to be effectively redistributed.
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The internal protector 13, 14 can be designed so as to optimise the aforesaid effects of absorbing shock and/or of redistributing the energy transmitted to the helmet. For example, it can be produced so as to comprise regions having different elasticity so as to improve the performance in terms of protection of the user's head.
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Simultaneously, although the elastically deformable internal protector 13, 14 has a relatively complex three-dimensional structure, it can be easily manufactured on an industrial scale, given that the aforesaid first and second structures made of thermoplastic material can be produced separately with "planar" type manufacturing technologies, which can, for example, involve injection moulding processes.
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The internal protector 13, 14 of the padding arrangement facilitates the formation of a gap between the mutually superimposed layers 11, 12. This allows improved aeration and breathability for the user's head, when the helmet is being worn. The padding arrangement according to the invention is easy to manufacture on an industrial scale, with significant advantages in terms of reducing production times and costs. It is easy to apply to the protective shell of a helmet and ensures a high level of comfort for the user.