GB2565524A

GB2565524A - Deformable structure

Info

Publication number: GB2565524A
Application number: GB1709041.6A
Authority: GB
Inventors: Clive Williams Steven; Nathany Gautam
Original assignee: Be Safe Honeycomb Ltd
Current assignee: Be Safe Honeycomb Ltd
Priority date: 2017-06-07
Filing date: 2017-06-07
Publication date: 2019-02-20
Also published as: GB201709041D0

Abstract

A foldable bicycle helmet 30 is formed from a waterproof material such as polypropylene. The helmet may be made from sheets of a synthetic paper material arranged in a honeycomb-like concertina folding structure. When folded, the sheets may be layered on top of another in a stack with alternating sheets offset from one another, and the sheets may form a plurality of hexagonal cells when unfolded. The sheets may be glued together, for example using a water-based synthetic resin emulsion adhesive. A strap 35, optionally comprising an overband 40 or underband attached over the top or to the inside of the helmet 30 may be provided. The overband 40 may limit the extent to which the helmet 30 can unfold. The helmet 30 may include a means for spreading the load of the strap 35 where it meets the helmet, such as an acetate load bearing sheet. The strap 35 may be formed from nylon webbing or synthetic paper.

Description

DEFORMABLE STRUCTURE

The present invention relates generally to a deformable structure and particularly, although not exclusively, to a foldable protective structure.

Some aspects and embodiments of the present invention are partly based on a honeycomb-like, folding concertina structure formed as shown in Figure I. Individual sheets 5 of material are layered on top of each other. Alternating sheets are offset from each other as shown to form a stack. Each layer has lines of glue (shows as dotted lines 10) applied. This basic unit can then be used to form many different structures, for example as illustrated in Figure 2 in which two different shapes 15, 20 are cut through the stack. When the cut-outs are opened out they form honeycombbased structures.

One example of the type of protective structure which can be formed in this way is a folding cycling helmet. If, for example, the structure is formed using a lightweight material such as paper then the resulting helmet is lightweight and space efficient. This could support various applications, such as city centre bike hire locations. It is also printable, so could be a promotional item for brands.

In order to be certified safe for use as a cycle helmet there are regulatory tests. One regulatory test is that the helmet is submersed in water between 4 and 24 hours before impact tests. Accordingly for any product to satisfy this test it must be wate r p roof/ wate r- res i stant.

Another test requires the helmet strap to not deflect move more than 30mm when a 4kg weight is dropped onto it. The concertina nature of a honeycomb design can present problems for such tests.

Waterproof Material

In one aspect of the present invention there is provided a protective structure formed using the basic folding honeycomb design and using sheets formed from a waterproof material. For example in one embodiment a polymeric plastics material is used. In some embodiments synthetic paper is used, for example a pulp-free paper. In one embodiment a synthetic paper known under the product name “Yupo” is used, which is a recyclable, waterproof, tree-free synthetic “paper”. It is extruded from polypropylene pellets.

In some embodiments a glue called Pidivyl KPS (MH) manufactured by Pidilite Industries Ltd is used to glue sheets together. It is a water based synthetic (Vinyl Acetate Copolymer) resin emulsion adhesive.

The present invention also provides a foldable cycle helmet formed from a synthetic paper material.

Overband/Underband

The present invention provides a strap design that continues over the top or inside of a helmet. It allows the helmet to fold, but stops the helmet from opening further when the strap is under load. This could be made, for example, from a nylon webbing strap or from the same material as the rest of the helmet, such as synthetic paper. It may be attached over the top, or within the helmet.

The present invention provides such an overband/underband arrangement for a foldable, concertina-like cycle helmet.

Attachment of the strap

The present invention includes means for spreading the load of the strap where it joins the helmet. The strap is attached to an acetate load bearing sheet, this is bonded into the base of the helmet and stitched or riveted. This spreads the load between the over/under band and the base of the helmet.

This aspect of the present invention could be used, for example, with a foldable, concertina-like cycle helmet of the type described herein.

Innovative Uses of Waterproof Honeycomb other than Cycling Helmets

This same manufacturing process and components can be used to make innovative deformable structures, such as covers for concrete safety bollards erected outside public buildings. This would have many commercial opportunities for venues and or brands to create interesting shapes and branding platforms whilst enhancing safety.

Different aspects and embodiments of the invention may be used separately or together. For example, the overband/underband aspect could be used on a foldable helmet and/or a helmet formed from a synthetic paper material.

Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combinations other than those explicitly set out in the claims.

The present invention is more particularly described, by way of example, with reference to the accompanying drawings.

The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein.

Accordingly, while embodiment can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealised or overly formal sense unless expressly so defined herein.

In the description, all orientational terms, such as upper, lower, radially and axially, are used in relation to the drawings and should not be interpreted as limiting on the invention.

Figures 3 to 7 show a cycle helmet generally indicated 30. The helmet could be made from a cut out (20) of the type shown in Figure 2. The helmet is shown in an open configuration. A strap 35 and overband 40 are provided; these features and options therefor are discussed in more detail below.

Due to the honeycomb construction of the helmet it can be collapsed/folded to a generally flat configuration as shown in Figures 8 to 10. Figures II to 13 show the helmet intermediate the folded and unfolded configurations.

Figures 14 to 19 discuss different options for the strap/overband/underband arrangement.

Figure 14 The strap and over band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper over band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the over band.

The Stitch and acetate stiffener add additional strength to the key stress points at the moment of impact.

Figure 15 The strap and over band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper over band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the over band.

The additional strap is attached to the upper section of the over band prior to assembly, the lower segment is stitched, post assembly, strengthening the joint.

Figure 16 The strap and over band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper over band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the over band.

The joint is then strengthened with a rivet.

Figure 17 The strap and over band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper over band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the over band. The strap exit point is brought closer to the head to reduce leverage forces on the edge of the helmet.

The Stitch and acetate stiffer add additional strength to the key stress points at the moment of impact.

Figure 18 The strap and under band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper over band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the strap. The strap exit point is brought closer to the head to reduce leverage forces on the edge of the helmet.

Figure 19 The strap and under band are one length of materiel, such as nylon webbing or synthetic paper. Or the synthetic paper under band is bonded to the strap within the joint near the acetate stiffener. This configuration stops the honeycomb cells opening beyond the length of the strap.

Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.

Claims

I. A foldable cycle helmet formed from a waterproof material.

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2. A helmet as claimed in claim I, formed from synthetic paper material.
3. A helmet as claimed in claim I or claim 2, having a honeycomb-like, folding concertina structure.

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4. A helmet as claimed in any of claims I to 3, comprising a plurality of sheets of synthetic paper material.
5. A helmet as claimed in claim 4, in which in a folded configuration the sheets of material are layered on top of each other, with alternating sheets offset from each

15 other to form a stack.
6. A helmet as claimed in claim 4 or claim 5, in which the sheets are glued together with lines of glue so that in an unfolded configuration a plurality of honeycomb-like cells are formed.
7. A helmet as claimed in claim 6, in which the sheets are glued together with a water-based synthetic resin emulsion adhesive
8. A helmet as claimed in any preceding claim, in which the material is 25 polypropylene based.

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9. A helmet as claimed in any preceding claim, further comprising a strap.
10. A helmet as claimed in claim 9, in which the strap comprises an overband which 5 is attached over the top of the helmet.
11. A helmet as claimed in claim 9, in which the strap comprises an underhand which is attached inside the helmet.

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12. A helmet as claimed in any of claims 9 to I I, in which the strap over/under band limits the extent to which the helmet can unfold.
13. A helmet as claimed in any of claims 9 to 12, further comprising means for spreading the load of the strap where it joins the helmet.
14. A helmet as claimed in claim 13, in which the means for spreading the load comprise an acetate load bearing sheet for spreading the load between an over/under band and the base of the helmet.

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15. A helmet as claimed in any of claims 9 to 14, in which the strap is formed from nylon webbing or from synthetic paper material.