GB2597534A

GB2597534A - Improvements in or relating to helmets

Info

Publication number: GB2597534A
Application number: GB2011657.0A
Authority: GB
Inventors: Pei Huang Jian
Original assignee: Strategic Sports Ltd
Current assignee: Strategic Sports Ltd
Priority date: 2020-07-28
Filing date: 2020-07-28
Publication date: 2022-02-02
Also published as: US20230292873A1; EP4188145A1; GB202011657D0; WO2022023811A1; WO2022023811A8; CN115715160A

Abstract

A helmet 10 comprising an outer shell 12, inner lining 14 and at least one releasable connector arrangement adapted to enable the outer shell to be removed from the inner lining. The releasable connector arrangement includes a connecting stem 28 and a receiving channel 30. The releasable connector arrangement may include a removable cap 32. The helmet may have a strap arrangement (fig 1,16). The inner lining may have a recess 21 for a portion of the strap arrangement.

Description

Improvements in or relating to Helmets

Technical Field

The present invention relates to helmets, and in particular to sports helmets.

Background

A helmet is often recognized as an important piece of protective equipment for participating in activities in which impact to the head is possible. In particular, for some sports such as cycling, skiing, American football, horse riding and motor racing, as well as for the use of some specified vehicles, such as motorcycles and bicycles, a helmet has become indispensable.

It is known to provide such helmets with a rigid protective shell and a relatively softer lining to interface with the users head. For sports helmets in particular, the outer shell typically comprises a rigid plastics material, such as acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polyvinylchloride (PVC), polycarbonate, or composites such as fiberglass or carbon fibre, bonded to an expanded polystyrene (EPS) or expanded polypropylene (EPP) liner.

The hard outer shell protects the user's head from the initial impact and is designed to crack in order to dissipate energy from the impact over the whole surface of the helmet. The EPS or EPP liner is designed to compress in order to absorb energy and reduce the linear and rotational acceleration of the head. The shell is usually bonded to the liner using an adhesive. Alternatively, the helmet may be produced using in-moulding, which involves the expansion of polystyrene beads inside the shell to form the EPS or EPP liner. For helmets made using this latter technique, the shell must be made out of a material which can withstand the heat of the mould, for instance polycarbonate.

Further, sports helmets usually comprise chin straps to fasten the helmet to the user's head. The straps are usually made of nylon or polypropylene fabric. In helmets in which the shell is bonded to the liner using adhesive, the strap is usually positioned across the top of the liner, covered by the shell, and glued in place when the shell is glued onto the liner. In helmets comprising in-moulded shells, the straps are threaded into plastic strap anchors which are riveted, or otherwise attached, to the shell after moulding. The strap typically also comprises a plastic buckle.

The resulting helmet thus comprises a range of materials, which cannot easily be separated. In particular, for both glued and in-moulded shells, the shell is permanently fixed to the liner. In particular, the EPS or EPP will likely have to be broken up to remove it from the helmet.

As a result, sports helmets are particularly difficult to recycle easily and efficiently. Most recycling facilities require different materials to be separated. Further, recycling facilities will only recycle select materials, and it may be difficult to find a recycling facility that recycles all of the materials used in the different component parts of the helmet.

In order to reduce the amount of waste in landfills, it is clearly desirable to produce a helmet which may be easily separated for recycling.

Additionally, the ability to easily separate the outer shell of a helmet from the lining also allows either of the shell or lining to be used with different shells or lining. In particular, users of sports helmets are advised to replace their helmets after a crash or heavy impact, because the EPS or EPP liner is not effective as a shock absorbing material after it has been compressed. However, in a helmet in which the liner can be easily separated from the shell by the user, an intact shell could be provided with a new liner. Users may also find it desirable to be able to change the outer shell in order to display a different aesthetic, whilst avoiding the need to purchase a whole new helmet.

Summary of the Invention

The present invention provides a helmet comprising an outer shell; an inner lining; and at least one releasable connector arrangement adapted to enable the outer shell to be removably attached to the inner lining. The releasable connector arrangement includes a connecting stem of the outer shell and the inner lining, and a receiving channel of the inner lining. Accordingly, the present invention provides a helmet in which the outer shell may be easily separated from the inner lining by the user.

The inner lining includes an outer surface which, in use, faces an inner surface of the outer shell, and an inner surface which, in use, faces the head of a wearer of the helmet. In some embodiments, the receiving channel in the inner lining has aligned openings in the inner and outer surfaces of the inner lining. Further, the presence of an opening on the inner surface of the inner lining, allows the tip of the connecting stem to be accessed when the outer shell is located on the inner lining.

The term "connecting stem", as it is used herein refers to elongated projections which may be received within a corresponding receiving channel in the inner lining of the helmet to form a load bearing connection between the outer shell and the inner lining when the outer shell is appropriately located on the inner lining for use. Preferably the outer shell comprises a plurality of connecting stems which are each received within one of a plurality of appropriately located receiving channels in the inner lining. Preferably still, the locations of the plurality of connecting stems are spread over a majority of the area of the inner surface of the outer shell, so that loads tending to displace the outer shell off the inner lining are spread over a majority of the inner surface of the outer shell. The connecting stems may comprise any suitable shape for forming a load bearing connection between the outer shell and the inner lining. In a preferred embodiment the connecting stem(s) comprise(s) hollow half-cylindrical projections. However, the connecting stem(s) may comprise a solid shape and/or any alternative regular or irregular prismatic shape. Alternatively still, the connecting stem(s) need not comprise a prismatic shape at all so long as it(they) comprise(s) an elongated shape which can be received in a receiving channel to form a load bearing connection between the outer shell and the inner lining.

Preferably the connecting stem(s) is(are) integrally moulded with the rest of the outer shell. Alternatively, the connecting stem(s) may not be integrally moulded with the rest of the outer shell and may be otherwise attached to the outer shell by, for example, welding or riveting.

Preferably, the releasable connector arrangement further includes a removable cap, the removable cap being configured to fit over and engage a distal end of the connecting stem to maintain the connecting stem in the receiving channel. In some embodiments comprising a removable cap, a width of the receiving channel may increase towards an opening in the inner surface of the inner lining such that a shoulder is defined in a wall of the inner lining which defines the receiving channel. This wider portion of the receiving channel may then be used to receive the removable cap.

In some embodiments, the connecting stem may project beyond this shoulder when the connecting stem of the outer shell is inserted into the receiving channel of the inner lining in use. In such embodiments, a width of the removable cap is larger than the width of the receiving channel on the proximal side of the shoulder and directly proximate the shoulder such that, in use, the removable cap maintains the connecting stem in the receiving channel by abutting against the shoulder.

In a preferred embodiment, the helmet preferably also comprises a cap connection having a locked and an unlocked configuration, the cap connection comprising a projection on the connecting stem and an aperture in the removable cap, the aperture in the removable cap comprising a circumferential portion, which extends in a circumferential direction with respect to the removable cap, and a radial portion, which extends in a radial direction with respect to the removable cap, wherein in the locked configuration the projection is retained in the circumferential portion of the aperture, and wherein the cap connection is moved from the unlocked to the locked configuration by the user rotating the removable cap with respect to the connecting stem to move the projection from the radial portion to the circumferential portion. Such a connection arrangement is rapidly and easily engaged and released by a user.

Preferably the removable cap also comprises a viewing slot, wherein a user is able to view the projection on the connecting stem through the viewing slot when the cap connection is in the locked configuration, and the user is not able to view the projection through the viewing slot when the cap connection is in the unlocked configuration. Providing a visual cue in this way enables the user to ensure that the cap connection is locked and the outer shell is securely held on the inner lining of the helmet, thus improving the safety of the device. Users may also find it reassuring to be able to check that the helmet is ready for use.

In preferred embodiments, the helmet also comprises a strap arrangement for fastening the helmet to a user's head. The strap arrangement may be removably attachable to at least one of the inner lining and the outer shell. The provision of a removable strap arrangement allows the user to easily separate the straps from the rest of the helmet for disposal/recycling separately from the rest of the helmet.

In preferred embodiments comprising a removable strap arrangement, the strap arrangement comprises at least one portion located between the outer surface of the inner lining and the inner surface of the outer shell in use. Accordingly, this portion is removed from the outer shell and is unable to affect the sliding friction, or aerodynamic profile, of the outer surface of the outer shell. This portion is also removed from the inner surface of the inner lining and therefore will not interface with the user's head to cause discomfort. Preferably, the outer surface of the inner lining is provided with at least one recess in which said at least one portion of the strap arrangement is located in use. Accordingly, the strap does not interfere with the interface between the outer surface of the inner lining and the inner surface of the outer shell, for instance by creating an air gap at said interface. Alternatively or additionally, at least one recess could be provided in the inner surface of the outer shell. A portion of the strap could then alternatively or additionally be located within this recess in the outer shell in use.

Preferably, the strap arrangement comprises at least one strap connector, the at least one strap connector being configured to form an interference or snap-fit with a corresponding engagement structure of the outer shell in order to effect the removable attachment. Interference or snap-fit assembly allows for easy and rapid assembly and disassembly of the strap to the outer shell. Preferably the at least one strap connector is configured as a hook and the engagement structure of the outer shell defines a seating location for the hook. The hook configuration provides for easy and stable mounting of the strap connector on the outer shell. Preferably, the hook includes a barb and the seating location of the outer shell includes a recess adapted to receive the barb. Accordingly, the barb resists forces tending to urge the hook away from the seating location to lock the strap onto the outer shell. Preferably, the barb snap-fits into the recess in the seating location of the outer shell, although this need not be the case in all embodiments. Preferably, the strap arrangement includes a plurality of hooks and the outer shell includes a corresponding plurality of seating locations. This increases the stability of the attachment of the strap arrangement to the outer shell.

Brief Description of the Fiqures

The invention will now be described, by way of example only, with reference to the following figures in which: Figure 1 is a perspective side view of a sports helmet 10 according to a preferred embodiment of the present invention; Figure 2 is a top view of the helmet 10 of figure 1; Figure 3 is a front view of the helmet 10 of figures 1 and 2; Figure 4 is a rear view of the helmet 10 of figures 1 to 3; Figure 5 is a bottom view of the helmet 10 of figures 1 to 4; Figure 6 is an exploded view of the helmet 10 of figures 1 to 5; Figure 7 is a perspective bottom view of the assembled helmet 10; Figure 8 is an enlarged cross-sectional view of the connector arrangement of figure 7; Figures 9a and 9b are enlarged bottom views of the connector in the assembled helmet 10 when the connector arrangement is in the unlocked (figure 9a) and locked (figure 9b) configurations; Figure 10 is a perspective view of the helmet 10 of figures 1 to 10 showing the strap arrangement 16 in exploded view; Figure 11 is a perspective view of the helmet of figure 10 showing the strap arrangement assembled for use; and Figure 12 is an enlarged cross-sectional view of the strap connector 26 and engagement structure 50 of figure 11 in which the outer shell 12 has been emitted for clarity.

Specific description of embodiments

In the following description, relative and directional references (including: upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, side, above, below, front, middle, back, vertical, horizontal, and so forth) are given by way of example to aid the reader's understanding of the particular embodiments described herein. Anatomical terms of location have similarly been used and should be understood to correspond to anatomical locations of the human head. The terms "inner" and "outer" are also used. Unless otherwise stated, "inner" and "outer" should be understood herein to refer to relative locations towards and away from the human head in use. For instance, an "inner surface" would be a surface closest towards the human head in use, and an "outer surface" would be a surface furthest away from the human head in use. Directional or locational references should not be read to be requirements or limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the claims. Connection references (e.g., attached, coupled, connected, joined, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other, unless specifically set forth in the claims.

Referring first to each of figures 1 to 6, the helmet 10 comprises an outer shell 12, an inner lining 14 and a chin strap arrangement 16.

The outer shell 12 comprises a hard plastic material such as any of ABS, PET, PVC, Polycarbonate, Kevlar0, or a composite, such as fibreglass or carbon fibre. The outer shell 12 comprises fourteen ventilation holes 18 which are shaped to direct air onto a wearer's head. Referring to figures 1 to 4 in particular, the ventilation holes 18 in the outer shell 12 comprise two front central ventilation holes 18A, two front side ventilation holes 18B, five crown ventilation holes 18C, three rear ventilation holes 18D and two occipital ventilation holes 18E.

The inner lining 14 is made of moulded EPS or EPP and also comprises fourteen ventilation holes 20 which register with the outer shell ventilation holes 18. In use, the inner lining ventilation holes 20 receive air through the outer shell ventilation holes 18 and direct air over the hottest parts of the user's head and out through ventilation holes 18, 20 in the rear or occipital region of the helmet 10.

The number, shape and position of the ventilation holes 18,20 on the helmet 10 is shown is not intended to be limiting and is an example of a helmet ventilation hole arrangement. It will thus be appreciated that other ventilation hole arrangements may be provided.

As can be seen in figure 2, the outer surface of the inner lining 14 comprises four recesses 21 for accommodating a portion of the strap arrangement 16 as described in more detail below.

The chin strap arrangement 16 comprises two chin straps and a buckle 22 for fastening said chin straps together under the chin of the user. Each strap comprises two strap arms 24 comprising a front strap arm 24A and a rear strap arm 24B.

Each strap arm 24 is attached to the outer shell 12 via a respective strap connector 26, as described in more detail below, and thereafter passes into a respective recess 21 in the outer surface of the inner lining 14. The recesses 21 thereby allow the strap arms 24 to pass between the outer shell 12 and the inner lining 14 without affecting with the fit between them, for instance, by causing an unwanted separation between the shell and lining 12,14.

Referring now to figures 2 to 5, the helmet 10 includes a connector arrangement between the shell 12 and lining 14 comprising connecting stems 28 on the inner surface of the outer shell, receiving channels 30 in the inner lining 14 and removable caps 32.

Referring to figure 6, the inner surface of the outer shell 12 comprises three connecting stems 28 positioned symmetrically about the sagittal plane of the helmet 10 and roughly equidistant from each other. Two of said connecting stems 28 are positioned towards the rear of the helmet 10 and a third connecting stem 28 is positioned towards the front of the helmet 10. The connecting stems 28 extend from the inner surface of the outer shell 12.

The connecting stems 28 each have a substantially cylindrical shape and are integrally moulded with the rest of the outer shell 12. Each connecting stem 28 includes two projections 34 at a distal end thereof. The projections 34 project in diametrically opposite directions and extend laterally outwards from a respective connecting stem 28.

Each receiving channel 30 of the inner lining 14 is located to correspond to one of the connecting stems 28 on the outer shell 12. Towards the opening in the inner surface of the inner lining 14, there is a step change in the diameter of the receiving channel 30 such that a shoulder 35 is formed in the wall of the inner lining 14 which defines the receiving channel 30.

Each of the removable caps 32 comprises a flat, circular base portion 36 and a side wall 38 which extends perpendicularly to the base portion 36 to form a circular cavity in the removable cap 32. A top edge of the side wall 38 comprises two radial flanges 40 which extend in diametrically opposite directions inwards towards a centre of the removable cap 32. The base portion 36 of the cap 32 comprises three slots including a diametric slot 42 and two viewing slots 44. The diametric slot 42 extends along a diameter of the cap 32 and only partially through the thickness of the base portion 36. The viewing slots 44 extend through the full thickness of the base portion 36, such that a user may see through said viewing slots 44 into the cavity defined in the removable cap 32. Each viewing slot 44 extends in a circumferential direction to describe an arc which subtends an angle of approximately 500 relative to the centre of the base portion 36. The viewing slots 44 are angularly displaced from the flange 40 in the top edge of the side wall 38.

In other embodiments, the viewing slots 44 may extend around an angle other than 50°. Further, the viewing slots 44 need not even necessarily be circumferential. The cap 32 could also comprise fewer or more than two viewing slots 44. For instance, the cap 32 may comprise a single viewing slot 44 which extends 360° around the cap 32. In some embodiments, the cap 32 need not comprise a viewing slot 44, however, this is not preferred.

Referring to figures 6, 7, 8, 9a and 9b, the method of assembling the helmet 10, and locking the outer shell 12 onto the inner lining 14 will now be described. The user first locates the outer shell 12 on the inner lining 14 such that the connecting stems 28 are fully inserted into the receiving channels 30. As can be seen in figure 8, in this configuration, the projections 34 of the connecting stems 28 are located beyond the shoulder 35 defined in the wall of the respective receiving channel 30, in the wider portion of the receiving channel 30. The user is then able to access the distal end of the connecting stem 28 through the opening of the receiving channel 30 in the inner surface of the inner lining 30. The user then positions the removable cap 32 over the distal end of the connecting stem 32, such that the projections 34 of the connecting stems 28 are received within the cavity defined in the removable cap 32. In order to do this, the user must first ensure that the removable cap 32 is oriented with respect to the connecting stem 28 such that the flange 40 of the removable cap 32 are angularly displaced from the projections 34 of the connecting stem 28 such that the projections 34 do not abut against the flange 40 and thereby prevent translational motion. The user then rotates the removable cap 32 such that the projections 34 are radially aligned with the flange 40 to move the connector from an unlocked (figure 9a) to a locked (figure 9b) configuration.

As can be seen from figure 8, in this locked configuration, the removable cap 32 is fixed against translational movement with respect to the connecting stem 28 by the radial flange 40 of the removable caps 32 abutting against the projections 34 of the connecting stems 28. This has the result of locking the connecting stem 28 within the receiving channel 30, as the removable cap 34, which is locked over the distal end of the connecting stem 28, is too large to fit into the narrower section of the receiving channel 30, and abuts against the shoulder 35 in the wall of the receiving channel 30.

The diametric slot 42 in the base portion 36 of the removable cap 32 is provided in order to aid the user in rotating the removable cap 32 with respect to the connecting stem 28, as the user can insert a tool, such as a coin or a key, into the diametric slot 42 to gain purchase on the removable cap 32.

Referring to figure 9a, because the viewing slots 44 are angularly displaced with respect to the flange 40 in the top edge of the side wall 36 of the removable cap 32, the projections 34 of the connecting stem 28 are angularly aligned with the viewing slots 44 in the unlocked configuration, and thus, are visible through the viewing slots 44. Referring to figure 9b, when the user has rotated the removable cap 32 into the locked configuration such that the radial flange 40 abut against the projections 34 of the connecting stem 28, the projections 34 are no longer angularly aligned with the viewing slots 44, and are therefore no longer visible through the viewing slots 44. The viewing slots 44 therefore provide a visual cue for the user, which allows them to know when the removable cap 32 is in the locked configuration.

Referring to figures 10 to 12, the connection of the chin strap arrangement 16 to the outer shell 12 will now be described. As described above, each strap arm 24 comprises its own strap connector 26. The strap connector 26 connects to the outer shell 12 by engagement with a corresponding engagement structure 50 in the outer shell 12.

Each strap connector 26 comprises a hook 46 and an eye 48. The strap arm 24 is threaded through the eye 48 of its respective strap connector 26 and stitched to form a loop through the eye 48 in order to fix the strap arm 24 to the connector 26. As can be seen in figure 12, the strap connector 26 further comprises a barb 52.

Referring to figure 10 in particular, the outer surface of the outer shell 12 comprises four engagement structures 50A,50B including two front engagement structures 50A and two rear engagement structures 50B. Each of the front engagement structures 50A are located on the lower edge of a respective one of the front side ventilation holes 18B, and each of the rear engagement structures 50B are each located on a respective one of the occipital ventilation holes 18E.

Referring to figure 10, each of the front engagement structures 50A is configured as a groove in the lower edge of its respective ventilation hole 18. Each front engagement structure 50A further comprises an aperture 54. The rear engagement structures 50B of the outer shell 12 are defined by edge portions of the occipital ventilation holes 18E.

To connect the chin strap arrangement 16 to the rest of the helmet 10, the user locates the strap arms 24 in the recesses 21 in the outer surface of the inner lining 14. The user then locates the outer shell 12 on the inner lining 14, as described above. The user then threads each of the strap arms 24 through its respective ventilation hole 18 in the outer shell 12 by pulling on the strap connectors 26. The user then connects each strap connector 26 with its corresponding engagement structure 50. Both the strap connectors 26 and the engagement structures 50 comprise a resilient plastics material. The front engagement structures 50A are sized and shaped such that the hook 46 snap fits into the groove defined by the engagement structure 50A. The barb 52 on the strap connector 26 simultaneously snap fits into the aperture 54 in the front engagement structure 50A to help to ensure that the hook 46 is not inadvertently unseated from the groove defined by the front engagement structure 50A. The strap connectors 26 which fit to the rear engagement structures 50B are positioned such that the hooks 46 fit over respective edges of the occipital ventilation holes 18E and are held in place via an interference fit.

Claims

CLAIMS1. A helmet comprising: an outer shell; an inner lining; and at least one releasable connector arrangement adapted to enable the outer shell to be removably attached to the inner lining, wherein the releasable connector arrangement includes a connecting stem on the outer shell, and a receiving channel in the inner lining.
2. A helmet according to claim 1, wherein the inner lining includes an outer surface which, in use, faces an inner surface of the outer shell, and an inner surface which, in use, faces the head of a wearer of the helmet, wherein the receiving channel has aligned openings in the inner and outer surfaces of the inner lining.
3. A helmet according to claim 2, wherein the releasable connector arrangement further includes a removable cap, the removable cap being configured to fit over and engage a distal end of the connecting stem to maintain the connecting stem in the receiving channel.
4. A helmet according to claim 3, wherein a width of the receiving channel increases towards an opening in the inner surface of the inner lining such that a shoulder is defined in a wall of the inner lining which defines the receiving channel, and wherein the connecting stem projects beyond the shoulder when the connecting stem of the outer shell is inserted into the receiving channel of the inner lining in use, and wherein a width of the removable cap is greater than the width of the receiving channel on the proximal side of the shoulder and directly proximate the shoulder such that, in use, the removable cap maintains the connecting stem in the receiving channel by abutting against the shoulder.
5. A helmet according to either of claims 3 or 4, further comprising a cap connection having a locked and an unlocked configuration, the cap connection comprising a projection on the connecting stem and an aperture in the removable cap, the aperture in the removable cap comprising a circumferential portion, which extends in a circumferential direction with respect to the removable cap, and a radial portion, which extends in a radial direction with respect to the removable cap, wherein in the locked configuration the projection is retained in the circumferential portion of the aperture, and wherein the cap connection is moved from the unlocked to the locked configuration by the user rotating the removable cap with respect to the connecting stem to move the projection from the radial portion to the circumferential portion.
6. A helmet according to claim 5, wherein the removable cap also comprises a viewing slot, wherein a user is able to view the projection on the connecting stem through the viewing slot when the cap connection is in the locked configuration, and the user is not able to view the projection through the viewing slot when the cap connection is in the unlocked configuration.
7. A helmet according to any previous claim, further comprising a strap arrangement for fastening the helmet to a user's head, the strap arrangement being removably attachable to at least one of the inner lining and the outer shell, wherein, in use, at least one portion of the strap arrangement is located between the outer surface of the inner lining and the inner surface of the outer shell.
8. A helmet according to claim 7, wherein the strap arrangement is removably attachable to the outer shell.
9. A helmet according to claim 8, wherein the outer surface of the inner lining is provided with at least one recess in which said at least one portion of the strap arrangement is located in use.
10. A helmet according to claim 8 or claim 9, wherein the strap arrangement comprises at least one strap connector, the at least one strap connector being configured to form an interference or snap-fit with a corresponding engagement structure of the outer shell in order to effect the removable attachment.
11. A helmet according to claim 10, wherein the at least one strap connector is configured as a hook and the engagement structure of the outer shell defines a seating location for the hook.
12. A helmet according to claim 11, wherein the hook includes a barb and the seating location of the outer shell includes an aperture adapted to receive the barb.
13. A helmet according to either of claims 11 or 12, wherein the strap arrangement includes a plurality of hooks and the outer shell includes a corresponding plurality of seating locations.
14. An outer shell of a helmet as defined in any previous claim.
15. An inner lining of a helmet as defined in any previous claim.