US20020002732A1 - Light reflective protective headwear - Google Patents

Light reflective protective headwear Download PDF

Info

Publication number
US20020002732A1
US20020002732A1 US09/943,605 US94360501A US2002002732A1 US 20020002732 A1 US20020002732 A1 US 20020002732A1 US 94360501 A US94360501 A US 94360501A US 2002002732 A1 US2002002732 A1 US 2002002732A1
Authority
US
United States
Prior art keywords
sheet
cover sheet
reflective
protective headwear
optical radiation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/943,605
Inventor
Chang-San Lin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US09/943,605 priority Critical patent/US20020002732A1/en
Publication of US20020002732A1 publication Critical patent/US20020002732A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F1/00—Designs or pictures characterised by special or unusual light effects
    • B44F1/02—Designs or pictures characterised by special or unusual light effects produced by reflected light, e.g. matt surfaces, lustrous surfaces
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/06—Impact-absorbing shells, e.g. of crash helmets
    • A42B3/061—External coatings, e.g. with light reflective material
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C2/00—Manufacturing helmets by processes not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0446—Ornamental plaques, e.g. decorative panels, decorative veneers bearing graphical information
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4807—Headwear
    • B29L2031/4814—Hats
    • B29L2031/4821—Helmets

Definitions

  • the invention relates to protective headwear, for example, a helmet that reflects light.
  • One conventional approach for producing a light-reflective object includes attaching a number of reflective decals formed on a paper or plastic base to the surface of these objects, for example with an adhesive.
  • a reflective material is sprayed directly onto the object, for example through a patterned mask, or a desired pattern of the reflective material is formed and is then sewn on a fabric. The object is then covered with the fabrics.
  • the reflective material can also be sewn directly onto the object.
  • the conventional approaches described above suffer from a number of disadvantages.
  • One disadvantage is that the reflectivity of these surfaces can degrade prematurely since the reflective material is, in most cases, directly exposed to the environment, i.e., the ambient air, moisture, sunlight and dust.
  • the reflective surfaces are formed of thin metal coatings, for example, silver or aluminum, such coatings tend to oxidize in air causing their reflectivity characteristics to degrade rapidly.
  • An unprotected reflective surface can also be easily damaged and/or scratched upon contact with other objects, for example, when used in harsh environments, such as at a construction site. Reflective surfaces that are produced by spraying a reflective paint on the object, tend to have poor reflectivity and produce less vibrant colors.
  • the invention relates to protective headwear having a light-reflecting surface with high reflectivity.
  • the protective headwear includes a shell member having a molded base; a cover sheet, covering the molded base, with a pattern defined by areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation and a reflective sheet sealed between the molded base and the cover sheet from the environment.
  • Embodiments of this aspect of the invention may include one or more of the following features.
  • the patterned structure can be formed directly on the cover sheet.
  • the protective headwear may further include a separate patterned sheet that is arranged between the cover sheet and the reflective sheet.
  • the cover sheet is preferably made of a plastic that is impervious to air and moisture.
  • the reflective sheet can be a metal foil or a plastic sheet that is coated with a reflective metal.
  • the reflective sheet can also have the form of a reflective dielectric stack.
  • the reflective sheet and the cover sheet can have spectrally selective optical characteristics.
  • the base can be in the form of a shaped object, for example a helmet made by injection molding from polyurethane.
  • the pattern can be an ornamental design, a logo and the like.
  • the invention provides a method of manufacturing protective headwear, for example a helmet, by placing a patterned cover sheet in first molding die to shape the cover sheet in the shape of the die.
  • a reflective sheet is placed on the shaped patterned cover sheet and molding material is injected between the reflective sheet and a second molding die to form the shaped object.
  • the reflective sheet is thereby sealed between the cover sheet and the molded shaped object.
  • a method of manufacturing light-reflecting objects includes first forming a shaped object and then covering the shaped object, in succession, with a reflective sheet and a patterned cover sheet.
  • Embodiments of these methods may include one or more of the following features.
  • the reflective sheet is sealed between the shaped object and the cover sheet, for example, by applying heat and pressure between the shaped object and the cover sheet.
  • the pattern is defined by areas that are transparent to the optical radiation passing through the cover sheet and by other areas that are opaque to the optical radiation.
  • the pattern can also be defined by a separate patterned sheet placed between the cover sheet and the reflective sheet.
  • the light-reflecting object can be a molded helmet that is preferably made of polyurethane.
  • FIG. 1 shows an embodiment of the reflective object according to the invention
  • FIG. 2 shows another embodiment of the reflective object according to the invention
  • FIGS. 3A to 3 C show examples of applications for the reflective objects
  • FIG. 4 shows another embodiment of the reflective object with a lateral seal
  • FIGS. 5 and 6 show other embodiments of the reflective object
  • FIGS. 7 and 8 are flow diagrams of methods for producing the reflective object.
  • a reflective object 10 includes a base 12 that is made of a material impervious to moisture, such as metal or plastic and preferably polyurethane.
  • the base 12 can be rigid or flexible. Overlaying the base 12 are, in succession, a reflective sheet 13 , a patterned sheet 14 and a transparent cover sheet 19 .
  • the cover sheet 19 is preferably made of a plastic material that is essentially impervious to air and moisture.
  • the reflective sheet 13 includes a plastic sheet coated with a highly reflective metal, such as aluminum, silver or gold, or other suitable material with a high index of refraction.
  • the patterned sheet 14 need not be a separate sheet, but can be printed on or embossed onto the transparent cover sheet 19 .
  • the patterned sheet 14 includes areas 18 that are opaque to light passing through the transparent cover sheet 19 , and areas 16 that are transparent to the light.
  • the transparent areas 16 and opaque areas 18 in aggregate, form a desired pattern or design.
  • the opaque areas and the transparent areas can be colored, i.e., the areas can reflect and/or transmit selected spectral ranges of the light striking the surface of the object.
  • the opaque areas 18 of patterned sheet 14 prevent a portion of the light 17 from reaching the reflective sheet 13 , so that little, if any, light is reflected.
  • light 15 that passes through the transparent areas 16 of the patterned sheet 14 and reaches the reflective sheet 13 is reflected by the reflective sheet 13 .
  • the opaque areas 18 appear dark, whereas the transparent areas 16 reflect the light and appear bright. In other words, the viewer sees a pattern having a shape that is defined by the shape of the transparent areas 16 .
  • the reflective object is a shaped object, e.g., a molded object 22 , such as a molded helmet, a sculptured sign and the like.
  • the shaped object is preferably made from a material that is impervious to air and moisture.
  • FIGS. 3A to 3 C illustrative examples of various reflective objects having base 10 or shaped base 31 of FIG. 1A and 1B are shown.
  • FIG. 3A shows a warning sign 30 with reflective lettering and/or a reflective background.
  • the base 12 , the reflective sheet 13 , the patterned sheet 14 , and the transparent cover sheet 19 are preferably sealed along the lateral edges 42 , as also illustrated more particularly in FIG. 4. This design prevents air and moisture from the environment from reaching the reflective sheet 13 .
  • a reflective object is a protective helmet 32 , for example a safety helmet (e.g., a bicycle or motorcycle helmet or a construction helmet) is shown.
  • the reflective pattern applied to the helmet 32 can have the form of an ornamental design 34 (FIG. 3B) or a descriptive label and/or a logo 36 (FIG. 3C).
  • the helmet 32 can be produced, for example, by an injection molding process, as described below.
  • the reflective sheet 13 can advantageously be hermetically sealed against the environment with a seam 42 .
  • a molding machine or a sealing press (not shown) can apply pressure and/or heat between the cover sheet and the base along predetermined seams 42 to encapsulate the reflective sheet between the base and the cover sheet.
  • large sheets with several objects 32 can be manufactured on a base 12 in a single manufacturing process.
  • the sheets are then cut along the seams 42 to separate the individual objects which are now sealed along their respective marginal edges.
  • the base 12 and the shaped object 22 respectively, and the reflective sheet 13 can also be sealed between the cover sheet 19 and the base 12 or the shaped object 22 by applying heat and/or pressure over the surface area of the base or the shaped object and 19 .
  • a reflective object 50 includes a reflective sheet 52 in the form of a multilayer dielectric stack.
  • the reflective sheet 52 is formed of a sequence of thin alternating dielectric layers 131 , 132 , wherein consecutive layers have a different index of refraction.
  • the stack 52 selectively reflects one or more colors of the light. The color depends on the thickness and the index of refraction of the thin sheets and on their arrangement with respect to each other, as is known in the art. The specific color or colors can also depend on the direction from which the object is viewed.
  • a dielectric stack 52 can have a significantly higher reflectivity than a single reflective sheet 13 .
  • the reflective sheet 52 can also include holograms (not shown).
  • a reflective object 60 can be designed to reflect more than one color of the light striking the object.
  • the dielectric stack 52 can be designed to reflect, for example, the red and blue spectral range of the light. Since the red and blue reflected colors add to form a green color, the transparent areas 64 appear green while the opaque areas 62 appear dark, as described above.
  • the optical properties of the patterned sheet 14 and/or of the transparent cover sheet 19 can also be made color-selective, i.e., these sheets can function as optical filters.
  • the areas 62 of sheet 14 can be designed to absorb the red portion of the light and will therefore transmit only the blue portion of the red and blue light reflected by the dielectric stack 52 . The areas 62 will therefore appear blue in reflection.
  • the areas 64 of sheet 14 can be designed to absorb the blue portion of the reflected light and will therefore transmit only the red portion of the light. The areas 64 will therefore appear blue in reflection.
  • the cover sheet 19 can also have a spectrally selective light transmission.
  • the reflective sheet 52 , the patterned sheet 14 and cover sheet 19 can be designed to have different optical properties. Consequently, these sheets can be combined to produce a variety of different colors. The invention can therefore provide colorful reflective objects that can be produced in a simple manner.
  • FIG. 7 a process 70 for manufacturing a molded shaped object 20 (FIG. 2) with a reflective pattern is described.
  • a printed pattern of desired shape and color is applied to a transparent cover sheet 19 , step 72 .
  • a patterned sheet 14 can be placed on the cover sheet 19 .
  • the transparent cover sheet 19 and the patterned sheet 14 are then placed in a first molding die (not shown), with the pattern or the patterned sheet 14 facing away from the molding die, step 73 .
  • the combination formed by the cover sheet 19 and the patterned sheet 14 is then molded to conform to the shape of the molding die, using high temperature and vacuum techniques, step 74 .
  • the reflective sheet 13 , 52 is placed on top of the molded patterned sheet 14 , step 75 , and a plastic molding material, e.g., polyurethane, is injected between a second molding die (not shown) and the reflective sheet 13 , step 76 .
  • the shaped object is formed by applying heat and pressure to the mold, step 77 .
  • the reflective shaped object 20 e.g., the helmet 32 , which now includes the reflective pattern on its outer surface, is removed from the mold, step 78 .
  • a shaped object 22 , 32 is initially formed in a molding machine (not shown), step 82 .
  • the shaped object 22 , 32 is then covered with, in that order, the reflective sheet 13 , 52 and the patterned cover sheet 19 , step 84 .
  • a separate patterned sheet 14 can be inserted between the cover sheet 19 and the reflective sheet 13 , 52 .
  • the reflective sheet 13 is then sealed between the cover sheet 19 and the shaped object 22 , 32 to protect the reflective sheet 13 against the environment, step 86 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Helmets And Other Head Coverings (AREA)

Abstract

Protective headwear (e.g., helmet) is provided with patterned reflective surfaces that are highly reflective and resist rough handling. The reflective surface is produced by sealing a reflective sheet between a base and a cover layer that includes a pattern, to protect the reflective sheet from the environment. The protective headwear can reflect light in different colors. A method for cost-effectively producing reflective objects by injection molding is also provided.

Description

    FIELD OF THE INVENTION
  • The invention relates to protective headwear, for example, a helmet that reflects light. [0001]
    • BACKGROUND OF THE INVENTION
  • One conventional approach for producing a light-reflective object includes attaching a number of reflective decals formed on a paper or plastic base to the surface of these objects, for example with an adhesive. In other approaches, a reflective material is sprayed directly onto the object, for example through a patterned mask, or a desired pattern of the reflective material is formed and is then sewn on a fabric. The object is then covered with the fabrics. The reflective material can also be sewn directly onto the object. [0002]
  • The conventional approaches described above suffer from a number of disadvantages. One disadvantage is that the reflectivity of these surfaces can degrade prematurely since the reflective material is, in most cases, directly exposed to the environment, i.e., the ambient air, moisture, sunlight and dust. For example, if the reflective surfaces are formed of thin metal coatings, for example, silver or aluminum, such coatings tend to oxidize in air causing their reflectivity characteristics to degrade rapidly. An unprotected reflective surface can also be easily damaged and/or scratched upon contact with other objects, for example, when used in harsh environments, such as at a construction site. Reflective surfaces that are produced by spraying a reflective paint on the object, tend to have poor reflectivity and produce less vibrant colors. [0003]
  • Using an adhesive to attach reflecting decals on objects requires a large number of processing steps, such as printing, cutting and attaching. Thus, this approach is not cost-effective. Cutting and sewing is also required when the decals are attached to fabrics. [0004]
    • SUMMARY OF THE INVENTION
  • The invention relates to protective headwear having a light-reflecting surface with high reflectivity. In one aspect of the invention, the protective headwear includes a shell member having a molded base; a cover sheet, covering the molded base, with a pattern defined by areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation and a reflective sheet sealed between the molded base and the cover sheet from the environment. [0005]
  • Embodiments of this aspect of the invention may include one or more of the following features. The patterned structure can be formed directly on the cover sheet. Alternatively, the protective headwear may further include a separate patterned sheet that is arranged between the cover sheet and the reflective sheet. The cover sheet is preferably made of a plastic that is impervious to air and moisture. The reflective sheet can be a metal foil or a plastic sheet that is coated with a reflective metal. The reflective sheet can also have the form of a reflective dielectric stack. The reflective sheet and the cover sheet can have spectrally selective optical characteristics. The base can be in the form of a shaped object, for example a helmet made by injection molding from polyurethane. The pattern can be an ornamental design, a logo and the like. [0006]
  • In another aspect, the invention provides a method of manufacturing protective headwear, for example a helmet, by placing a patterned cover sheet in first molding die to shape the cover sheet in the shape of the die. A reflective sheet is placed on the shaped patterned cover sheet and molding material is injected between the reflective sheet and a second molding die to form the shaped object. The reflective sheet is thereby sealed between the cover sheet and the molded shaped object. [0007]
  • In another aspect of the invention, a method of manufacturing light-reflecting objects includes first forming a shaped object and then covering the shaped object, in succession, with a reflective sheet and a patterned cover sheet. [0008]
  • Embodiments of these methods may include one or more of the following features. The reflective sheet is sealed between the shaped object and the cover sheet, for example, by applying heat and pressure between the shaped object and the cover sheet. The pattern is defined by areas that are transparent to the optical radiation passing through the cover sheet and by other areas that are opaque to the optical radiation. The pattern can also be defined by a separate patterned sheet placed between the cover sheet and the reflective sheet. The light-reflecting object can be a molded helmet that is preferably made of polyurethane. [0009]
  • Additional features and advantages of the present invention will be apparent from the following description of preferred embodiments and from the claims.[0010]
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows an embodiment of the reflective object according to the invention; [0011]
  • FIG. 2 shows another embodiment of the reflective object according to the invention; [0012]
  • FIGS. 3A to [0013] 3C show examples of applications for the reflective objects;
  • FIG. 4 shows another embodiment of the reflective object with a lateral seal; [0014]
  • FIGS. 5 and 6 show other embodiments of the reflective object; and [0015]
  • FIGS. 7 and 8 are flow diagrams of methods for producing the reflective object.[0016]
    • DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • In the drawings, identical elements or elements performing identical functions are indicated with identical reference numerals. [0017]
  • Referring to FIG. 1, a [0018] reflective object 10 includes a base 12 that is made of a material impervious to moisture, such as metal or plastic and preferably polyurethane. The base 12 can be rigid or flexible. Overlaying the base 12 are, in succession, a reflective sheet 13, a patterned sheet 14 and a transparent cover sheet 19. The cover sheet 19 is preferably made of a plastic material that is essentially impervious to air and moisture. The reflective sheet 13 includes a plastic sheet coated with a highly reflective metal, such as aluminum, silver or gold, or other suitable material with a high index of refraction. The patterned sheet 14 need not be a separate sheet, but can be printed on or embossed onto the transparent cover sheet 19. The patterned sheet 14 includes areas 18 that are opaque to light passing through the transparent cover sheet 19, and areas 16 that are transparent to the light. The transparent areas 16 and opaque areas 18, in aggregate, form a desired pattern or design. The opaque areas and the transparent areas can be colored, i.e., the areas can reflect and/or transmit selected spectral ranges of the light striking the surface of the object.
  • When [0019] light 15, 17 passes through the transparent cover sheet 19, the opaque areas 18 of patterned sheet 14 prevent a portion of the light 17 from reaching the reflective sheet 13, so that little, if any, light is reflected. On the other hand, light 15 that passes through the transparent areas 16 of the patterned sheet 14 and reaches the reflective sheet 13, is reflected by the reflective sheet 13. As a result, from the perspective of a viewer facing the transparent cover sheet 19, the opaque areas 18 appear dark, whereas the transparent areas 16 reflect the light and appear bright. In other words, the viewer sees a pattern having a shape that is defined by the shape of the transparent areas 16.
  • Referring now to FIG. 2, in another embodiment of the invention, the reflective object is a shaped object, e.g., a [0020] molded object 22, such as a molded helmet, a sculptured sign and the like. The shaped object is preferably made from a material that is impervious to air and moisture.
  • Referring to FIGS. 3A to [0021] 3C, illustrative examples of various reflective objects having base 10 or shaped base 31 of FIG. 1A and 1B are shown. FIG. 3A shows a warning sign 30 with reflective lettering and/or a reflective background. In this embodiment, the base 12, the reflective sheet 13, the patterned sheet 14, and the transparent cover sheet 19 are preferably sealed along the lateral edges 42, as also illustrated more particularly in FIG. 4. This design prevents air and moisture from the environment from reaching the reflective sheet 13.
  • Referring to FIGS. 3B and 3C, a reflective object is a [0022] protective helmet 32, for example a safety helmet (e.g., a bicycle or motorcycle helmet or a construction helmet) is shown. The reflective pattern applied to the helmet 32 can have the form of an ornamental design 34 (FIG. 3B) or a descriptive label and/or a logo 36 (FIG. 3C). The helmet 32 can be produced, for example, by an injection molding process, as described below.
  • As seen in FIG. 4, the [0023] reflective sheet 13 can advantageously be hermetically sealed against the environment with a seam 42. For example, a molding machine or a sealing press (not shown) can apply pressure and/or heat between the cover sheet and the base along predetermined seams 42 to encapsulate the reflective sheet between the base and the cover sheet. In this way, large sheets with several objects 32 can be manufactured on a base 12 in a single manufacturing process. The sheets are then cut along the seams 42 to separate the individual objects which are now sealed along their respective marginal edges. Alternatively, the base 12 and the shaped object 22, respectively, and the reflective sheet 13 can also be sealed between the cover sheet 19 and the base 12 or the shaped object 22 by applying heat and/or pressure over the surface area of the base or the shaped object and 19.
  • Referring now to FIG. 5, in another embodiment, a [0024] reflective object 50 includes a reflective sheet 52 in the form of a multilayer dielectric stack. In this case, the reflective sheet 52 is formed of a sequence of thin alternating dielectric layers 131, 132, wherein consecutive layers have a different index of refraction. When a dielectric stack 52 of this type is illuminated, the stack 52 selectively reflects one or more colors of the light. The color depends on the thickness and the index of refraction of the thin sheets and on their arrangement with respect to each other, as is known in the art. The specific color or colors can also depend on the direction from which the object is viewed. A dielectric stack 52 can have a significantly higher reflectivity than a single reflective sheet 13. The reflective sheet 52 can also include holograms (not shown).
  • Referring now to FIG. 6, a [0025] reflective object 60 can be designed to reflect more than one color of the light striking the object. For example, when the thickness and refractive index of the thin layers 131, 132 are properly dimensioned, the dielectric stack 52 can be designed to reflect, for example, the red and blue spectral range of the light. Since the red and blue reflected colors add to form a green color, the transparent areas 64 appear green while the opaque areas 62 appear dark, as described above. However, the optical properties of the patterned sheet 14 and/or of the transparent cover sheet 19 can also be made color-selective, i.e., these sheets can function as optical filters. For example, the areas 62 of sheet 14 can be designed to absorb the red portion of the light and will therefore transmit only the blue portion of the red and blue light reflected by the dielectric stack 52. The areas 62 will therefore appear blue in reflection. Likewise, the areas 64 of sheet 14 can be designed to absorb the blue portion of the reflected light and will therefore transmit only the red portion of the light. The areas 64 will therefore appear blue in reflection. The cover sheet 19 can also have a spectrally selective light transmission. In other words, the reflective sheet 52, the patterned sheet 14 and cover sheet 19 can be designed to have different optical properties. Consequently, these sheets can be combined to produce a variety of different colors. The invention can therefore provide colorful reflective objects that can be produced in a simple manner.
  • Referring now to FIG. 7, a [0026] process 70 for manufacturing a molded shaped object 20 (FIG. 2) with a reflective pattern is described. A printed pattern of desired shape and color is applied to a transparent cover sheet 19, step 72. Alternatively, as described above, instead of applying the pattern directly to the cover sheet 19, a patterned sheet 14 can be placed on the cover sheet 19. The transparent cover sheet 19 and the patterned sheet 14 are then placed in a first molding die (not shown), with the pattern or the patterned sheet 14 facing away from the molding die, step 73. The combination formed by the cover sheet 19 and the patterned sheet 14 is then molded to conform to the shape of the molding die, using high temperature and vacuum techniques, step 74. The reflective sheet 13, 52 is placed on top of the molded patterned sheet 14, step 75, and a plastic molding material, e.g., polyurethane, is injected between a second molding die (not shown) and the reflective sheet 13, step 76. The shaped object is formed by applying heat and pressure to the mold, step 77. The reflective shaped object 20, e.g., the helmet 32, which now includes the reflective pattern on its outer surface, is removed from the mold, step 78.
  • Referring now to FIG. 8, in an [0027] alternate process 80, a shaped object 22, 32 is initially formed in a molding machine (not shown), step 82. The shaped object 22, 32 is then covered with, in that order, the reflective sheet 13, 52 and the patterned cover sheet 19, step 84. As mentioned above, instead of forming a pattern on the cover sheet 19, a separate patterned sheet 14 can be inserted between the cover sheet 19 and the reflective sheet 13, 52. The reflective sheet 13 is then sealed between the cover sheet 19 and the shaped object 22, 32 to protect the reflective sheet 13 against the environment, step 86.
  • It is to be understood that the embodiments and variations shown and described above are illustrative of the principles of this invention only and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention.[0028]

Claims (28)

We claim:
1. Protective headwear to be worn by a wearer, the article of headwear comprising:
a shell member having an internal volume sized and shaped to receive the head of a wearer, said shell member including:
a molded base;
a cover sheet including a pattern defined by areas that are transparent to optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation, wherein the cover sheet is contiguous and substantially covers the base,
a contiguous reflective sheet arranged between the base and the cover sheet and sealed between the base and the cover sheet.
2. The protective headwear according to claim 1, wherein the cover sheet includes a patterned sheet defining the transparent and opaque areas, with the patterned sheet arranged between the cover sheet and the reflective sheet.
3. The protective headwear according to claim 1, wherein at least one of the base and the cover sheet is made of plastic.
4. The protective headwear according to claim 3, wherein the plastic is substantially impervious to at least one of air and moisture.
5. The protective headwear according to claim 1, wherein the reflective sheet comprises a metal.
6. The protective headwear according to claim 1, wherein the reflective sheet selectively reflects a spectral range of the optical radiation.
7. The protective headwear according to claim 1, wherein the cover sheet selectively transmits a spectral range of the optical radiation.
8. The protective headwear according to claim 1, wherein the molded base is made of polyurethane.
9. The protective headwear according to claim 1, wherein the reflective sheet is a dielectric stack.
10. The protective headwear according to claim 1, wherein at least one of the transparent areas and the opaque areas have spectrally selective optical characteristics.
11. The protective headwear according to claim 10, wherein the spectrally selective optical characteristics include light transmission at least two different colors.
12. The protective headwear according to claim 1, wherein the pattern defines an ornamental design.
13. The protective headwear according to claim 1, wherein the pattern defines a logo.
14. The protective headwear according to claim 1, wherein the pattern defines an alphanumeric pattern.
15. A method for producing protective headwear that reflects optical radiation, the method comprising:
placing in a first molding die defining an outer shape of the protective headwear a patterned cover sheet having areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation, and shaping the cover sheet to conform to the outer shape;
placing a reflective sheet on the shaped cover sheet;
injecting a molding material between the reflective sheet and a second molding die that faces the reflective sheet and defines an inner shape of the protective headwear; and
molding the molding material to form the protective headwear,
the reflective sheet being sealed between the cover sheet and the protective headwear.
16. The method according to claim 15, wherein the molding material is polyurethane.
17. The method according to claim 15, wherein the patterned cover sheet comprises a transparent cover sheet and a patterned sheet in contact with the cover sheet.
18. The method according to claim 15, wherein at least portions of the pattern selectively transmit a spectral range of the optical radiation.
19. The method according to claim 15, wherein the reflective sheet selectively reflects a spectral range of the optical radiation.
20. An article for reflecting optical radiation comprising:
a base;
a cover sheet including a pattern defined by areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation, wherein the cover sheet is contiguous and substantially covers the base,
a contiguous reflective sheet arranged between the base and the cover sheet and sealed between the base and the cover sheet.
21. The object according to claim 20, wherein the base is a shaped object.
22. The object according to claim 21, wherein the shaped object is a molded object.
23. The object according to claim 22, wherein the molded object is made of polyurethane.
24. The object according to claim 21, wherein the shaped object is a protective head cover.
25. A method for producing a shaped object reflecting optical radiation, comprising the steps of:
placing a patterned cover sheet having areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation, in a first molding die and shaping the cover sheet to conform to the shape of the first molding die;
placing a reflective sheet on the shaped cover sheet; and
injecting a molding material between the reflective sheet and a second molding die facing the reflective sheet to form the shaped object,
wherein the reflective sheet is sealed between the cover sheet and the shaped object.
26. A method for producing a reflective shaped object comprising the steps of:
forming a shaped object;
covering the shaped object with a reflective sheet;
covering the reflective sheet with a cover sheet that includes a pattern having areas that are transparent to the optical radiation passing through the cover sheet and other areas that are opaque to the optical radiation,
so that the reflective sheet is sealed between the shaped object and the cover sheet.
27. The method according to claim 26, wherein the pattern is provided on a patterned sheet arranged between the cover sheet and the reflective sheet.
28. The method according to claim 26, wherein the cover sheet is made of plastic.
US09/943,605 1999-02-17 2001-08-30 Light reflective protective headwear Abandoned US20020002732A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US09/943,605 US20020002732A1 (en) 1999-02-17 2001-08-30 Light reflective protective headwear

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/251,959 US6305028B1 (en) 1999-02-17 1999-02-17 Light reflective protective headwear
US09/943,605 US20020002732A1 (en) 1999-02-17 2001-08-30 Light reflective protective headwear

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US09/251,959 Division US6305028B1 (en) 1999-02-17 1999-02-17 Light reflective protective headwear

Publications (1)

Publication Number Publication Date
US20020002732A1 true US20020002732A1 (en) 2002-01-10

Family

ID=22954091

Family Applications (3)

Application Number Title Priority Date Filing Date
US09/251,959 Expired - Fee Related US6305028B1 (en) 1999-02-17 1999-02-17 Light reflective protective headwear
US09/943,288 Abandoned US20020002731A1 (en) 1999-02-17 2001-08-30 Light reflective protective headwear
US09/943,605 Abandoned US20020002732A1 (en) 1999-02-17 2001-08-30 Light reflective protective headwear

Family Applications Before (2)

Application Number Title Priority Date Filing Date
US09/251,959 Expired - Fee Related US6305028B1 (en) 1999-02-17 1999-02-17 Light reflective protective headwear
US09/943,288 Abandoned US20020002731A1 (en) 1999-02-17 2001-08-30 Light reflective protective headwear

Country Status (1)

Country Link
US (3) US6305028B1 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1671775A1 (en) * 2004-12-20 2006-06-21 SCAME Srl Method to produce a protective helmet and protective helmet thus produced
US20080212181A1 (en) * 2005-06-16 2008-09-04 Avery Dennison Corporation Retroreflective Sheet Structure
US20100162471A1 (en) * 2008-12-30 2010-07-01 Avants International Corp. Helmet
US20110131700A1 (en) * 2008-08-05 2011-06-09 Hon Keung Tsui Multi Function air-bubble plastic clothes and its manufacturing method
US9351531B1 (en) 2013-10-14 2016-05-31 Ed Bennett Reflective head covering assembly

Families Citing this family (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6526596B2 (en) * 2001-05-02 2003-03-04 Carl Anderson Vinyl hat
US6619751B1 (en) * 2001-09-27 2003-09-16 Mrugesh K. Shah Heat restraint for a passenger of a vehicle
US6709062B2 (en) * 2001-09-27 2004-03-23 Mrugesh K. Shah Head restraint for a passenger of a vehicle
GB2388298A (en) * 2002-05-11 2003-11-12 John Matthew Mchale Headgear with reflective material
USD478710S1 (en) 2003-02-20 2003-08-26 Suen Ching Yan Reflective cap
JP4986503B2 (en) * 2005-11-08 2012-07-25 富士通コンポーネント株式会社 Thermoplastic resin casing and manufacturing method thereof
US20080178367A1 (en) * 2007-01-31 2008-07-31 Alan Norman Higgins Headwear
EP2277678B1 (en) * 2008-05-22 2019-01-02 Panasonic Intellectual Property Management Co., Ltd. Exterior component
US9119431B2 (en) * 2011-05-23 2015-09-01 Juliana Bain Helmet for reducing concussive forces during collision
US8763163B1 (en) 2011-12-01 2014-07-01 Foamula Products, Inc. Visor with plug in accessory sockets
USD749303S1 (en) 2012-11-30 2016-02-16 Foamula Products, Inc. Head visor with plug-in accessory sockets
US9402433B2 (en) 2011-12-01 2016-08-02 Foamula Products, Inc. Visor improvements
USD768964S1 (en) 2012-11-30 2016-10-18 Foamula Products, Inc. Head visor
US9980530B2 (en) * 2013-09-26 2018-05-29 Adam S. Hassan Optimized visual field helmets
CN105096770B (en) * 2014-05-09 2018-05-04 苏俊龙 Colored reflective article, material structure thereof and manufacturing method thereof
US10112366B2 (en) * 2014-12-19 2018-10-30 Triforce Luggage, Llc Aluminum thermoplastic composite material
CN104489992B (en) * 2015-01-08 2017-02-22 东莞星锐安新材料有限公司 Helmet with reflecting and protecting functions
US11430354B2 (en) 2016-04-21 2022-08-30 F.D. Signworks, Llc Photoluminescent identifier system for firefighting equipment
US10074295B2 (en) * 2016-04-21 2018-09-11 F. D. Signworks, LLC Photoluminescent identifier system for firefighting equipment
US11206887B1 (en) 2016-05-16 2021-12-28 Elegant Headwear Co., Inc. Method of forming a raised three-dimensional decorative image on a fabric product and cap made thereby
KR102219358B1 (en) * 2020-04-09 2021-02-22 강통두 Pad for identification of friend or foe
USD1137891S1 (en) 2025-02-13 2026-07-28 Yin Jianying Safety helmet with reflective stickers

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3770483A (en) * 1968-02-28 1973-11-06 Komine Auto Center K K Noctilucent reflective helmet
US3839129A (en) * 1970-09-25 1974-10-01 Pictorial Prod Inc Reflective foil and process
US3766565A (en) * 1970-11-06 1973-10-23 Ray Ban Solarscreen Inc Head covering having metallic reflecting surface
US3885246A (en) * 1973-11-05 1975-05-27 Minnesota Mining & Mfg Retroreflective protective helmet
US4008949A (en) * 1975-11-06 1977-02-22 Jerry Martin Luna Protective reflective helmet
US4100625A (en) * 1976-11-22 1978-07-18 Minnesota Mining And Manufacturing Company Helmets and other articles reflectorized with retroreflective platelet particles
US4993082A (en) * 1990-01-05 1991-02-19 Giro Sport Design, Inc. Method for making helmet with indelibly ornamented cover
US5106126A (en) * 1990-11-29 1992-04-21 Longobardi Lawrence J Process printed image with reflective coating
US5407711A (en) * 1993-11-30 1995-04-18 Signs & Glassworks, Incorporated Display with enhanced highlights
US5716682A (en) * 1995-12-06 1998-02-10 S & G Chromium Graphics Three dimensional card
US6219849B1 (en) * 1996-08-02 2001-04-24 Lynda N. Crescentini Distinctive protective headgear
US5829063A (en) * 1998-01-12 1998-11-03 Cheng; Tong-Hsin Luminescent cap that possesses a function for replacing patterns

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1671775A1 (en) * 2004-12-20 2006-06-21 SCAME Srl Method to produce a protective helmet and protective helmet thus produced
US20080212181A1 (en) * 2005-06-16 2008-09-04 Avery Dennison Corporation Retroreflective Sheet Structure
US8177374B2 (en) 2005-06-16 2012-05-15 Avery Dennison Corporation Retroreflective sheet structure
US9308696B2 (en) * 2005-06-16 2016-04-12 Avery Dennison Corporation Retroreflective sheet structure
US20110131700A1 (en) * 2008-08-05 2011-06-09 Hon Keung Tsui Multi Function air-bubble plastic clothes and its manufacturing method
US20100162471A1 (en) * 2008-12-30 2010-07-01 Avants International Corp. Helmet
US9351531B1 (en) 2013-10-14 2016-05-31 Ed Bennett Reflective head covering assembly

Also Published As

Publication number Publication date
US20020002731A1 (en) 2002-01-10
US6305028B1 (en) 2001-10-23

Similar Documents

Publication Publication Date Title
US6305028B1 (en) Light reflective protective headwear
US4656072A (en) Retroreflective material for providing a colored decorative effect in visible light
US6120882A (en) Article with holographic and retroreflective features
KR100479385B1 (en) Coloring and decorative lighting
EP1149317B1 (en) Durable, open-faced retroreflective prismatic construction
AU607802B2 (en) Trim strip with three-dimensional markings
CA2077165A1 (en) Security element
DK0559754T3 (en) Reflective display unit and method of manufacturing thereof
JP2000321414A (en) Light retroreflective sheet
US20070157365A1 (en) Cap for hearing protection
KR20020086278A (en) A protective casing for a display screen and a method and tool for manufacturing such a casing
JP2002307639A (en) Printed sheet for molding and key top member for push button switch
US7887745B2 (en) Reflecting material
JPH06134804A (en) Insert sheet
CN223515820U (en) Novel but helmet plastic uptake layer that has safety warning effect
JP2859012B2 (en) Light reflective clothing buttons
US20040146697A1 (en) Optically decorative product
CN223093811U (en) Phone Cases
CN217373998U (en) Colorful color-changing film and colorful hot stamping film
JPH0755520B2 (en) Method of manufacturing side illumination display panel
CN217653788U (en) Lamp shell structure, car lamp and vehicle
JP3068227U (en) Light reflective patches
JP2005126866A (en) Ornamental helmet and method for producing the same
JP3049338U (en) Decorative items overlaid with iridescent film
KR200286243Y1 (en) cap

Legal Events

Date Code Title Description
STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION