WO2016116872A1

WO2016116872A1 - Helmet and process for manufacturing such a helmet

Info

Publication number: WO2016116872A1
Application number: PCT/IB2016/050270
Authority: WO
Inventors: Andrea Azzolin; Lino Dainese; Stefano Zanotto
Original assignee: Dainese S.P.A.
Priority date: 2015-01-21
Filing date: 2016-01-20
Publication date: 2016-07-28

Abstract

A helmet (100) including a cap-like multilayered sub-portion or multilayered structure (10) is described, said helmet including at least one layer of thermoformable foam material (14, 18) and one anti-penetration layer (16) coupled to said thermoformable foam layer so as to define at least partly the cap-like multilayered sub-portion or multilayered structure. The helmet (100) further includes at least one layer with energy absorption function (22), wherein the layer with energy absorption function (22) is arranged on, facing or coupled to, an intrados side of the first cap-like multilayered sub-portion or multilayered structure (10). A process for manufacturing this helmet (100) is also described.

Description

HELMET AND PROCESS FOR MANUFACTURING SUCH A HELMET

DESCRIPTION

The present disclosure relates in general to the technical sector of protective helmets. More particularly, the present disclosure relates to a helmet and to a process for manufacturing such a helmet. The protective helmet according to the present disclosure may be particularly suitable for dynamic sports such as skiing, horse-riding, cycling, motorcycling, American football and similar sports where the use of a protective helmet is required.

A known helmet for providing protection against impact includes a semi- spherical cap conventionally formed by an outer shell of rigid plastic material and an inner layer of polystyrene. In connection with the present disclosure, every spatial reference such as inner, outer, right-hand, left-hand, above or below is to be understood as referring to the head of a user when wearing the helmet. It follows that, for example, an inner side of the helmet is a side of the helmet directed towards the head of the user, and an outer side of the helmet is a side of the helmet directed towards an opposite outer zone with respect to the user's head; or a zone above the helmet is to be understood as being a zone which, when the helmet is worn, is located above the user's head.

The outer shell of rigid plastic material of the cap has mainly an anti-penetration function, while the polystyrene layer has a mainly an energy absorbing function. Both the outer shell and the inner polystyrene layer have a substantially spherical form, with a variable inner circumference which depends on the head size of the user.

The inventors of the present disclosure have recognized that in a conventional helmet with cap, in order to ensure comfort for the user, an inner lining which acts as a soft layer or comfort layer between the cap and head is provided. The lining has a predefined height depending on the internal circumference of the cap, and more particularly on the circumference of the inner layer of polystyrene, and is such as to fill the space between the inner circumference of the cap and the circumference of the user's head. Essentially, the inner lining has a height which depends on the difference in the average dimensions of the circumference of the head and the inner diameter of the cap, in order to fill the space between the rigid outer cap and the head.

However, with a known helmet it is not always possible to provide optimum comfort and at the same time ensure the stability of the helmet. In fact, considering the variable anatomy of a user's head, it is not always possible to have a helmet in which the comfort layer is able to fill perfectly the space between the inner polystyrene layer and the user's head.

In an attempt to overcome this drawback, it is sometimes required to choose a helmet with a smaller size in order to guarantee the stability of the helmet, to the detriment of the comfort.

Sometimes, instead, in order to obtain better comfort and a helmet which is not tight-fitting, one is obliged to choose a larger size helmet. In this case, however, the inner lining does not adhere perfectly to the head and therefore the helmet is not perfectly immobile when worn, despite the use of any chin straps or belts. Basically, there is the risk of an unsatisfactory stability of the helmet when it is worn.

One technical problem underlying the present disclosure is that of providing a helmet and a process for manufacturing a helmet which is able to overcome at least one of the drawbacks described above and/or which provides a number of advantages.

This technical problem is solved by a helmet and by a process as defined in the respective independent claims. Secondary characteristic features forming the subject of the present disclosure are defined in the corresponding dependent claims.

In particular, in connection with the present description and the following claims, the helmet may be called a "soft helmet" or "flexible helmet" in the sense that it includes a plurality of layers which are per se adaptable to the user's head, namely which may be deformed at least partly manually by an operator and which, in combination with each other, once superimposed are able to ensure impact protection against both penetration and energy absorption, while allowing basic adaptability of the helmet to a user's head. Such a helmet may be referred to in jargon by the term "soft helmet", "flexible helmet" or similar definition and is a helmet which may be slightly deformed, for example, by manually compressing the sides of the helmet.

In particular, the term "energy absorption" is understood as meaning the capacity of the helmet to absorb the energy of an impact which occurs on the outside, while minimizing the transmission to the skull. A layer with an "energy absorption" function is therefore to be understood as being a layer whose properties and capacities are already well-known as possessing this function or which is made of materials not yet known, but which, following tests and trials, prove to have this energy absorption function.

The expression "anti-penetration" is understood as meaning the capacity of the helmet to dissipate the impact force which occurs on an outer side of the helmet, in particular in the case of an impact against sharp or pointed surfaces, so that at the moment of impact the force is distributed over a wider area before being transmitted into the internal zone of the helmet. A layer with an "anti-penetration" function is therefore to be understood as being a layer whose properties and capacities are already well-known as possessing this function or which is made of materials not yet known, but which, following tests and trials, prove to have this anti-penetration function.

By means of such a helmet it is possible to adapt in an optimum manner the structure and form of the helmet on the basis of given anatomical requirements. In fact, owing to the "adaptability" of the layers, the helmet, overall, may be adapted to any anatomical imperfections or forms of a user's head. As a result, a helmet of a specific size may be comfortably worn by users who generally use such a size, but who have a particular or anomalous head shape.

As is described below in the present disclosure, the layers which form said "soft" helmet assume or have generally a cap-like or semi-spherical form or a form defining a concavity, and these layers are arranged one on top of the other maintaining said cap-like form. Consequently, with reference to the cap-like form, for each layer, it is possible to identify an intrados side or zone of the each layer, namely a side of the helmet directed inwards or situated on the concavity side and intended to be directed towards the head of a user wearing the helmet, and an extrados side or zone of each layer, namely a side of the helmet directed outwards, on the opposite side to the concavity and intended to be directed away from the head of a user wearing the helmet.

Even more particularly, in accordance with the present disclosure, the helmet includes a cap-like multilayered sub-portion or multilayered structure including a plurality of layers and, in particular, at least one layer of thermoformable foam material and at least one anti-penetration layer, or plate or sheet-like layer. The layer of thermoformable foam material and the anti-penetration layer are coupled together one on top of the other or, vice versa, so as to form at least partly said multilayered cap structure. The term "coupled" in the context of the present disclosure is understood as meaning that the two layers are superimposed one on top of the other or vice versa, directly (i.e. making direct contact) or indirectly (via another layer arranged in between), so as to form a multilayered structure.

The helmet further includes at least one layer with energy absorption function, wherein the layer with energy absorption function is arranged on, facing or coupled to, an intrados side of the cap-like multilayered sub-portion or multilayered structure defined above. Basically, in accordance with the present disclosure, a multilayered "soft" helmet is proposed where roles and functions of the layers are distinguished as follows: an outer portion of the helmet, called also cap-like multilayered sub-portion or multilayered structure, includes at least one anti-penetration layer of smaller thickness so as to be in practice malleable or pliable manually by a user, and a second sub-portion of the helmet includes at least one layer having an energy absorption function. Basically, the anti-penetration layer has a limited and small thickness which is compatible with the adaptability requirements of the helmet and thickness such that it may be manually flexed at least partly by a user.

In order to compensate for this flexibility/adaptability of the small-thickness anti- penetration layer, the helmet includes the thermoformable foam layer which may give structure to the anti-penetration layer. The layer of thermoformable material is therefore able to give the anti-penetration shell or layer a three-dimensional caplike structure. In other words, the present disclosure is based on the intuition that the, owing to the use of the thermoformable foam layer in combination with the anti-penetration layer, it is possible to use an anti-penetration layer of smaller thickness (in order to obtain a flexible helmet) without adversely affecting the protective capacity and solidity of the helmet.

In other words, an underlying idea of the present disclosure is that, in place of a substantially rigid cap which has a considerable thickness, and therefore is not malleable or pliable manually, as known in the prior art, a shell body which ensures the same penetration resistance properties, but is much more flexible and lighter, is used. This is possible owing to the combination of at least one thermoformable foam material, which has a supporting function once thermoformed, and at least one very thin anti-penetration material (namely a thin layer which is flexible and malleable, but resistant to penetration). In some embodiments the anti-penetration layer has a thickness or height comprised between 0.2 mm and 1 mm. In a more specific embodiment the anti-penetration layer may have a thickness or height comprised between 0.4 mm and 0.8 mm such as to ensure an optimum equilibrium between flexibility and penetration resistance.

Preferably, the layer of thermoformable foam material does not have a padding function. In fact it is a material which possesses a certain consistency when thermoformed.

The layer with energy absorption function may be a foam material. Alternatively, the layer with energy absorption function may be a layer having a honeycomb structure, for example made of plastic or aluminium. Alternatively also the layer with energy absorption function may be a gel-based structure, a rubber or the like. In connection with the multilayered sub-portion defined above, the layer of thermoformable foam material may be arranged internally (intrados side) or externally (extrados side) with respect to the anti-penetration layer.

More particularly, in some embodiments, the anti-penetration layer is arranged on the outside of the helmet, namely on an extrados side of the thermoformable foam layer, which is therefore on the inside, so that the anti-penetration material performs simultaneously also the function of providing protection against wear by external agents.

In other embodiments, the layer of thermoformable foam material is arranged externally with respect to the anti-penetration layer, namely on an extrados side of the anti-penetration layer so as to give the helmet a soft feel. In these embodiments, for stylistic and wear protection reasons, the helmet includes a further outer layer for covering the layer of thermoformable foam material. This further outer layer is placed on an extrados side of the layer of thermoformable foam material. The further layer may be a layer made of fabric or mesh material.

In some embodiments of the present disclosure, the further layer is a thin and flexible material, such as leather, plastic film or the like intended to provide protection against wear and atmospheric agents.

In some embodiments of the present disclosure, the helmet includes both the layer of thermoformable foam material (first layer of thermoformable foam material) placed on an extrados side of the anti-penetration layer and a layer of thermoformable foam material (second layer of thermoformable foam material) placed on an intrados side, in order to give the anti-penetration layer a maximum three-dimensional structure. In this case, the first layer of thermoformable foam material is protected by the aforementioned further layer with wear protection function.

It should also be noted that, if the further layer placed on the extrados side of the layer of thermoformable foam material consists of a fabric or mesh, this fabric or mesh, if realized with a suitable gramme weight and strength, may help increase the energy absorption capacity of the helmet.

Moreover, in accordance with a process according to the present disclosure, in order to give the anti-penetration layer the three-dimensional cap structure, this anti-penetration layer is coupled to at least one layer of thermoformable foam material during a single thermoforming processing step so as to form a single body. In particular, by arranging a layer of glue, or other layer of binding agent, or adhesive film, between the anti-penetration layer and the layer of thermoformable foam material and subjecting the layer of thermoformable foam material and the anti-penetration layer to thermoforming in a mould having a suitable shape, it is possible to provide the layer of thermoformable material and consequently also the anti-penetration layer with said cap-like form. Basically, the multilayered sub- portion of the helmet may be formed as one piece during a single thermoforming step.

Also the layer with energy absorption function may have a cap-like form or a configuration which can be adapted to a cap-like form of the aforementioned multilayered sub-portion, and therefore be fixed to the intrados surface of the multilayered sub-portion after thermoforming. For example, in one embodiment, the layer with energy consumption function may include a plurality of members fixed adjacent to each other on a support made of flexible material with a small interspace between them. This layer may then be placed on the inside of the caplike multilayered sub-portion so as to line the inner side or intrados of the cap-like multilayered sub-portion.

The members are therefore fixed beforehand to the support layer and then fixed to the intrados side of the cap-like multilayered sub-portion. Owing to the presence of a plurality of members, these members may be adapted to the concave shape of the cap-like multilayered sub-portion. In particular, the members are arranged so that the members are fixed to the intrados side of the multilayered sub-portion and the support layer made of flexible material is directed towards the inner side of the helmet. Owing to the fact that the members are fixed beforehand on the support layer made of flexible material it is possible to handle all the members together and facilitate the helmet production process.

Further characteristic features and modes of use forming the subject of the present disclosure will become clear from the following detailed description of a number of preferred exemplary and non-limiting embodiments thereof. It is evident, however, that each example of embodiment may have one or more of the advantages listed above; in any case it is not required that each embodiment should have simultaneously all the advantages listed.

It should also be understood that the scope of the present disclosure includes all the possible combinations of the embodiments indicated above and those described with reference to the following detailed description.

Reference will be made to the figures of the accompanying drawings in which:

- Figure 1 shows an axonometric view, from the front, of a helmet according to an embodiment of the present disclosure;

- Figure 2 shows an axonometric view, from the rear, of a helmet according to the embodiment shown in Figure 1 ; - Figure 3 shows a view, from the front, of a helmet according to the embodiment shown in Figure 1 ;

- Figure 4 shows a view, from the rear, of a helmet according to the embodiment shown in Figure 1 ;

- Figure 5 shows a view, in schematic form, of an operating step of a process for manufacturing a helmet portion according to the embodiment shown in Figure 1 ;

- Figure 6 shows a partially sectioned side view of a portion of a helmet manufactured in accordance with the operating step shown in Figure 5;

- Figure 6A a shows a view, on a larger scale, of a detail VI of the sectioned part shown in Figure 6;

- Figure 7 shows a view of a first helmet multilayered sub-portion obtained after the step shown in Figure 5;

- Figure 8 shows a view of an operating step for the assembly of further parts of a second sub-portion of the helmet after the step according to Figure 5;

- Figure 9 shows a cross-sectional view of a helmet portion obtained after the steps illustrated in Figure 5 and Figure 8;

- Figure 10 and Figure 11 show a view of some of the operative steps for assembly of accessory parts of a helmet according to the embodiment shown in Figure 1 ;

- Figure 12 shows a view, from the inside and from below, of a helmet according to the embodiment shown in Figure 1.

With reference to the attached figures, the reference number 100 indicates a helmet according to the present disclosure.

in particular, the helmet 100 includes a plurality of layers configured and arranged to provide the helmet with properties for protection against both energy absorption and penetration. The helmet includes a first multilayered sub-portion 10 in the form of a cap and a second sub-portion 20 which are intended to be coupled one on top of the other so as to form a cap-like or semi-spherical body 30.

More particularly, a first cap-like multilayered sub-portion 10 includes:

- a first layer of thermoformable foam material 14 such as thermoformable polyethylene foam; and

- an anti-penetration layer 16 such as a shell-like body and/or a sheet-like body. The anti-penetration layer 16 is, for example, a layer of PVC or other material suitable for performing an anti-penetration function, such as polycarbonate. Preferably (optionally) a second layer of thermoformable foam material 18, such as thermoformable polyethylene foam, is also provided.

The two layers of thermoformable foam material 14, 18 and the anti-penetration layer 16 each have a cap-like or semi-spherical form and provide the entire multilayered sub-portion 10 with a cap-like form, namely provide the helmet with a structure suitable for combination with the other portions of the helmet 100.

In particular, the two layers of thermoformable foam material 14, 18 have a structural function, namely they provide the helmet with a multilayered structure, and also allow the anti-penetration layer 16 to be kept in an intermediate sandwiched position.

In fact, the anti-penetration layer 16 is arranged in sandwich form, namely in an intermediate position between the two layers of thermoformable foam material 14, 18.

Each layer of thermoformable material 14, 18 is glued, or otherwise secured, to the anti-penetration layer 16. As a result, the anti-penetration layer 16 has an extrados side glued, or fixed in some other way, to a corresponding intrados side of the first layer of thermoformable foam material 14 and an intrados side glued, or otherwise secured, to a corresponding extrados side of the second layer of thermoformable foam material 18. It is also possible for other intermediate materials to be provided such as to produce indirect contact or fixing between each layer of thermoformable material 14, 18 and the anti-penetration layer 16.

The anti-penetration layer 16 has a limited/small height compatible with the generally soft and adaptable structure of the helmet 100 to be obtained. This height is of the order of a few tenths of a millimetre, for example between 0.2 mm and 1 mm, and preferably between 0.4 mm and 0. 8 mm.

In accordance with the present disclosure, it is possible to limit/reduce the height of the anti-penetration layer 16 owing to the presence of at least one of the layers of thermoformable foam material which is coupled to the anti-penetration layer 16.

In a preferred embodiment such as that shown in the figures, in order to reinforce the anti-penetration function of the helmet 100, the helmet 100 further comprises a fabric layer 12 or mesh layer. The latter is placed on an outer side or extrados or convex surface of the first layer of thermoformable material 14. Also the fabric layer 12 or mesh layer is glued, or otherwise secured, to the first layer of thermoformable material 14.

The fabric layer 12 is also able to protect from wear the first layer of thermoformable material 14.

Either one of or both the thermoformable foam layer 14 and the second layer of thermoformable foam material 18 is/are intended to act as a three-dimensional support for the fabric layer 12 and the anti-penetration layer 16 and therefore also provide, as already mentioned above in the embodiment described, the fabric layer 12 with a three-dimensional form and support the anti-penetration layer 16. In fact, the fabric 12, when coupled to the first layer of thermoformable foam material 14, maintains a three-dimensional configuration and, at the same time, the anti- penetration layer 16, when inserted between the first layer of thermoformable foam material 14 and the second layer of thermoformable foam material 18, is kept in position by these two layers.

It should also be noted that the assembly formed by the first layer of thermoformable foam material 14, the second layer of thermoformable foam material 18, the fabric layer 12 and the anti-penetration layer 16 results in the formation of a waterproof structure which therefore makes the helmet suitable for daily use.

By way of example, in one embodiment of the present disclosure, a high- strength polyester fabric with a weight per unit area of about 230 g/cm² was used as first fabric layer 12.

By way of example, in one embodiment of the present disclosure a polyethylene, for example polyethylene hardened to 90 Kg/m² and/or 150 Kg/m², was used as thermoformable foam material 14. For example, polyethylene hardened to 90 Kg/m² may be used for the first layer of thermoformable foam material 14 and polyethylene hardened to 150 Kg/m² may be used for the second layer of thermoformable foam material 18. Alternatively, polyethylene hardened to 90 Kg/m² may be used both for the first layer of thermoformable foam material 14 and for the second layer of thermoformable foam layer 18. It is to be understood that a person skilled in the art may consider using polyethylene hardened to values different from those indicated.

The first cap-like multilayered sub-portion 10 is completed preferably by a layer of velvet 19, or other flexible and soft material, which is suitable for or favours a connection with the aforementioned second cap-like sub-portion 20, for example by means of a removable Velcro fastening. The velvet layer 19 is glued, or fixed in another manner, to the intrados side of the second layer of thermoformable foam material 18.

Consequently, the anti-penetration layer 16 has an intrados side glued, or fixed in another way, to a corresponding extrados side of the velvet layer 19.

In one embodiment of the present disclosure, such as that shown in the drawings, a belt, strap or cord-like portion is inserted between the first layer of thermoformable foam material 14, such as thermoformable polyethylene foam, and the anti-penetration layer 16, or between the anti-penetration layer 16 and the second layer of thermoformable foam material 18 and is designed to protrude from the sides, for example the right and left of the first cap-like multilayered sub-portion 10. This belt-like portion may be a single belt which extends as one piece between a right-hand zone and a left-hand zone of the helmet and emerges in the side areas substantially in the region of the helmet zones situated close to or opposite the ears. The end parts or free ends of the belt-like portion 17 serve to provide a chin strap for the helmet.

Basically, the belt-like portion 17 intended to form a chin strap of the helmet passes over the head of a user and is embedded between the layers of the helmet. Preferably, as shown in the drawings, the belt-like portion 17 is placed between the first layer of thermoformable foam material 14, such as thermoformable polyethylene foam, and the anti-penetration layer 16. The anti-penetration layer 16 may include suitable eyelets or holes so that the belt-like portion may pass in a winding manner between the intrados side and the extrados side and vice versa of the anti-penetration layer 16 and for allowing stable positioning of the belt-like portion 17.

In an embodiment such as the one shown in the drawings, the belt-like portion 17 is a single strip which extends from right to left, passing over the top of the first cap-like multilayered sub-portion 10.

In an embodiment such as that shown in the drawings, in order to favour breathability of the helmet 100, the anti-penetration layer 16 and either one of or both the first layer of thermoformable foam material 14 and the second layer of thermoformable foam material 18 are perforated layers, with holes 13 having a diameter of between 1 and 15 mm, preferably between 4 and 8 mm. The holes 13 in the anti-penetration layer 16 and in either one of or both the first layer of thermoformable foam material 14 and the second layer of thermoformable foam material 18 are aligned with each other so as to allow the continuous passage of air.

In one embodiment, the first multilayered sub-portion 10 has an overall height of between 4 and 8 mm, and of preferably about 6 mm, so as to allow a high degree of flexibility and adaptability of the helmet 100. This first sub-portion 10 may have a height preferably between a minimum of 1 mm and a maximum of 10 mm.

According to one aspect of the present disclosure and as already mentioned above, the cap 100 further includes a second cap-like or semi-spherical sub-portion 20 which includes, for example, a layer of foam material which preferably is a non- thermoformable material and is intended to have mainly an energy absorbing function. As will be clarified below, a material suitable for the purpose of energy absorption may be in general both a material with a foam structure and a material without a foam structure.

Even more particularly, preferably the second cap-like sub-portion 20 includes a plurality of foam material elements or members 22 with energy absorption function. In other words, these elements or members 22 form, once arranged alongside each other inside the first multilayered sub-portion 10, the layer with energy absorption function.

These elements 22 are elements initially structurally independent of each other and able to be handled individually. For example, the elements 22 are elements made of foam material, for example in the form of a parallelepiped or prism, and are arranged on a second support 24 consisting of flexible material such as light velvet fabric and arranged alongside each other at a minimum distance with a respective interspace or making light contact with each other. Owing to this not tight, i.e. loose, arrangement alongside each other, it is possible to arrange in a free and versatile manner the elements 22 on the inside of the intrados or concave zone of the first portion, without compressing them together, and allow the helmet to be adapted to the user's head.

These elements or members 22 are for example made of a material known commercially by the name Plastazote® and including crosslinked closed-cell polyethylene foam (obtained with a foaming process using pure high-pressure nitrogen). More specifically, in the embodiment shown, the material used is a foam material with exceptional uniformity in terms of density, cellular size and colour intensity, which is resistant to water and chemical agents and available in a density ranging from 15 to 120 Kg/m³. Such a material is also available in the versions for conductive use and for dissipation of the static electricity. Preferably such a material having a density of between 80 and 120 Kg/m³, preferably between 100 and 120 Kg/m³, and even more preferably between 1 10 and 120 Kg/m³, for example 1 15 Kg/m³, is used.

For example, the Plastozote® material used is Plastozote ® HDPE.

Alternatively, the elements or members 22 are made of polystyrene, polypropylene, preferably polypropylene foam, rubber, aluminium honeycomb or other material suitable for absorbing energy. The polypropylene foam may require thicknesses smaller than polyethylene foam described above, for the same performance features.

Each foam material member may be provided on the surface exposed towards the concave zone of the first multilayered sub-portion 10 with a removable fastening portion, such as the Velcro® fastening portion, so as to allow fixing to the support layer of flexible material 19 which is located in the concave inner zone or intrados of the first multilayered sub-portion 10.

It is to be understood that the layer with energy absorption function may also include a single cap-like part or two or more cap-like parts (larger than the members 22 shown). The important thing is that this layer should be provided with incisions, interspaces or cavities for allowing a certain relative movement of the parts and therefore allow the aforementioned adaptation of the helmet to the user's head.

Consequently, according to one aspect of the present disclosure, the helmet is modified with respect to the prior art in the sense that a shell body with anti- penetration function having a relatively small thickness so as to ensure a sufficient adaptability to the user's head is coupled to at least one thermoformable foam material which supports, protects and gives structure to the small-thickness anti- penetration layer. At the same time, a suitable energy absorption is ensured by the layer with energy absorption function, which may also be configured for adaptation to a user's head.

Preferably, the layer of thermoformable foam material is not a material with a padding or damping function. Even more preferably, the layer of thermoformable foam material has, per se, a three-dimensional cap structure and acts as a structural support for the anti-penetration layer 16 and/or is able to give the anti- penetration layer 16 a three-dimensional structure.

It is also to be understood that, preferably, the layer of thermoformable foam material is a material able to acquire the three-dimensional cap-like structure after thermoforming treatment. As a result, preferably, the layer of thermoformable foam material is in a thermoformed condition in the final helmet.

The second cap-like sub-portion 20 and in particular the velvet support fabric 24 may be further joined together with the first cap-like multilayered sub-portion 10 by means of edging of the known type so as to form the cap-like body 30. Basically, an edging strip may be glued or stitched along the edges of the first cap-like multilayered sub-portion 10 and the second cap-like sub-portion 20 for aesthetic purposes and as an instrument for joining together the first cap-like multilayered sub-portion 10 and the second cap-like sub-portion 20.

The helmet 100 may be completed by means of an inner helmet lining 70. The inner helmet lining is understood for example as being a generally soft assembly which has the function of covering, at least partially, an inner or concave side and acting as a soft layer or comfort layer for a user. The inner helmet lining 70 may be that described in European patent application EP12154042.1 or in European patent application EP12154040.5. In order to fix the inner helmet lining 70, it may be sufficient to provide the inner helmet lining 70 with Velcro for fastening to the intrados side of the second sub- portion 20. Alternatively, the helmet 100 also includes a ring-like body 72 associated with the inner lining 70 and configured to be fixed to the second sub- portion of the helmet. It is to be understood that a person skilled in the art may use any known technology or solution to provide the helmet 100 with an inner comfort lining for the helmet.

In one embodiment such as that shown in the drawings, the helmet 100 may further comprise a cheekbone protection structure 80 which is fixed in a removable manner by means of press buttons, or a similar fastening system, to the helmet 100.

A process for manufacturing a helmet 100, such as that for example shown in the drawings, is described hereinbelow.

Initially the following are prepared:

- the first layer of thermoformable foam material 14, such as thermoformable polyethylene foam;

- the anti-penetration layer 16, such a shell-like body, a sheet-like body, for example a layer made of PVC or other suitable material, such polycarbonate; and

- optionally the second layer of thermoformable foam material 18, such as thermoformable polyethylene foam, is also provided.

Optionally, in addition to these layers, it is possible to arrange in between one or more belt, strap or cord-like portions so that the free end parts thereof protrude on the right-hand and left-hand sides of the first cap-like multilayered sub-portion 10. This belt-like portion 17 may be, as mentioned, a single belt which extends as one piece between a right-hand zone and a left-hand zone of the helmet and emerges in the lateral areas substantially in the region of the helmet zones situated opposite the ears. In this way, it is possible to provide belts for forming a chin strap and these belts must be sewn to a remaining part of the helmet. Basically, they consist of belts embedded integrally in the helmet.

Preferably, as shown in the drawings, the belt-like portion 17 is placed between the first layer of thermoformable foam material 14, such as thermoformable polyethylene foam, and the anti-penetration layer 16. As mentioned above, the belt-like portion may be inserted in a winding arrangement inside respective holes or eyelets of the anti-penetration layer/shell 16, thus passing between the intrados side and the extrados side, and vice versa, of the anti-penetration layer 16, and allow stable positioning of the belt-like portion 17.

Optionally, in addition to the three layers mentioned above and the belt-like portion 17, the fabric layer 12 or mesh layer may be arranged on top of the first layer of thermoformable foam material 14.

Optionally, a first flexible support layer, for example the aforementioned velvet layer 19, is arranged on a side of the three aforementioned layers opposite to that of the first fabric layer 12.

A layer or film of glue (not visible in the figures) may be arranged in an intermediate zone between each of the layers (including the optional layers) mentioned hereinabove, namely

optionally between the fabric layer 12 and the first layer of thermoformable foam material 14;

between the first layer of thermoformable foam material 14 and the anti- penetration layer 16;

optionally between the anti-penetration layer 16 and the second layer of thermoformable foam material 18;

optionally between the second layer of thermoformable foam material 18 and the first flexible support layer 19. The layer of glue may also be applied by means of rolling on one side of the layers in question or on both sides of these layers.

After application of the layer of glue, all the layers mentioned, namely the first layer of thermoformable foam material 14, the anti-penetration layer 16 and the second layer of thermoformable foam material; and optionally the fabric layer 12, the first support layer 19 and the one or more belt-like portions 17 undergo thermoforming treatment in a suitably shaped press so as to obtain a single three- dimensional structure including the fabric layer 12, the first layer of thermoformable material 14, the anti-penetration layer 16 and the second layer of thermoformable foam material 18. In particular, the press may include a mould 90 with a substantially spherical shape and a die 91 of matching shape, including a substantially spherical shaped recess.

The press is suitably heated (for example to a temperature of about 170°C) so as to favour the adhesion and gluing together of all the layers.

The press may include suitable means for keeping tensioned all the layers in question during thermoforming, including the fabric layer 12 and the first flexible support layer 19 when subjected to thermoforming, and prevent the formation of wrinkles in either one of or both these layers. In order to keep the layers tensioned, the press may comprise, for example, a circular disk structure which surrounds the die 91 and which is intended to press on the perimeter of the layers when thermoforming is performed, preventing them from moving.

It is to be understood that other technical solutions may be envisaged, all these being within the scope of the person skilled in the art and helping keep the layers tensioned when they are joined together. For example, it is possible to use a circular structure provided with springs arranged in a radial direction and connected to the layers which form the helmet. This structure is fixed along the entire perimeter on one or more of the layers at the time of thermoforming, keeping these layers tensioned.

By means of thermoforming the first aforementioned multilayered sub-portion 10 is obtained. The first multilayered sub-portion 10 is then joined to the second sub- portion 20 by fixing the members 22 made of foam material to an intrados side of the first multilayered sub-portion 10. In this way the support layer is directed towards an inner intrados zone of the helmet.

In order to fix the members 22 many alternative solutions may be provided. In one solution, the members 22 are glued directly onto the intrados zone of the multilayered sub-portion 10.

Alternatively, the members 22 may be first fixed by means of gluing to the second support layer 24 made of flexible material. The members 22 are provided with a Velcro ® fastening portion on the side intended to be joined together with the support layer 19 (which is the opposite to the side for performing gluing to the second support layer 24 made of flexible material). Then, the members 22 are fixed by means of Velcro ® to the inner intrados surface/side of the first multilayered sub-portion 10 so that the second support layer 24 is exposed towards an inner side of the body 30 and may be connected together with the comfort layer 70.

The preliminary fixing of the members 22 to the second flexible support layer 24 is useful for being able to handle the members 22 as a single body and facilitate manufacture of the helmet 100.

The helmet 100 is then completed by means of suitable edging provided along all the layers for aesthetic purposes and by fixing the comfort layer 70 and the cheekbone protection structure 80, using methods known to the person skilled in the art.

Therefore a so-called soft helmet 100 is obtained since it contains layers of manually deformable material, but at the same time allows an optimum performance to be obtained in terms of:

- penetration strength; and

- absorption energy.

In particular, using the materials and the thicknesses indicated above, it has been possible to obtain results in compliance with the standard EN 1077:2007, which is currently the reference standard in the sector of helmets.

The subject-matter of the present disclosure has been described hitherto with reference to preferred embodiments thereof. It is to be understood that other embodiments relating to the same inventive idea may exist, all of these falling within the scope of protection of the claims which are attached below.

Claims

1. Helmet (100) including a cap-like multilayered sub-portion or multilayered structure (10) including at least one layer of thermoformable foam material (14, 18) and an anti-penetration layer (16) coupled to said layer of thermoformable foam material in order to define at least in part said cap-like multilayered sub-portion or multilayered structure;

and wherein the helmet (100) includes at least one layer with energy absorption function (22), wherein the layer with energy absorption function (22) is arranged on, facing, or coupled to, an intrados side of the cap-like multilayered sub-portion or multilayered structure (10).

2. The helmet (100) according to claim 1 or 2, wherein said anti-penetration layer (16) has a height comprised between 0.2 mm and 1 mm.

3. The helmet (100) according to any one of the preceding claims, wherein said anti-penetration layer (16) has a height comprised between 0.4 mm and 0.8 mm.

4. The helmet (100) according to any one of the preceding claims, wherein the anti-penetration layer (16) is arranged in an outer area of the multilayered sub-portion (10), i.e. on an extrados side of the thermoformable foam layer (18).

5. The helmet (100) according to any one of the preceding claims 1 to 3, wherein the layer of thermoformable foam material (14) is arranged externally with respect to the anti-penetration layer (16), that is on an extrados side of the anti-penetration layer (16), so as to give the helmet a soft feel.

6. The helmet (100) according to claim 6, including a further outer layer (12) placed on an extrados side of the layer of thermoformable foam material (14).

7. The helmet (100) according to claim 7, wherein the further outer layer (12) is a fabric layer (12), or a mesh layer placed on an outer side, or extrados, or convex surface of the layer of thermoformable material (14).

8. The helmet (100) according to any one of the preceding claims, wherein the layer with energy absorption function (22) includes a plurality of members or blocks.

9. The helmet (100) according to any one of the preceding claims, wherein said layer of thermoformable material (14, 18) is glued, or otherwise secured, directly or indirectly to the anti-penetration layer (16).

10. The helmet (100) according to any one of the preceding claims, wherein the anti-penetration layer (16) is a shell-like body made of thermoplastic material, such as PVC or polycarbonate, or a similar thermoplastic material suitable for forming a shell body.

1 1. The helmet (100) according to any one of the preceding claims, wherein said layer of thermoformable foam material (14, 18) is made of polyethylene foam.

12. The helmet (100) according to any one of the preceding claims, wherein the layer of thermoformable foam material is a first layer of thermoformable foam material and the helmet includes a second layer of thermoformable foam material (18), and wherein the anti-penetration layer (16) is placed between the first layer of thermoformable foam material (14) and the second layer of thermoformable foam material (18) such that an extrados side of the anti- penetration layer (16) is arranged on, facing, or coupled to, an intrados side of the first layer of thermoformable foam material (14) and an intrados side of the anti-penetration layer (16) is arranged on, facing, or coupled to, an extrados side of the first layer of thermoformable foam material (14).

13. The helmet (100) according to claim 12, wherein the first layer of thermoformable foam material (14) and the second layer of thermoformable foam material (18) are made of the same material.

14. The helmet (100) according to any one of the preceding claims, including one or more belt, strap, or cord-like portions embedded between two adjacent layers of the helmet (100), wherein said one or more belt-like portions (17) has/have one or more end parts or free ends which protrude from one of, or both, the side areas of the helmet.

15. The helmet (100) according to claim 14, wherein said one or more belt-like portions constitute(s) part of, or is/are intended to be part of, a chin strap of the helmet.

16. The helmet (100) according to claim 14 or 15, wherein the one or more belt- like portions (17) is/are placed between the layer of thermoformable foam material (14) and the anti-penetration layer (16).

17. The helmet (100) according to any one of the preceding claims, wherein the layer with energy absorption function (22) includes a plurality of members made of foam material arranged on a flexible support layer (24), next to each other at a mutual distance with an interspace, or making slight contact with each other.

18. The helmet (100) according to any one of the preceding claims, wherein the layer with energy absorption function includes, or is made of, foam material.

19. The helmet (100) according to any one of the preceding claims, wherein said layer of thermoformable foam material (14, 18) is not material with a padding or damping function.

20. The helmet (100) according to any one of the preceding claims, wherein said layer of thermoformable foam material has, per se, a three-dimensional cap structure and acts as a structural support for the anti-penetration layer (16) and/or is suitable for giving the anti-penetration layer (16) a three- dimensional structure.

21. The helmet (100) according to any one of the preceding claims, wherein said layer of thermoformable foam material is a material suitable for acquiring a three-dimensional cap structure after thermoforming treatment.

22. A process for manufacturing a helmet (100) according to any one of the preceding claims, wherein a layer of glue or adhesive is placed in an intermediate region between the layer of thermoformable foam material (14, 18) and the anti-penetration layer (16), and wherein the layer of thermoformable foam material (14) and the anti-penetration layer (16) are subjected together to a thermoforming step.

23. The process according to claim 22 in combination with claim 14, claim 15 or claim 16, wherein the belt-like portion (17) is placed between the anti- penetration layer (16) and the layer of thermoformable foam material (14, 18) during the thermoforming step.

24. The process according to claim 22 or 23 in combination with claim 7 or 8, wherein during the thermoforming step, the further outer layer (12) is fixed on the outer side or extrados, or convex surface of the layer of thermoformable material (14).

25. The process according to any one of claims 22 to 24, wherein the layer with energy absorption function is joined to a concave surface of the first multilayered sub-portion (10) of the helmet after, or once, the thermoforming step has finished.