WO2016125037A1 - Protective helmet for sporting use, and particularly for skiing use - Google Patents

Abstract

Protective helmet for sporting use, and particularly for skiing use, comprising an external dome (2) made from elastically yielding material, an internal dome (3) contained inside the external dome (2) and comprising a plurality of portions (6a, 6b) of internal dome, made from expanded material, structurally independent from one another, means of interconnection of the said portions (6a, 6b) of internal dome (3) capable of reciprocally interconnecting the said portions of internal dome, the said internal dome (3) delimiting a cavity (4) capable of accommodating the head of the user, the said cavity (4) being open to the exterior along a lower perimetral edge (5) of the said domes (2, 3). The means of interconnection between the portions (6a, 6b) of internal dome (3) comprise an elastically deformable mesh structure (9), which is bonded to the portions (6a, 6b) of internal dome in order to allow limited relative movement between contiguous portions of the internal dome (3), and the internal dome (3) is bonded to the external dome (2) at least partially along the said lower perimetral edge (5) of the domes.

Description

PROTECTIVE HELMET FOR SPORTING USE, AND PARTICULARLY FOR SKIING USE

Technical scope

The present invention relates to a protective helmet for sporting use, and particularly for skiing use, having the characteristics set out in the preamble of main claim 1.

Technological background

In the specific technical field of protective helmets for sporting use, and particularly for skiing use, there is a known need to produce helmet structures suitable for providing, in addition to comfort and adaptability of fit, an adequate capacity for absorbing impacts.

Generally speaking, an adequate shell rigidity, suitable for resisting and distributing impact stresses, must be combined with an appropriate deformability of the structure suitable for maximising the absorption of impact energy. On the basis of these properties, the structures of conventional protective helmets represent a reasonable compromise between the various requirements cited above.

Protective helmet structures are also known in which an external dome structure is formed that is distinct from an internal dome structure, and in which the internal dome structure, made from an elastically deformable material, is made up of a plurality of adjacent and interconnected dome portions, in a configuration in which the dome portions can be kept separated or unseparated from each other by means of interstitial spaces that allow limited relative movement. Typically, the interconnecting elements provided between the dome portions comprise deformable structures such as straps. Also known are so-called "cage" structures, for example made with flexible bands or strips, suitable for interconnecting the internal dome portions in an elastically deformable manner. Description of the invention

The main aim of the invention is to disclose a protective helmet that is suitable for improving on the helmet structures of the known solutions, and in particular that is structurally and functionally designed to ensure a high adaptability of fit together with adequate ventilation, and that at the same time makes it possible to obtain a constructional simplicity while providing the required protection and safety properties.

This and other aims are achieved by the invention by means of a protective helmet for sporting use produced in accordance with the appended claims. Brief description of the drawings

Further characteristics and advantages of the invention will be made clearer by the following detailed description of a preferred embodiment, given by way of non-limitative example, with reference to the accompanying drawings in which :

- Figure 1 is a perspective view of a helmet produced according to the invention,

Figure 2 is another partial perspective view of the helmet of Figure 1,

- Figures 3 and 4 are perspective views of a detail of the helmet of the preceding figures,

Figure 5 is a perspective view of another detail of the helmet of the preceding figures,

Figures 6 and 7 are schematic partial cross-sectional views, on an enlarged scale, of respective details of the helmet of the preceding figures, Preferred embodiments of the invention

With reference to the above-mentioned figures, the numeral 1 indicates a protective helmet for sporting use, and particularly for skiing use, produced according to the present invention .

The helmet comprises an external dome 2 and an internal dome 3, the latter being inserted into the external dome and being capable of delimiting a cavity 4 open to the exterior, in order to accommodate the head of the user, along a lower perimetral edge 5 of the domes.

The internal dome 3 comprises a plurality of portions 6a, 6b, preferably made from expanded material, structurally independent from one another and reciprocally interconnected with limited relative movement between adjacent portions, as will become clear subsequently. The internal dome 3 is therefore designed to be received in the cavity of the external shell 2 and to be secured to the same.

The numeral 7 indicates protective structures for ears, extending in extension of the domes 2, 3, while the numeral 8 indicates a system of straps for retaining the helmet on the head of the user, the said system including suitable means for adjustment of the straps.

Figure 5 shows the structure of the internal dome 3 defined by the portions 6a, 6b made from expanded material. The said portions are produced in the form of plates having a shape such as to define, when placed adjacent with each other in a complementary manner, the overall arrangement of the internal dome. A preferred configuration provides, in the structure of the assembled internal dome 3, a first central dome portion or plate 6a, located at the summit of the dome, and a plurality of dome portions or plates 6b extending in a ring around the said first portion 6a and downwards to the lower edge 5.

The internal dome portions 6a, 6b are interconnected and held together by an elastically deformable mesh structure 9, which is bonded to the convex upper surfaces of the internal dome portions. The mesh structure 9 is preferably a mesh fabric, where the lattice of this configuration comprises openings through the thickness of the structure, of predetermined geometry (for example oval, hexagonal, square, or any other type) .

Advantageously, the mesh fabric 9 is made from polyester or other polymeric material characterised by an adequate capacity for deforming elastically.

The thickness of the mesh fabric 9 is preferably a few tenths of a millimetre, and in any event less than 1 mm.

It is also provided that the mesh structure 9 may be formed by a plurality of mesh portions, structurally independent from each other, capable of being applied on to the internal dome 3 by following the overall convex shape of the said dome, so as to maintain the internal dome portions in the chosen configuration . The said portions of the mesh structure 9 extend in a complementary and interconnected manner so as to cover, at least partially and preferably completely, the whole of the convex surface development of the internal dome.

The internal dome portions 6a, 6b are interconnected by the mesh structure 9 in a configuration in which the portions 6a, 6b are adjacent and spaced apart from each another. It is therefore provided that empty spaces remain between each pair of adjacent portions 6b of the ring and between each of the portions 6b of the ring and the central/summit portion 6a. In other words, the respective edges or corners of the portions 6a, 6b are not in contact with each other. The aim of this configuration is to allow, if need be, a certain relative movement between each internal dome portion and its neighbour, particularly in two specific conditions. The first condition relates to the fit of the helmet, in which the relative movement of the internal dome portions allows the helmet to auto- fit, within certain limits, to the head of the user, allowing greater comfort of fit. The second condition relates to the occurrence of an impact, for example during a fall or a collision with an obstacle. In this case, the deformation of the internal dome structure helps to absorb the impact, thus mitigating the effects on the structure of the helmet and therefore on the head of the user.

The distance that separates the edge of each portion 6a, 6b from the perimetral edge of the adjacent portions is chosen so as to allow a good width of movement between the said internal dome portions. Preferably, it is provided that each portion 6a, 6b never comes into contact with one or more adjacent portions, even in the event of marked deformation. Preferably, the distance between one portion and the next is in the order of a few millimetres.

The use of a mesh fabric according to the invention serves the main function of assembling and holding the different portions 6a, 6b that form the internal dome.

It is provided that the different dome portions are held together by one or more portions of mesh fabric 9, applied on to the upper surface(s) of the dome portions by various possible application methods.

As a whole, the mesh fabric or portions of mesh fabric 9 therefore constitute the means of joining the various portions of internal dome 3, following the envisaged form of the dome and maintaining the dome portions in the desired configuration . The mesh structure 9 also provides the internal dome with elastic deformability, allowing the relative movement of each dome portion 6a, 6b with respect to the adjacent portions.

The mesh fabric 9 may, for example, be applied on to the portions 6a, 6b by means of a co-moulding process. For example, a mould may be provided for forming the portions of internal dome 3 from an expanded material (for example polystyrene or polypropylene), the mesh 9 being positioned inside the said mould before the injection of the material. The material of the dome portions is then injected and expanded, thus uniting the mesh and the internal dome portions.

The main factors to be determined in a manufacturing process based on co- moulding are the number of recesses or cavities of the injection mould, their arrangement in the mould, and the number and shape of the mesh fabric sections to be positioned in the mould.

In the embodiment described, namely in the case of an internal dome 3 consisting essentially of a ring of dome portions 6b positioned radially and converging on a central/summit portion 6a, it is particularly effective to use a single mould for the entire dome 3, thus containing all the cavities corresponding to the individual portions 6a, 6b, the said cavities being arranged according to the intended positions of the portions in the assembled dome.

It is therefore possible to position the mesh fabric 9 in the mould before injecting the material from which the portions of dome 3 are formed. The material is then injected, so as to obtain the dome portions already in their final positions. To this end, a single section or cutout of mesh fabric 9 may be used, shaped to match the form of the complete dome.

In some applications, it may be difficult to make the whole of the section of mesh fabric 9 adhere to the walls of the cavities of the mould, for example when the dome portions - and therefore the corresponding mould cavities - have particularly marked curvatures. In this case there is the possibility of creating wrinkles or corrugations in the mesh fabric, with consequent incorrect positioning of the mesh fabric in the mould and associated difficulty in correctly matching the portions of dome and mesh .

In such applications it may be advantageous to provide in the structure of the mesh fabric 9 a plurality of interruptions, for example obtained in the form of a series of incisions, made in the fabric portions intended to be fixed on to the surfaces of the corresponding portions of dome 3, but not in the free spaces provided between one portion of dome 3 and the next such portion .

Thanks to these incisions, the mesh fabric 9 is more easily deformable and therefore adaptable to the surfaces of the mould. Once the material of the dome 3 has been injected and expanded, the fabric is fixed on to each dome portion . The discontinuity corresponding to the cut in the fabric is of no consequence for the manufacturing process, since both edges of the fabric are joined to the corresponding dome portions 6a, 6b.

In the creation of the mould, provision may also be made for the presence of movable parts if these are rendered particularly necessary, for example in order to ensure the perfect immobility of the fabric in the mould, and/or to facilitate the removal of the product from the mould.

With reference to the manufacture of products made from expanded material, including internal domes for protective helmets, use is frequently made of a phase of sintering the material following injection and expansion in the mould. Sintering essentially consists of heating the piece for a determined period of time, for example through the action of water vapour at high temperature. For example, in the case of expanded polystyrene or EPS, temperatures above 90°C are used.

Sintering results in optimal welding (adhesion) between the particles or 'pearls' that make up the expanded material. It also has the effect of highly compacting the particles of the material, and overall is carried out to ensure good and uniform mechanical characteristics in the piece.

In the embodiment described, using a manufacturing method based on co- moulding, it may be convenient to subject the internal dome 3 to the sintering process with the containing mesh 9 already co-injected.

In some cases, depending on the chemical nature of the material from which the mesh 9 is made, the sintering phase may help in obtaining good adhesion between the dome material and the mesh fabric.

Alternatively, it is possible to proceed by forming the various portions 6a, 6b of internal dome 3, including separately from each other, and then attaching the mesh or mesh portions to the various dome portions by gluing with a suitable adhesive.

In this case, as an alternative to using a single piece of mesh fabric 9, it is also possible to use a greater number of fabric sections complementary to each other, fixing them on to the internal dome 3 in such a way that together they entirely cover the dome.

In this second approach, the application of the mesh fabric 9 on to the internal dome 3 may conveniently be carried out after the phase of sintering the expanded material, if such a phase is provided for.

For positioning the mesh fabric 9 on the internal dome 3 in the gluing phase, a suitable T-shaped supporting form or head may be used (Fig. 5).

The structure of the mesh fabric 9 has a flexibility that is suitable for its ability to adapt itself to the curves of the mould for the internal dome portions, as well as allowing any relative movement between the dome portions. The said fabric is therefore designed to be soft and easily flexed, as well as resistant to tearing. Where it is intended to fix the mesh in place by means of co-moulding with the internal dome, the size of the apertures of the mesh 9 should preferably be no smaller than the maximum size of a particle or 'pearl' of the expanded material of the dome, and should preferably be equal to the total size of a number of pearls greater than one. Thus, during the injection/expansion moulding, there is a tendency for the pearls present on the surface of the portions of dome 3 to insert themselves into the apertures of the mesh, thus resulting in a mechanical gripping of the mesh on to the dome.

The mesh structure 9, which is characterised by a lattice of through apertures, not only makes the fabric suitably deformable but also has the further advantage of facilitating the ventilation of the helmet. The structure of the internal dome 3 allows adequate ventilation of the interior of the helmet, thanks to the empty spaces provided between the various portions 6a, 6b.

The air inside the helmet can find outlet through these openings, around which there are mesh portions which, as described, have an 'open-work' structure and therefore allow the passage of air.

In addition, further openings 10 may be provided through the various portions of dome 3, in order to increase the rate of the air flow.

Returning to the structure of the external dome 2, this contributes, in a manner that is conventional per se, to the at least partial absorption of the shock at the moment of impact, and also provides protection against sharp objects and against abrasion in the event of any grazing on rough surfaces.

According to the invention, the structure of the external dome 2 has a certain degree of flexibility or elastic deformability, so as to allow movement of the portions of the internal dome 3.

The external dome 2 may conveniently be made from an ABS plastic material, produced with a thickness such as to be sufficiently elastic.

Between the internal dome 2 and the external dome 3, an interspace may conveniently be defined by means of a plurality of distance pieces 11, for example produced with distancing projections protruding from the convex surface of the internal dome 3 and capable of making supporting contact with the concave internal surface of the external dome 2. Preferably, the said distance pieces 11 are produced of a piece with the respective portions 6a, 6b of internal dome 3. In the phase of assembling the internal dome 3 with the mesh structure 9, it is provided that the mesh covers the convex surface of the internal dome as well as the projections 11, by virtue of its elastic deformability. Alternatively, passages may be made through the thickness of the mesh 9 around the projections 11 so that the mesh 9 can adhere to the convex surface of the internal dome 3 without interfering with the projections.

Thanks to the provision of the distance pieces 11, a sort of interspace is created between the domes 2, 3 with the definition of channels or corridors, which are in communication with the spaces that separate the various portions 6a, 6b of internal dome 3, and possibly also with the through apertures 10 made in the internal dome. The corridors therefore serve as channels for the air flow necessary for the ventilation of the helmet, the said flow being particularly effective when the user is in motion.

This being the case, the air that enters the front area of the helmet, through suitable front apertures communicating with the above-mentioned internal corridors, flows in a front-to-rear direction in the interspace between the domes 2, 3 before exiting the helmet through apertures made in the rear area. The front apertures and the rear apertures may be formed simply by interspaces between the internal dome and the external dome, open respectively on the front edge and the rear edge of the helmet.

In flowing in a front-to-rear direction, the incoming air tends to suck in the air present in the apertures of the internal dome (created either as apertures passing through the thickness or as interspaces between one portion of internal dome and another), i .e. the air that is present in the vicinity of the user's head and that therefore contains the product of any perspiration.

The volumes of air drawn from the apertures of the internal dome are also expelled through the apertures of the helmet made in the rear area.

A continuous exchange of air is therefore obtained, by extracting the air containing the perspiration of the head and replacing it with "fresh" new air. The external dome 2 may also have a number of through apertures 10' provided for ventilation purposes. The said apertures 10' may be located around the apertures 10 provided in the internal dome and/or be partially superposed on the free spaces present between each portion 6a, 6b of the internal dome 3 and the adjacent portions.

As regards the assembly of the external dome 2 on to the internal dome , it is desirable that the fixing system should not prevent the internal dome 3 from deforming freely, within the limits permitted by the mesh structure 9. It is therefore preferable to use an assembly system of a type that is not completely rigid, i.e. of the partially bonded type. For example, on the external dome 2 may be provided a series of buttresses 12 or protruding structures (which may also be of a piece with the said external dome) positioned along the lower edge 5, pointing downwards and partially towards the interior of the helmet, suitable for engaging with corresponding lower edges 6c of the portions 6b of internal dome 3, making contact with the said edges by means of an essential form fit.

By applying adhesive in the areas of contact between the buttresses 12 of the external dome and the edges 6c of the internal dome, and therefore avoiding the application of adhesive on the convex upper surfaces of the internal dome, the said internal dome will be bonded only around limited perimetral areas. The capacity for elastic deformation is therefore safeguarded.

Alternatively, provision may be made for fixing the buttresses 12 to the internal dome by means of an elastic coupling, for example with a snap-clip system. Such a system may also fulfil the requirement of preserving the deformability of the internal dome assembled with the outer dome. However, since these are helmets with a protective function, the security offered by fixing with adhesive is the preferred choice.

The invention thus achieves the proposed aims, providing numerous advantages with respect to the known solutions.

A first advantage lies in the high adaptability of fit combined with a high degree of ventilation that can be obtained with the protective helmet produced according to the invention .

Another advantage is linked to the simplification of the construction of the helmet according to the invention, in particular thanks to the easy and immediate positioning of the mesh in the mould, or of the mesh on the inner dome in the case of gluing, compared with the solutions of the known art. For the manufacture of the helmets known to date, it is necessary to use phases which, overall, make the construction of the helmet more expensive. These phases include, for example, the prior manufacture of a cage, an elastic strap structure or some such for eventual co-moulding with the dome. Another factor is the complexity associated with the need to incorporate the cage or elastic structure in the internal dome, so that in the co-moulding process the cage involves the thickness of the internal dome portions, rather than their surface, resulting in greater problems and complications in terms of positioning and stability in the mould, the robustness of the expanded part incorporating the strap, etc.

Compared with helmets of the conventional type with a deformable internal dome comprising plates, the invention has the advantage of providing a further reduction in the overall weight of the helmet, with a consequent increase in comfort of fit. Because of the reduced thickness and the open-work structure, a section of mesh (extended over the entire dome) is lighter in weight than, for example, a cage or a structure of straps made from technical fabric or plastic clips.

Claims

1. Protective helmet for sporting use, and particularly for skiing use, comprising : an external dome (2) made from elastically yielding material,

- an internal dome (3) contained inside the external dome (2) and comprising a plurality of portions (6a, 6b) of internal dome, made from expanded material, structurally independent from one another,

- means of interconnection of the said portions (6a, 6b) of internal dome (3) capable of reciprocally interconnecting the said portions of internal dome,

- the said internal dome (3) delimiting a cavity (4) capable of accommodating the head of the user, the said cavity (4) being open to the exterior along a lower perimetral edge (5) of the said domes (2, 3), characterised in that the said means of interconnection between the said portions (6a, 6b) of internal dome (3) comprise an elastically deformable mesh structure (9), which is bonded to the portions (6a, 6b) of internal dome (3) in order to allow limited relative movement between contiguous portions of the internal dome (3), and in that the internal dome (3) is bonded to the external dome (2) at least partially along the said lower perimetral edge (5) of the said domes.

2. Helmet according to claim 1, in which the said mesh structure comprises a mesh fabric (9) .

3. Helmet according to claim 1 or claim 2, in which the said mesh structure (9) is applied to the respective surfaces of the portions (6a, 6b) of internal dome (3) facing towards the external dome (2) and is bound to the said surfaces in such a way as to maintain each portion of internal dome (3) at a preset distance from the portion of internal dome contiguous with it.

4. Helmet according to one or more of the preceding claims, in which the said mesh structure (9) has a thickness of less than 1 mm.

5. Helmet according to one or more of the preceding claims, in which the said mesh structure (9) comprises a plurality of mesh portions, structurally independent from one another, capable of being applied on to the internal dome (3) in order to interconnect between the said portions of internal dome (3), the said mesh portions extending into the internal dome (3), in a complementary manner between one another and covering, at least partially, the internal dome.

6. Helmet according to one or more of the preceding claims, in which the said mesh structure (9) comprises localised interruptions in the form of incisions, capable of facilitating the superficial mating with the internal dome (3) .

7. Helmet according to one or more of the preceding claims, in which the said mesh structure (9) is applied to the portions (6a, 6b) of internal dome (3) by a process of injection co-moulding.

8. Helmet according to one or more of claims 1 to 6, in which the said mesh structure (9) is applied to the portions of internal dome by gluing with adhesive.

9. Helmet according to one or more of the preceding claims, comprising means and counter-means of fixing between the internal dome (3) and the external dome (2), provided along the said lower edge (5) of the domes and capable of being joined together by gluing with adhesive.

10. Helmet according to one or more of the preceding claims, in which the internal dome (3) comprises a first summit portion (6a) of internal dome and a plurality of second portions (6b) of dome extending in a ring around the said first portion (6a) as far as the said lower edge (5).