WO2017035984A1 - 新型发光头盔及制造方法 - Google Patents

新型发光头盔及制造方法 Download PDF

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Publication number
WO2017035984A1
WO2017035984A1 PCT/CN2015/097493 CN2015097493W WO2017035984A1 WO 2017035984 A1 WO2017035984 A1 WO 2017035984A1 CN 2015097493 W CN2015097493 W CN 2015097493W WO 2017035984 A1 WO2017035984 A1 WO 2017035984A1
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WO
WIPO (PCT)
Prior art keywords
light
outer layer
transmitting
helmet
led lamp
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PCT/CN2015/097493
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English (en)
French (fr)
Inventor
刘勇
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深圳前海零距物联网科技有限公司
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Application filed by 深圳前海零距物联网科技有限公司 filed Critical 深圳前海零距物联网科技有限公司
Priority to DE112015006781.7T priority Critical patent/DE112015006781B4/de
Publication of WO2017035984A1 publication Critical patent/WO2017035984A1/zh

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    • 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
    • A42B3/0406—Accessories for helmets
    • A42B3/0433—Detecting, signalling or lighting devices
    • A42B3/044—Lighting devices, e.g. helmets with lamps

Definitions

  • the invention relates to the technical field of outdoor sports safety protection, in particular to a novel luminous helmet and a manufacturing method thereof.
  • Bicycles are the most commonly used means of transportation for people. With the rise of outdoor sports, more and more enthusiasts use bicycle riding as a way of tourism, competition and leisure.
  • a safety helmet for passive protection when riding, to prevent important heads from being protected after an accidental fall.
  • the helmet can reduce the damage caused by the fall itself, such as a fall, but in the case of a poor line of sight, it is prone to accidents such as collisions with moving vehicles in the rear.
  • the illuminating helmet is usually embedded with an FPC (Flexible Printed Circuit) 3 between the outer layer 1 and the inner layer 2, an electroluminescent component 31 is disposed on the FPC board 3, Such as an LED lamp, the LED lamp 31 has a certain thickness, and a bump is formed on the FPC board 3.
  • FPC plate and the outer layer need to be fixed before the outer layer 1 and the inner layer 2 of the helmet are formed by high temperature injection molding.
  • the EPS material of the high temperature inner layer will cause the FPC board 3 to be pressed, which is prone to breakage, resulting in a high product defect rate.
  • the technical problem to be solved by the present invention is to provide a luminous helmet and a manufacturing method thereof, the luminous helmet It can avoid the high defect rate in the manufacturing process of the illuminating helmet, improve the productivity of the product and reduce the production cost.
  • the present invention provides an illuminating helmet comprising: a helmet body composed of an outer layer and an inner layer, and an FPC board disposed between the inner layer and the outer layer, the FPC board At least one LED lamp is disposed thereon, and the outer layer corresponding to the position of the LED lamp is provided with a light-transmitting protrusion protruding outward.
  • the light-transmitting protrusion is further provided with a soft-light coating for softening the light.
  • the soft-light coating is a grid-like light-transmissive grid.
  • the light-transmitting protrusion is provided with a light-transmitting medium covering the LED lamp.
  • the light-transmitting protrusions are spherical or hemispherical.
  • annular rib is disposed outside the light-transmitting protrusion, and an annular groove is formed between the annular rib and the light-transmitting protrusion.
  • the invention also provides a method for producing a luminous helmet, comprising: firstly placing a partially colored PC sheet in a mold for plastic forming to form an outer layer with light-transmitting protrusions; secondly, fixing the outer layer An FPC board having at least one LED lamp, and the LED lamp is housed in the light-transmitting protrusion; finally, the outer layer fixed with the FPC board is placed in the molding die, and the inner layer material is injected to form a tight bond with the outer layer. Helmet body.
  • the inner side of the outer layer is provided with a coating layer for intimately bonding the inner layer to the outer layer when the inner layer is formed.
  • the light-transmitting protrusion is further provided with a soft-light coating for softening the light.
  • the soft light coating comprises a grid-like light transmissive grid.
  • the step of fixing the FPC board provided with the at least one LED lamp further comprises injecting a light-transmissive medium into the light-transmitting protrusion, so that the LED lamp is covered by the light-transmitting medium.
  • the light-transmitting protrusions are spherical or hemispherical.
  • an outer side of the light-transmitting protrusion is provided with an annular rib, and an annular groove is formed between the annular rib and the light-transmitting protrusion.
  • the illuminating helmet of the present invention comprises a helmet body composed of an outer layer and an inner layer, and an FPC board disposed between the inner layer and the outer layer, wherein the FPC board is provided with at least one LED lamp, and the LED lamp corresponds to The outer layer of the position is provided with a light-transmitting projection that protrudes outward.
  • the PC piece is first placed in the mold to be formed by suction molding to form an outer layer with light-transmitting protrusions, and then the FPC board of at least one LED lamp is fixed at the position of the light-transmitting protrusion, and finally the LED lamp is fixed.
  • the outer layer of the FPC board is placed in a molding die and pressed into the inner layer material to form a helmet that is tightly bonded to the outer layer. Since the light-transmitting protrusion can just accommodate the LED lamp, the gap between the FPC board and the outer layer which is close to the LED lamp is small, and the FPC board is not easily broken when the inner layer material is formed under high temperature and high pressure. The productivity of the product reduces the production cost. At the same time, since the LED lamp is located in the light-transmitting protrusion, the LED lamp is higher than the outer surface, so that the range of the light emitted by the LED lamp is wider.
  • FIG. 1 is a schematic structural view of an embodiment of a conventional illuminating helmet.
  • FIG. 2 is a schematic front elevational view of an embodiment of an illuminated helmet.
  • Figure 3 is a cross-sectional view taken along line B-B of Figure 2;
  • Figure 4 is an enlarged schematic view showing the structure of the portion A in Figure 3.
  • Fig. 5 is a front elevational view showing another embodiment of the light-transmitting projection.
  • Figure 6 is a cross-sectional view taken along line B-B of Figure 5;
  • Fig. 7 is an enlarged schematic view showing a structure of a portion C in Fig. 6.
  • Fig. 8 is an enlarged schematic view showing the structure of still another embodiment of the light-transmitting projection.
  • Figure 9 is a flow chart of the production of an illuminated helmet.
  • the present invention provides an embodiment of an illuminated helmet.
  • the illuminating helmet comprises: a helmet body comprising an outer layer 1 and a shock absorbing inner layer 2, and a illuminating light bar disposed between the inner layer 2 and the outer layer 1, the illuminating light bar comprising an FPC board 3 and At least one LED lamp 31 of the FPC board 3, the outer layer 1 corresponding to the position of the LED lamp 31 is provided with a light-transmitting protrusion 11 protruding outward.
  • the number of the LED lamps 31 is not limited, and may be one, two or more. Since the illuminating helmet usually forms a surface light source or a line light source by a plurality of LED lamps 31, the corresponding position of the LED lamp 31 refers to a specific position when the illuminating helmet is made, such as when the LED lamp 31 is disposed at the front of the illuminating helmet.
  • the light-transmitting protrusions 11 are disposed on the outer layer at the corresponding positions on the front portion of the illuminating helmet, and the LED lamps 31 are received in the light-transmitting protrusions 11.
  • the outer layer 1 is usually formed of a PC material such as a PC sheet.
  • the inner layer 2 usually adopts a material with a small density, such as an EPS material, which can reduce the weight of the helmet and has better shock absorption performance.
  • the EPS material is integrated with the outer layer by pressure injection under high temperature and high pressure conditions.
  • the number of the light-transmitting protrusions 11 is equivalent to the number of the LED lamps 31, and the shape and size of the light-transmitting protrusions 11 If necessary, it may be a spherical crown, a hemisphere or other shapes, and preferably is equivalent to the size of the LED lamp 31.
  • the FPC board 3 can just The inner side of the outer layer 1 is preferably in smooth contact.
  • the outer layer 1 is formed by plastic molding, a plurality of light-transmitting protrusions 11 can be formed, and the light-transmitting protrusions 11 mean that the light energy of the LED passes. Then, the light bar is fixed on the outer layer 1.
  • the FPC board 3 with at least one LED lamp 31 is fixed on the outer layer 1 so that the LED lamp 31 is located in the light-transmitting protrusion 11, and the FPC board 3 can be externally
  • the inner side of the layer 1 is smoothly contacted, so that the gap between the FPC board 3 and the outer layer 1 which is closer to the LED lamp 31 is the smallest, and it is not easy to cause the inner layer EPS material to be pressed between the FPC board 3 and the outer layer 1 under high temperature and high pressure.
  • the LED lamp is located in the light-transmitting protrusion, the LED lamp is higher than the outer surface, so that the range of the light emitted by the LED lamp is wider.
  • the LED lamp 31 Although the power of the LED lamp 31 is small, the brightness is large, and the power supply capacity limitation of the helmet is filtered. Therefore, the LED light 31 can be used as the electric light source to improve the lighting time. When the battery capacity is not measured, other electroluminescence can of course be used. The device replaces the LED lamp 31.
  • the outer layer 1 When the outer layer 1 is tightly combined with the inner layer 2 which is injection molded with the EPS material to form a helmet, since the EPS material particles are large, it is difficult to enter the small cavity formed by the light-transmitting protrusions 11, and thus the helmet is formed,
  • the light protrusion 11 is empty except for the LED lamp 31, so that the light-transmitting protrusion 11 has a small force strength, and is easily deformed when the light-transmitting protrusion 11 slightly collides, and the LED light in the light-transmitting protrusion 11 is easily damaged.
  • the above embodiment provides another embodiment of the illuminating helmet.
  • the outer side of the light-transmitting protrusion 31 is provided with an annular rib 14 and an annular groove 15 is formed between the annular rib 14 and the light-transmitting protrusion 11.
  • the other structure is the same as that of the above embodiment. Since the annular rib 14 is provided on the outer side of the light-transmitting projection 31, the light-transmitting projection 31 can be protected, and the overall strength of the light-transmitting projection 31 can be increased.
  • a cavity formed in the light-transmitting projection 11 Or a light-transmissive medium 5 covering the LED lamp is disposed in the cavity formed by the light-transmitting protrusion 11 and the annular protrusion 14 .
  • the light-transmissive medium may be a PC or a silica gel material, or may be other light-transmissive materials. Since the refractive index of the light-transmitting medium is greater than that of air, the exit angle of the light emitted from the LED lamp 31 through the light-transmitting medium 5 can be made larger, which is advantageous for increasing the visible range of the light emitted by the LED lamp 31.
  • the transparent medium 5 is filled before the high temperature and high pressure molding of the inner layer 2, so that the gap between the FPC board 3 and the outer layer 1 which is closer to the LED lamp 31 is filled, and the FPC board 3 can be protected.
  • the LED lamp 31 can be protected, and the strength of the light-transmitting projection 11 can be increased.
  • the LED lamp 31 Since the LED lamp 31 is used as a light source, the brightness of the LED lamp is large, which is more glaring and affects the line of sight; in particular, when a plurality of LED lamps 31 are provided, the line of sight may be seriously affected, and the light-transmitting protrusion 11 may be provided with softening light.
  • a soft-light coating comprising a grid-like light-transmissive grid 12, as shown in FIG.
  • the grid-like light-transmitting grid 12 is disposed inside or outside the light-transmitting projections 11.
  • the LED lamp 31 can be made to pass through the grid-like light-transmitting grid 1 to make the light softer, thereby reducing visual interference.
  • the present invention also provides an embodiment of a method for producing a luminous helmet.
  • the luminous helmet production method comprises:
  • Step S10 the outer layer is plastically molded, specifically, the PC sheet is first placed in a mold for plastic forming to form an outer layer with at least one light-transmitting protrusion, and the number of the light-transmitting protrusions is according to the LED lamp. The number is determined, but one, two or more;
  • Step S11 fixing the light bar, specifically, fixing the FPC board with a plurality of LED lights on the outer layer, and accommodating the LED lights in the light-transmitting protrusions, the light-emitting strips including the FPC board 3 and the FPC Board LED light 31.
  • step S12 the inner laminated body of the helmet is formed. Specifically, the outer layer of the light-emitting strip fixed in the above step S11 is placed in the inner layer forming mold, and the inner layer is injected into the inner layer to form a tight joint with the outer layer.
  • the outer layer 1 is usually formed of a PC material such as a PC sheet.
  • the inner layer 2 is usually made of a material having a small density, such as an EPS material, which can reduce the weight of the helmet while Has a good shock absorption performance.
  • the pressure is 8 standard pressure conditions, through the injection molding process, the EPS material is pressed into the mold, and combined with the outer layer to form a helmet body.
  • the number of the light-transmitting protrusions 11 is equivalent to the number of the LED lamps 31.
  • the shape and size of the light-transmitting protrusions 11 are set as needed, and may be spherical, hemispherical or other shapes, preferably with the LED lamp 31.
  • the size is adapted.
  • the FPC board 3 is just in smooth contact with the inner side of the outer layer 1 as the best.
  • the outer layer 1 is formed by plastic molding, a plurality of light-transmitting projections 11 can be formed, and the light-transmitting projections 11 mean that light such as LED light can pass.
  • the light strip is fixed on the outer layer 1 so that the LED lamp 31 is located just inside the light-transmitting protrusion 11, and the FPC board 3 can just contact the inner side of the outer layer 1 so that the FPC is closer to the LED lamp 31.
  • the gap between the plate 3 and the outer layer 1 is the smallest, that is, the light bar can be in contact with the inner side of the outer layer 1.
  • the FPC plate 31 is not easily broken, thereby improving the yield of the product during molding. ,reduce manufacturing cost.
  • the LED lamp 31 is fixed in the light-transmitting projection 11, the LED lamp 31 is higher than the surface of the outer layer 1, so that the light-emitting range of the LED lamp 31 is wider.
  • the LED lamp 31 Although the power of the LED lamp 31 is small, the brightness is large, and the power supply capacity limitation of the helmet is filtered. Therefore, the LED light 31 can be used as the electric light source to improve the lighting time. When the battery capacity is not measured, other electroluminescence can of course be used. The device replaces the LED lamp 31.
  • the outer layer 1 When the outer layer 1 is tightly combined with the inner layer 2 which is injection molded with the EPS material to form a helmet, since the EPS material particles are large, it is difficult to enter the small cavity formed by the light-transmitting protrusions 11, and thus the helmet is formed,
  • the light protrusion 11 is empty except for the LED lamp 31, so that the light-transmitting protrusion 11 has a small force strength, and is easily deformed when the light-transmitting protrusion 11 slightly collides, and the LED light in the light-transmitting protrusion 11 is easily damaged.
  • the above embodiment provides another embodiment of the illuminating helmet.
  • the outer side of the light-transmitting protrusion 31 is provided with an annular rib 14 and an annular groove 15 is formed between the annular rib 14 and the light-transmitting protrusion 11.
  • the other structure is the same as that of the above embodiment. Since the annular rib 14 is provided on the outer side of the light-transmitting protrusion 31, the light-transmitting protrusion 31 can be protected, and at the same time The overall strength of the light-transmitting projections 31 is increased.
  • a transparent medium 5 enclosing the LED lamp is disposed in a cavity formed by the cavity or the light-transmitting protrusion 11 formed by the light-transmitting protrusion 11 and the annular ridge 14.
  • the light transmissive medium may be a PC or a silica gel material, or may be other light transmissive materials. Since the refractive index of the light-transmitting medium is greater than that of air, the exit angle of the light emitted from the LED lamp 31 through the light-transmitting medium 5 can be made larger, which is advantageous for increasing the visible range of the light emitted by the LED lamp 31.
  • the transparent medium 5 is filled before the high temperature and high pressure molding of the inner layer 2, so that the gap between the FPC board 3 and the outer layer 1 which is closer to the LED lamp 31 is filled, and the FPC board 3 can be protected.
  • the LED lamp 31 can be protected, and the strength of the light-transmitting projection 11 can be increased.
  • the LED lamp 31 Since the LED lamp 31 is used as a light source, the brightness of the LED lamp is large, which is more glaring and affects the line of sight; in particular, when a plurality of LED lamps 31 are provided, the line of sight may be seriously affected, and the light-transmitting protrusion 11 may be provided with softening light.
  • a soft-light coating comprising a grid-like light-transmissive grid 12, as shown in FIG.
  • the grid-like light-transmitting grid 12 is disposed inside or outside the light-transmitting projections 11.
  • the LED lamp 31 can be made to pass through the grid-like light-transmitting grid 1 to make the light softer, thereby reducing visual interference.
  • the grid-like light-transmitting grid 12 is subjected to silk screen printing, spraying, etc. before fixing the FPC board 3 and the LED lamp 31, and may also be performed after the inner layer 3 and the outer layer 1 are combined to form a helmet body, in comparison to the helmet.
  • the mesh-shaped light-transmitting grid 12 is formed by screen printing, spraying, etc. after the main body is formed, the light-transmitting protrusion 11 has a shape such as a hemisphere or a spherical crown, which increases the process difficulty.
  • the grid-like light-transmitting grid 12 When the grid-like light-transmitting grid 12 is combined with the outer layer 1 to form the helmet body, and then screen-printed and sprayed, it can only be disposed on the outer side of the light-transmitting protrusion 11, in comparison with the inner layer 2 after molding.
  • the screen-like grid-like transparent grid 12 is in the shape of a hemisphere or the like, the process difficulty is increased and the drop is easy.
  • a coating step fused with the inner layer 2 is applied on the inner side of the outer layer 2, that is, in the outer layer. 2 After molding, apply a silver layer on the inside.
  • the screen layer is applied, the pattern layer is sprayed, and the protective layer is sprayed on the pattern layer. Placed on the protective layer.

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  • Helmets And Other Head Coverings (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

一种发光头盔，包括由部分透光的外层（1）和减震的内层（2）构成的头盔主体，以及设于内层（2）与外层（1）之间的FPC板（3）。该FPC板（3）设有至少一个LED灯（31），LED灯（31）对应位置的外层（1）设有向外侧凸出的透光凸起（11）。发光头盔的生产方法包括先将PC片放置在模具内进行吸塑成型形成有透光凸起（11）的外层（1），再将带有至少一个LED灯（31）的FPC板（3）固定在透光凸起（11）位置，最后将固定有带LED灯（31）的FPC板（3）的外层（11）放置在成型模具内，注入内层（2）EPS料压注形成与外层（1）紧密结合的头盔。由于透光凸起（11）恰好能收纳LED灯（31），使得与LED灯（31）较近的FPC板（3）与外层（11）之间的间隙（4）较小，在高温高压下压注内层（2）材料成型时不容易使得FPC板（3）断裂，提高产品的生效率，降低生产成本。

Description

新型发光头盔及制造方法 技术领域
本发明涉及户外运动安全保障技术领域，尤其涉及一种新型发光头盔及制造方法。
背景技术
自行车是人们最常用的代步工具，而且随着户外运动兴起，越来越多的爱好者将自行车骑行作为旅游、竞技、休闲的方式。
现有骑行者在骑行时通常戴有安全头盔进行被动保护，防止意外跌倒后对重要的头部进行保护。虽然头盔可以降低跌落等骑行自身原因造成的伤害，但视线差的情况下，容易出现被后方移动车辆等碰撞的意外。
因而目前出现了发光头盔，该发光头盔通过主动发光对其后面的车辆等进行提示，降低发生被碰撞的风险。如图1所示，由于发光头盔通常是在外层1和内层2之间预埋有FPC(Flexible Printed Circuit，柔性线路)板3，在FPC板3上设有电致发光的元器件31，如LED灯，LED灯31有一定的厚度，在FPC板3形成凸起。在头盔的外层1与内层2是通过高温度压注成型前需要将FPC板与外层固定。由于灯光需要从头盔表面出射，因此需面将LED灯侧于朝向外层一侧，这样就使得靠近LED灯的FPC板3与外层1之间形成较大的间隙4。在压注成型时，高温度压内层的EPS材料会使得FPC板3受压，容易出现拉断现象，造成产品不良率较高。
发明内容
本发明主要解决的技术问题是提供一种发光头盔及制造方法，该发光头盔 可以避免发光头盔制造过程中出现较高的不良率，提高产品的生效率，降低生产成本。
为了解决上述技术问题，本发明提供一种发光头盔，该发光头盔包括：包括由外层和内层构成的头盔主体，以及设于所述内层与外层之间的FPC板，该FPC板上设有至少一颗LED灯，所述LED灯对应位置的外层设有向外侧凸出的透光凸起。
进一步地说，在进行外层吸塑成型前还包括透光凸起设有使光柔和的柔光涂层。
进一步地说，所述柔光涂层网格状透光栅格。
进一步地说，所述透光凸起内设有包覆LED灯的透光介质。
进一步地说，所述透光凸起呈球冠状或半球状。
进一步地说，所述透光凸起外侧设有的环形凸条，该环形凸条与透光凸起之间形成环形凹槽。
本发明还提供一种发光头盔生产方法，该发光头盔生产方法包括：包括先将部分着色的PC片放置在模具内进行吸塑成型，形成带透光凸起的外层；其次在外层固定设有至少一颗LED灯的FPC板，并使LED灯收纳于透光凸起内；最后将固定有FPC板的外层放置在成型模具内，注入内层材料压注形成与外层紧密结合的头盔主体。
进一步地说，在内层成型前将外层的内侧设有压注时使内层与外层紧密结合的涂层。
进一步地说，在进行外层吸塑成型前还包括透光凸起设有使光柔和的柔光涂层。
进一步地说，所述柔光涂层包括网格状透光栅格。
进一步地说，将设有至少一个LED灯的FPC板固定步骤还包括向透光凸起内注入透光介质，使LED灯被透光介质包覆。
进一步地说，所述透光凸起呈球冠状或半球状。
进一步地说，所述透光凸起外侧设有环形凸条，该环形凸条与透光凸起之间形成环形凹槽。
本发明发光头盔，包括由外层和内层构成的头盔主体，以及设于所述内层与外层之间的FPC板，该FPC板上设有至少一颗LED灯，所述LED灯对应位置的外层设有向外侧凸出的透光凸起。制作时，先将PC片放置在模具内进行吸塑成型形成有透光凸起的外层，再将至少一颗LED灯的FPC板固定在透光凸起位置，最后将固定有带LED灯的FPC板的外层放置在成型模具压入内层材料压注形成与外层紧密结合的头盔。由于透光凸起恰好能收纳LED灯，使得与LED灯较近的FPC板与外层之间的间隙较小，在高温高压下压注内层材料成型时不容易使得FPC板断裂现象，提高产品的生效率，降低生产成本。同时由于LED灯位于在透光凸起内，LED灯高于外层表面，使得LED灯的出射光的范围更广。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单介绍，显而易见地，而描述中的附图是本发明的一些实施例，对于本领域普通技术人员来说，在不付出创造性劳动的前提下，还可以根据这些附图获得其他附图。
图1是现有发光头盔实施例结构示意图。
图2是发光头盔实施例正视结构示意图。
图3是图2中沿B-B方向剖视结构示意图。
图4是图3中A部分结构放大示意图。
图5是透光凸起另一种实施例正视结构示意图。
图6是图5中沿B-B方向剖视结构示意图。
图7是图6中C部分结构放大示意图。
图8是透光凸起又一种实施例结构放大示意图。
图9是发光头盔生产流程图。
下面结合实施例，并参照附图，对本发明目的的实现、功能特点及优点作进一步说明。
具体实施方式
为了使发明的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图2至图4所示，本发明提出一种发光头盔实施例。
该发光头盔包括：包括外层1和减震的内层2构成的头盔主体，以及设于所述内层2与外层1之间的发光灯条，该发光灯条包括FPC板3和设于FPC板3的至少一个LED灯31，所述LED灯31对应位置的外层1设有向外侧凸出的透光凸起11。
具体地说，所述LED灯31的数量多少不限，可以是一个、两个或多个。由于发光头盔通常是由多个LED灯31时才能形成面光源或线光源，所述LED灯31对应位置是指制作发光头盔时需在设置具体位置，如在发光头盔前部设置LED灯31时，则需在发光头盔前部相应位置的外层设置透光凸起11，所述LED灯31收纳于透光凸起11内。
所述外层1通常采用PC材料，如PC片经过吸塑成型。所述内层2通常采用密度小的材料，如EPS材料，可以减轻头盔的重量，同时具有较好的减震性能。在高温高压条件下，通过压注将EPS材料与外层形成一体。所述透光凸起11的数量与LED灯31的数量相当即可，所述透光凸起11的形状大小 根据需要进行设置，可以是球冠状、半球状或其他形状，最好能与LED灯31的大小相当，当LED灯31收纳在所述透光凸起11时，所述FPC板3恰好能与外层1内侧平滑接触为最好。
由于外层1在吸塑成型时，可以形成多个透光凸起11，所述透光凸起11是指LED光能通过。再将发光灯条固定在外层1上，即将设有至少一LED灯31的FPC板3固定在外层1上，使LED灯31恰好位于透光凸起11内，所述FPC板3能与外层1内侧平滑接触，使得与LED灯31较近的FPC板3与外层1之间的间隙最小，在高温高压下压注内层EPS料时不容易使得FPC板3与外层1之间有较大间隙而出现断裂现象，从而可以提高产品成型时的成品率，提高生效率，降低生产成本。同时由于LED灯位于在透光凸起内，LED灯高于外层表面，使得LED灯的出射光的范围更广。
虽然LED灯31功率小，但亮度较大，考滤到头盔电源容量限制，因而采用LED灯31作为电光源可以提高发光时间，在不考滤电池容量时，当然也可以采用其他的电致发光器件代替LED灯31。
所述外层1与采用EPS材料注塑的内层2紧密结合形成头盔时，由于EPS材料颗粒较大，很难进入透光凸起11形成的较小空腔，因而头盔成型后，所述透光凸起11内除LED灯31外都是空的，造成透光凸起11受力强度小，当透光凸起11轻微碰撞时容易出现变形，容易损坏透光凸起11内的LED灯31。
为了解决头盔成型后的透光凸起11受力时容易变形和损坏LED灯31问题，如图5-图7所示，上述实施例的基础上还提供另一种发光头盔实施例。
具体地说，所述透光凸起31的外侧设有环形凸条14，在环形凸条14与透光凸起11之间形成环形凹槽15，其他结构与上述实施例相同。由于在透光凸起31的外侧设有环形凸条14，可以对透光凸起31起到保护作用，同时增加透光凸起31的整体强度。
为了进一步增加LED灯31出射光的角度，在透光凸起11形成的空腔 或透光凸起11与环形凸条14一起形成的空腔内设有包覆LED灯的透光介质5，该透光介质可以是PC或硅胶材料，也可以是其他可以透光材料。由于透光介质的折射率大于空气，可以使LED灯31通过透光介质5出射光的出射角度更大，有利于增加LED灯31出射光的可视范围。同时透光介质5是在内层2高温和高压成型前进行填充，使得与LED灯31较近的FPC板3与外层1之间的间隙被填充，既可以对FPC板3进行保护，也可以对LED灯31起到保护，还能增加透光凸起11受力强度。
由于LED灯31作为光源，其光亮度大，较刺眼，影响视线；尤其是设置多个LED灯31时，会严重影响视线，可以在所述透光凸起11的上设有使光柔和的柔光涂层，该柔光涂层包括网格状透光栅格12，如图8所示。所述网格状透光栅格12设在透光凸起11的内侧或外侧。可以使LED灯31通过网格状透光栅格1后光线更为柔和，减少视觉的干扰。
如图9所示，本发明还提供一种发光头盔生产方法实施例。
该发光头盔生产方法包括：
步骤S10，外层吸塑成型，具体地说，先将PC片放置在模具内进行吸塑成型，形成带有至少一个透光凸起的外层，所述透光凸起的数量根据LED灯的数量来确定，可是一个、两个或多个；
步骤S11，固定发光灯条，具体地说，在外层固定带有多个LED灯的FPC板，并使LED灯收纳于透光凸起内，所述发光灯条包括FPC板3和设于FPC板的LED灯31。
步骤S12，内层压注头盔主体成型，具体地说，将上述步骤S11中固定好发光灯条的外层放置在内层成型模具内，注入内层材料压注形成与外层紧密结合头盔。
具体地说，所述外层1通常采用PC材料，如PC片经过吸塑成型。所述内层2通常采用密度小的材料，如EPS材料，可以减轻头盔的重量，同时 具有较好的减震性能。在高温高压，如温度在120-180度左右，压力为8个标准气压条件下，通过注塑工艺，将EPS材料压入模具内，使其与外层结合形成一体，构成头盔主体。所述透光凸起11的数量与LED灯31的数量相当，所述透光凸起11的形状大小根据需要进行设置，可以是球冠状、半球状或其他形状，最好能与LED灯31的大小适应，当LED灯31收纳在所述透光凸起11时，所述FPC板3恰好能与外层1内侧平滑接触为最好。
由于外层1在吸塑成型时，可以形成多个透光凸起11，所述透光凸起11是指光如LED光能通过。再将所述发光灯条固定在外层1上，使LED灯31恰好位于透光凸起11内，所述FPC板3恰好能与外层1内侧平滑接触，使得与LED灯31较近的FPC板3与外层1之间的间隙最小，即发光灯条能与外层1内侧接触，在高温高压下压注成型时不容易使得FPC板31断裂现象，从而可以提高产品成型时的成品率，降低生产成本。同时由于LED灯31固定在透光凸起11内，LED灯31高出外层1表面，使得LED灯31的出光范围更广。
虽然LED灯31功率小，但亮度较大，考滤到头盔电源容量限制，因而采用LED灯31作为电光源可以提高发光时间，在不考滤电池容量时，当然也可以采用其他的电致发光器件代替LED灯31。
所述外层1与采用EPS材料注塑的内层2紧密结合形成头盔时，由于EPS材料颗粒较大，很难进入透光凸起11形成的较小空腔，因而头盔成型后，所述透光凸起11内除LED灯31外都是空的，造成透光凸起11受力强度小，当透光凸起11轻微碰撞时容易出现变形，容易损坏透光凸起11内的LED灯31。
为了解决头盔成型后的透光凸起11受力时容易变形和损坏LED灯31问题，如图5-图7所示，上述实施例的基础上还提供另一种发光头盔实施例。
具体地说，所述透光凸起31的外侧设有环形凸条14，在环形凸条14与透光凸起11之间形成环形凹槽15，其他结构与上述实施例相同。由于在透光凸起31的外侧设有环形凸条14，可以对透光凸起31起到保护作用，同时 增加透光凸起31的整体强度。
为了进一步增加LED灯31出射光的角度，在透光凸起11形成的空腔或透光凸起11与环形凸条14一起形成的空腔内设有包覆LED灯的透光介质5，该透光介质可以是PC或硅胶材料，也可以是其他可以透光材料。由于透光介质的折射率大于空气，可以使LED灯31通过透光介质5出射光的出射角度更大，有利于增加LED灯31出射光的可视范围。同时透光介质5是在内层2高温和高压成型前进行填充，使得与LED灯31较近的FPC板3与外层1之间的间隙被填充，既可以对FPC板3进行保护，也可以对LED灯31起到保护，还能增加透光凸起11受力强度。
由于LED灯31作为光源，其光亮度大，较刺眼，影响视线；尤其是设置多个LED灯31时，会严重影响视线，可以在所述透光凸起11的上设有使光柔和的柔光涂层，该柔光涂层包括网格状透光栅格12，如图8所示。所述网格状透光栅格12设在透光凸起11的内侧或外侧。可以使LED灯31通过网格状透光栅格1后光线更为柔和，减少视觉的干扰。
所述网格状透光栅格12在在固定FPC板3和LED灯31前进行丝印、喷涂等，也可以在内层3与外层1结合形成头盔主体后进行，相比较而言在头盔主体成型后再丝印、喷涂等方式制作网格状透光栅格12时，由于透光凸起11呈半球或球冠等形状，增加工艺难度。
当网格状透光栅格12在内层2与外层1结合形成头盔主体后进行丝印、喷涂时，只能设置在透光凸起11的外侧，相比较而言在内层2成型后丝印网格状透光栅格12时由于透光凸起11呈半球等形状，增加工艺难度，同时也容易掉落。
由于内层1与外层2材料不同，为了保证内层1与外层2在融合成型时能更好紧密结合，在外层2的内侧涂上与内层2融合的涂层步骤，即在外层2成型后在其内侧涂上银层。通常情况下，由于PC片为无色，为了美观在PC片适应当位置丝印、喷涂上图案层，再在图案层上喷涂上保护层，所述银层设 置在保护层上。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (13)

  1. 新型发光头盔，包括由外层和内层构成的头盔主体，以及设于所述内层与外层之间的FPC板，该FPC板上设有至少一颗LED灯，其特征在于：所述LED灯对应位置的外层设有向外侧凸出的透光凸起。
  2. 根据权利要求1所述的发光头盔，其特征在于：所述透光凸起上设有使光柔和的柔光涂层。
  3. 根据权利要求2所述的发光头盔，其特征在于：所述柔光涂层包括网格状透光栅格。
  4. 根据权利要求1或2所述的发光头盔，其特征在于：所述透光凸起内设有包覆LED灯的透光介质。
  5. 根据权利要求1或2所述的发光头盔，其特征在于：所述透光凸起呈球冠状或半球状。
  6. 根据权利要求1或5所述的发光头盔，其特征在于：所述透光凸起外侧设有的环形凸条，该环形凸条与透光凸起之间形成环形凹槽。
  7. 发光头盔生产方法，包括先将部分着色的PC片放置在模具内进行吸塑成型，形成带透光凸起的外层；其次在外层固定设有至少一颗LED灯的FPC板，并使LED灯收纳于透光凸起内；最后将固定有FPC板的外层放置在成型模具内，注入内层材料压注形成与外层紧密结合的头盔主体。
  8. 根据权利要求7所述的发光头盔生产方法，其特征在于：在内层成型前将外层的内侧设有压注时使内层与外层紧密结合的涂层。
  9. 根据权利要求7或8所述的发光头盔生产方法，其特征在于：在进行外层吸塑成型前还包括透光凸起设有使光柔和的柔光涂层。
  10. 根据权利要求9所述的发光头盔，其特征在于：所述柔光涂层包括网格状透光栅格。
  11. 根据权利要求7或6所述的发光头盔生产方法，其特征在于：将设有至少一个LED灯的FPC板固定步骤还包括向透光凸起内注入透光介质，使LED灯被透光介质包覆。
  12. 根据权利要求1所述的发光头盔生产方法，其特征在于：所述透光凸起呈球冠状或半球状。
  13. 根据权利要求9所述的发光头盔生产方法，其特征在于：其特征在于：所述透光凸起外侧设有环形凸条，该环形凸条与透光凸起之间形成环形凹槽。
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CN105342048A (zh) * 2015-12-10 2016-02-24 深圳前海零距物联网科技有限公司 新型发光头盔及制造方法
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