WO2018145151A1 - A helmet and manufacture thereof - Google Patents
A helmet and manufacture thereof Download PDFInfo
- Publication number
- WO2018145151A1 WO2018145151A1 PCT/AU2018/050088 AU2018050088W WO2018145151A1 WO 2018145151 A1 WO2018145151 A1 WO 2018145151A1 AU 2018050088 W AU2018050088 W AU 2018050088W WO 2018145151 A1 WO2018145151 A1 WO 2018145151A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- shell
- helmet
- inner shell
- density
- outer shell
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 6
- 238000000034 method Methods 0.000 claims abstract description 18
- 239000004794 expanded polystyrene Substances 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 6
- 238000001746 injection moulding Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 description 7
- 239000004417 polycarbonate Substances 0.000 description 3
- 229920000515 polycarbonate Polymers 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 208000027418 Wounds and injury Diseases 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 208000014674 injury Diseases 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/06—Impact-absorbing shells, e.g. of crash helmets
- A42B3/062—Impact-absorbing shells, e.g. of crash helmets with reinforcing means
- A42B3/063—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures
-
- 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
- A42B3/10—Linings
- A42B3/12—Cushioning devices
- A42B3/125—Cushioning devices with a padded structure, e.g. foam
- A42B3/128—Cushioning devices with a padded structure, e.g. foam with zones of different density
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
- A42C2/00—Manufacturing helmets by processes not otherwise provided for
- A42C2/002—In-mould forming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a non-planar shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
- B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/72—Density
- B32B2307/722—Non-uniform density
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2437/00—Clothing
- B32B2437/04—Caps, helmets
Definitions
- the present invention relates to a helmet.
- the invention relates, but is not limited, to a helmet for equestrian sports and to a method of manufacturing the helmet.
- Racing Australia introduced a high performance equestrian standard for helmets in 2012 called ARB HS 2012.
- the standard required the helmets to pass impact requirements over a range of impact forces for each individual test, rather than one impact force for each test.
- the standard also increased the impact attenuation properties of the helmet.
- a helmet for equestrian sports comprising:
- the helmet further comprises an intermediate shell located between the outer shell and the inner shell.
- the intermediate shell is located in at least a side portion of the helmet.
- the intermediate shell is formed as a annular or cylindrical band.
- the inner shell has non-uniform density.
- the inner shell comprises a cranium portion that has a lower density and front, back and side portions of the inner shell have higher densities.
- the lower density portion has a density in the range of about 35 - 60 g/L whereas the higher density portions have a density in the range of about 45 - 70 g/L.
- the inner shell is formed from expanded polystyrene.
- the inner shell is formed from a different material compared to the intermediate shell and/or the outer shell.
- the helmet also comprises a lower shell that is attached to an edge of the outer shell.
- the lower shell is U-shaped in cross-section.
- the lower shell defines opposed side walls and the inner shell has a portion located between the opposed side walls of the lower shell.
- the lower shell is formed from a different material compared to the inner shell, intermediate shell and/or outer shell.
- the helmet meets Australia Standard ARB HS 2012.
- a helmet for equestrian sports comprising:
- the method further comprises forming an intermediate shell in the mould prior to forming the inner shell, wherein the intermediate shell is located between the outer shell and the inner shell.
- the intermediate shell is located in at least a side portion of the helmet.
- the intermediate shell is formed as an annular or cylindrical band.
- the inner shell is formed with a non-uniform density.
- step c) comprises forming the inner shell with a cranium portion that has a lower density and front, back and side portions of the inner shell have higher densities.
- the lower density portion has a density in the range of about 35 - 60 g/L whereas the higher density portions have a density in the range of about 45 - 70 g/L.
- the inner shell is formed from expanded polystyrene.
- the inner shell is formed from a different material compared to the intermediate shell and/or the outer shell.
- the method further comprises forming a lower shell in the mould prior to forming the inner shell so that the lower shell is attached to an edge of the outer shell.
- the lower shell is U-shaped in cross-section.
- the lower shell defines opposed side walls, whereby forming the inner shell in step c) comprises forming the inner shell between the opposed side walls of the lower shell.
- the lower shell is formed from a different material compared to the inner shell, intermediate shell and/or outer shell.
- the outer shell is formed by injection moulding or vacuum moulding.
- a helmet for equestrian sports meeting Australia Standard ARB HS 2012 made by the method of the second aspect.
- Figure 1 is a cross-sectional view of a helmet according an embodiment of the present invention.
- Figure 2A is a cross-sectional view of a helmet according to another embodiment of the present invention.
- Figure 2B is a magnified view of a portion of the helmet of Figure 2A. Detailed Description
- FIG. 1 a helmet 10 according to an embodiment of the present invention is shown in cross-section.
- the helmet 10 comprises an outer shell 1 1 that forms a dome to define the external shape of the helmet.
- the outer shell 1 1 is formed by injection moulding or vacuum moulding a suitable polymeric material such as polycarbonate.
- the outer shell 1 1 is formed by moulding glass and/or carbon fibre.
- Injection moulding enables the outer shell to be formed with a consistent wall section at low cost. Vacuum moulding is better when producing a helmet with vents and for colouring and design (as injection moulding can only produce a single colour outer shell).
- vacuum moulding enables the outer shell to be formed with very thin wall section ( ⁇ 2 mm thick) to reduce the weight of the outer shell in regions which do not require as much impact protection.
- the helmet 10 also comprises a first inner shell 12 that is formed from a hard polymeric material such as polycarbonate.
- the first inner shell 12 is "in-moulded" with respect to the outer shell 1 1 . This involves placing the already formed outer shell 1 1 into a mould and forming the first inner shell 12 with the outer shell 1 1 in the mould. This results in the first inner shell 12 being bonded to the outer shell 1 1 which increases the strength, rigidity, crush resistance and puncture resistance of the helmet 10.
- the first inner shell 12 is shaped, at least in part, as a ring or annular/cylindrical band that extends around the front, back and sides of the helmet 10. That is, the first inner shell 12 forms a dome shape, in part, with an open upper portion. The first inner shell 12 does not extend to the top or cranium portion of the helmet 10. In this respect the first inner shell 12 is shaped to provide additional protection to the front, back and sides of a person's head, which are the parts of the head that are most susceptible to injury in equestrian sports. On this basis, the first inner shell 12 assists in reinforcing a lower portion of the outer shell 1 1 .
- the helmet 10 also comprises a second inner shell 13 that is formed from expanded polystyrene ('EPS').
- the second inner shell 13 is shaped as an inner dome within the outer shell 1 1 .
- the second inner shell 13 is formed over the first inner shell 12 such that the first inner shell 12 is an intermediate shell between the outer and second inner shells 1 1 ,13.
- the second inner shell 13 is also "in-moulded" to the outer shell 11 and also to the first inner shell 12.
- the outer shell 1 1 with the first inner shell 12 already moulded thereto, is placed in a mould and the second inner shell 13 is formed using techniques to mould expanded polystyrene objects known to a skilled person in the art.
- the second inner shell 13 is formed in this manner, it is bonded to the outer shell 1 1 and to the first inner shell 12.
- the second inner shell 13 can be formed with portions at different densities.
- a top or cranium portion 20 of the second inner shell 13 has a relatively lower density than front, back and side portions 21 .
- the weight of the helmet 10 can be reduced by having a lower density in regions not requiring the same amount of strength and rigidity as other regions (ie. the front, back and sides of the helmet).
- the lower density regions have a density in the range of 35 - 60 g/L whereas the higher density regions have a density in the range of 45 - 70 g/L.
- the first inner shell 12 in this embodiment is located adjacent to the front, back and side portions 21 of the second inner shell 13 and does not extend up to the cranium portion 20.
- FIG. 2A and 2B a helmet 1 10 according to another embodiment of the present invention is illustrated.
- the helmet 1 10 is similar to the helmet 10 of Figure 1 .
- Similar features of the helmet 1 10 shown in Figures 2A and 2B are designated with the same reference number but prefixed with the numeral 1 .
- the helmet 1 10 comprises an outer shell 1 1 1 , a first inner shell 1 12 and a second inner shell 1 13.
- the first and second inner shells 1 12, 1 13 are in-moulded to the outer shell 1 1 1 as described above for the inner shells 12, 13 of the helmet 10 shown in Figure 1 .
- the helmet 1 10 of Figures 2A and 2B also comprises a lower shell 130 that forms the lower part of the outer shell 1 1 1 structure of the helmet 1 10.
- the lower shell 130 is formed from a hard polymeric material such as polycarbonate.
- the lower shell 130 is connected to the base of the outer shell 1 1 1 and extends around the bottom lip 125 of the outer shell 1 1 1 .
- the lower shell 130 is also located below the first inner shell 1 12.
- the lower shell 130 has a U-shape with opposed walls 131 , 132 forming part of the inner and outer surfaces of the helmet 1 10 respectively.
- the outer wall 131 has an indentation 133 at its top, which is overlapped by the bottom lip 125 of the outer shell 1 1 1 so that the helmet 1 10 has a smooth finish.
- the lower shell 130 is "in-moulded" with respect to the outer shell 1 11 prior to the second inner shell 1 13 of expanded polystyrene is formed.
- the outer shell 1 1 1 is placed in a mould and the lower shell 130 moulded to the outer shell 1 1 1 so that they are bonded together.
- the polystyrene inner shell 1 13 is moulded to the outer shell, first inner shell 1 12 and lower shell 130 including by having a portion 134 that extends into the lower shell 130 between its opposed walls 131 , 132.
- the construction of the helmets 10, 1 10 according to embodiments of the present invention produces, for example, a helmet that meets the high performance equestrian standard for helmets, ARB HS 2012.
- these helmets have superior impact performance across a range of impact levels (with double the impact attenuation of conventional equestrian helmets), high strength, crush resistance and puncture resistance.
- One advantage of the helmet 1 10 of Figures 2A and 2B over the helmet 10 of Figure 1 is that it is lighter (yet still meets the same standard). However, the helmet 10 of Figure 1 is harder and therefore longer wearing.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Helmets And Other Head Coverings (AREA)
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2018217432A AU2018217432B2 (en) | 2017-02-07 | 2018-02-07 | A helmet and manufacture thereof |
GB1910163.3A GB2572306B (en) | 2017-02-07 | 2018-02-07 | A helmet and manufacture thereof |
AU2024203052A AU2024203052A1 (en) | 2017-02-07 | 2024-05-08 | A helmet and manufacture thereof |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2017900369A AU2017900369A0 (en) | 2017-02-07 | Manufacturing a Helmet | |
AU2017900369 | 2017-02-07 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2018145151A1 true WO2018145151A1 (en) | 2018-08-16 |
Family
ID=63106837
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2018/050088 WO2018145151A1 (en) | 2017-02-07 | 2018-02-07 | A helmet and manufacture thereof |
Country Status (3)
Country | Link |
---|---|
AU (2) | AU2018217432B2 (en) |
GB (1) | GB2572306B (en) |
WO (1) | WO2018145151A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3465363A (en) * | 1968-07-01 | 1969-09-09 | American Safety Equip | Safety helmet sizing band |
US20110047680A1 (en) * | 2009-08-31 | 2011-03-03 | Brian Hoying | Batting Helmet Having Localized Impact Protection |
US20150157083A1 (en) * | 2013-12-06 | 2015-06-11 | Bell Sports, Inc. | Multi-layer helmet and method for making the same |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4075717A (en) * | 1975-02-28 | 1978-02-28 | Lemelson Jerome H | Helmate |
US9814279B2 (en) * | 2013-10-08 | 2017-11-14 | Chang-Hsien Ho | Integrally formed safety helmet structure |
-
2018
- 2018-02-07 WO PCT/AU2018/050088 patent/WO2018145151A1/en active Application Filing
- 2018-02-07 GB GB1910163.3A patent/GB2572306B/en active Active
- 2018-02-07 AU AU2018217432A patent/AU2018217432B2/en active Active
-
2024
- 2024-05-08 AU AU2024203052A patent/AU2024203052A1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3465363A (en) * | 1968-07-01 | 1969-09-09 | American Safety Equip | Safety helmet sizing band |
US20110047680A1 (en) * | 2009-08-31 | 2011-03-03 | Brian Hoying | Batting Helmet Having Localized Impact Protection |
US20150157083A1 (en) * | 2013-12-06 | 2015-06-11 | Bell Sports, Inc. | Multi-layer helmet and method for making the same |
Also Published As
Publication number | Publication date |
---|---|
AU2018217432A1 (en) | 2019-08-01 |
GB201910163D0 (en) | 2019-08-28 |
AU2018217432B2 (en) | 2024-02-08 |
GB2572306B (en) | 2022-01-26 |
AU2024203052A1 (en) | 2024-05-23 |
GB2572306A (en) | 2019-09-25 |
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