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
  • A42B3/064—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures with relative movement between layers
• • 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
  • A42B3/124—Cushioning devices with at least one corrugated or ribbed layer
• • 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
• • 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

Definitions

• the present invention generally relates to protective headwear. More specifically, the present invention relates to helmets protecting a wearer’s head against impacts.
• a helmet is used for absorbing energy caused by the impact, thereby safeguarding the brain.
• helmets are customarily used when cycling, skiing, playing ice hockey, or any other activity during which a person risks on falling with his head on the underground, and/or be hit by an object, such as a hockey puck.
• a helmet typically comprises a shock absorbent material as an inner pad to absorb energy upon impact.
• an outer casing or outer shell covers the inner pad for purposes of additional protection, smooth aerodynamic characteristics and aesthetic reasons.
• a force impacting the outer shell comprises in real life situations both a normal and a tangential component.
• the two components will then be transferred to the inner pad.
• the normal component causes a linear impact on the wearer’s head by pushing on it, depending on the linear absorbing characteristics of the inner pad and the magnitude of the force.
• the tangential component on the other hand causes a rotational movement of the brain within the skull, depending on the direction and, likewise, the magnitude.
• a helmet may be designed in such a way that it reacts differently based on the magnitude and direction or angle of the impacted force on the helmet.
• WO2015089646A1 such a helmet comprising an inner pad configured to react differently on the normal and tangential component of an impacted force.
• the inner pad comprises a complex arrangement of a variety of materials arranged as shock absorbers connected to an array of connectors which deform elastically in response to a tangential component of an impacted force.
• the outer shell of the helmet can move relatively to the shock absorbers such that the tangential component will only partly be transferred to the wearer’s head, thereby reducing the risk of an injury due to a rotational rotation of the brain. It is however a disadvantage that the helmet is hard to assemble due to the complex arrangement.
• a helmet for protecting a wearer’s head comprising:
• a protective layer configured to, when the helmet is impacted by a force, absorb the normal component thereof by compression and rupture when the tangential component of the force exceeds a predefined threshold.
• the helmet protects the head of a wearer when wearing it, for example, during sporting activities, like cycling, skiing, or playing ice hockey.
• the helmet is thus a protective gear worn by the wearer to protect the head from injuries, and more in particular the wearer’s brain.
• the helmet further comprises a protective layer.
• the protective layer covers the wearer’s head, and has a certain thickness, which may depend on the type of activity the helmet is suitable for and the level of comfort it needs to provide in relation to this type of activity.
• the protective layer may further comprise ventilation holes, without restricting its protective characteristics.
• the protective layer is, on the one hand, configured to absorb a normal component from an impacted force, thus when the helmet is impacted by the force on its surface.
• the normal component is the component comprising a direction pointing to the head’s center of gravity at the point of impact on the surface. This force, for example, originates from a wearer’s fall on the ground with his head, or from an object hitting the helmet, for example a hockey puck.
• the normal component of the impacted force is then absorbed by compression.
• the protective layer protects the wearer’s head, and thus his brain, against the normal component by deforming elastically, or plastically depending on the magnitude of the impacted force and the modulus of elasticity of the protective layer.
• the protective layer does not transfer the tangential component to the wearer’s head or to an additional elastic or plastic layer but absorbs the tangential components largely by the rupturing of the protective layer.
• the impacted force may also comprise a tangential component, depending on the angle by which the force impacts the curved surface and transfers it to the protective layer.
• the tangential component is thus the tangent component at the point of impact perpendicular to the normal component.
• the protective layer is configured to rupture when the tangential component of the force exceeds a predefined threshold. In other words, when the tangential component of the force exceeds the predefined threshold, the protective layer breaks or ruptures.
• the protective layer absorbs the tangential component by rupturing instead of compression.
• the energy originating from the tangential component of the impacted force ruptures the protective layer.
• the effects of the tangential component are mitigated through cracking under the loading distribution that the tangential component creates.
• the rupturing has the further advantage that it becomes easily visible that the helmet is unsuitable for further use. This way, it is prevented that the wearer continues to wear the helmet when its protective characteristics are significantly reduced, or even absent.
• a continuous elastically or plastically deformation as a reaction to a tangential component of an impacted force results in a reduction of the protective characteristics of the helmet, especially when the material is frequently bended or sheared and a deterioration over time therefrom is inside the material, while this remains invisible to the wearer, and therefore doesn’t prevent a further inappropriate use.
• the rupturing on the other hand is not only immediately visible, but also ensures that the helmet will no further be used when its protecting capacity may no longer be assured.
• the protective layer comprises closed-cell foam configured to perform said absorbing and said rupturing.
• the protective layer is thus a light-weighted material with a solid structure like, for example, polyethylene foam or polystyrene foam, that is effective in absorbing a linear impact. Furthermore, by using a closed-cell foam, the protective layer may easily be shaped in a desired form in an efficiently and economical manner. Additionally, with a closed-cell foam no clean-cut or sharp edges will arise when rupturing due to the tangential component of the impacted force. In other words, the protective layer will rupture without causing harmful or dangerous spots.
• the closed-cell foam material further allows to provide, besides the desired shape, ventilation holes.
• the protective layer may be produced using only one material, which reduces an occurrence of making errors during the fabrication process
• the closed-cell foam comprises expanded beads.
• the protective layer is thus, for example, an in-mold expanded polystyrene comprising expanded beads which may be compressed and fused.
• the protective layer may then be fabricated using a mixture of beads with different characteristics to achieve the anisotropic strength characteristics of the protective layer.
• a rupture may then be initiated at beads having a lesser density compared to other beads.
• zones in the protective layer may be selected which will be more prone to rupture compared to other zones, such that the helmet may be adapted to the type of activity wherein it will be mainly used.
• beads of a particular colour may be used, or even a mixture of colours for aesthetic reasons or other reasons, such as, for example, when there is a need to distinguish athletes based on the colour of the helmet such as in team sporting. This way, there is no need on further painting the protective layer in a desired colour, yet it may be produced directly in said colour.
• the protective layer comprises:
• protuberances are configured to rupture from the first layer when exceeding the predefined threshold.
• the first layer and the protuberances extending therefrom form the protective layer, wherein the protuberances are configured and designed to rupture for protecting the wearer’s brain against a rotational movement or acceleration when the tangential component of the impacted force exceeds the predefined threshold.
• the rupturing can be controlled as it will appear or initiate at the transition between the layer and protuberances. This way, a good control over the rupturing characteristics by the dimensioning and number of protuberances is achieved.
• the protuberances may be faced towards the wearer’s head when the helmet is worn. This way, the head is in contact with the protective layer at these protuberances, and simultaneously allowing air to flow between the protuberances such that the head remains cool during intensive sporting activities, and at the same time a protection against a rotational movement or acceleration is guaranteed.
• the protuberances may also be faced away from the wearer’s head such that the head is in direct contact with the first layer. This may also be beneficial, for example, when the helmet through the first layer is shaped such that it covers the head in a comfortable and safe manner, while at the outside the protuberances likewise assure a protection against a rotational movement or acceleration.
• the protective layer further comprises a second layer covering the protuberances.
• the second layer may cover the protuberances either on the outside when the protuberances face away from the wearer’s head, either on the inside when the protuberances face towards the wearer’s head.
• the protuberances are protected against external conditions, such as rain and/or dust.
• the second layer when the second layer covers the wearer’s head when the helmet is worn, the second layer may be suitable to absorb sweat during sporting activities and may easily be replaced afterwards, thereby keeping the protuberances of the first layer clean.
• the second layer also comprises protuberances configured to rupture from the second layer when exceeding the predefined threshold.
• the protuberances of the first layer and the protuberances of the second layer face towards each other.
• the first or the second layer covers the wearer’s head, and the other layer, thus the layer not covering the wearer’s head is located on the outside of the helmet.
• the protuberances are present, one extending from the first layer, and one extending from the second layer.
• the protuberances of the first and the second layer protect the wearer’s brain against a rotational movement or acceleration. Additionally, this way the first and second layer may further relatively move to each other, which also provides an additional protection against a rotational movement or acceleration. Furthermore, this way the protective layer is easily to produce, since the first layer with its protuberances may in a straightforward manner put on the second layer with its protuberances.
• the first and second layer are connected with each other by the protuberances.
• the protuberances extending from both layers facing each other may formally or shapely correspond to each other and be arranged on their respective layer in such a way that they may clasp with an opposite protuberance, thereby connecting the first with the second layer.
• the helmet may be assembled by two parts, namely the first layer with protuberances and the second layer likewise with protuberances, from which one is regarded as an outer layer, this is facing the outside, and one layer as the inner layer, this is the layer covering a wearer’s head.
• the inner layer may then be equal for all type of helmets and thus economically be produced, while the outer layer may be adapted to the type of activity it will be used for and afterwards clasp on the inner layer.
• the protuberances of the first layer are interlinked with the protuberances of the second layer.
• the first and the second layer are interlinked or connected through the protuberances.
• the protective layer then comprises one whole comprising the first and second layer joined or interlinked with the protuberances. Between the protuberances, and thus also between the first and second layer, air or another gas may be present, thereby obtaining a light-weighted protective layer providing protection against a linear and rotational impact.
• the protective layer and thus the helmet is suitable for sporting activities wherein a light-weighted helmet is beneficial for delivering a performance like, for example, during time trials.
• the thickness of the protective layer may be reduced by, for example, reducing the space between the protuberances to a minimum.
• the protective layer may easily be assembled, since the protuberances of the first layer may be clicked in the protuberances of the second layer in a straightforward manner.
• the protuberances comprise at least one of the group of:
• a conical protuberance with an elliptic or polygonal base.
• the protuberances may have different shapes, like tubes, beam-shapes or bars, and cones or pyramids. This way, the characteristics of the protuberances with respect to their capacity to rupture when the tangential component is exceeded may be adapted.
• a conical protuberance comprises a base and apex, whereby, through the tapered or conical configuration from its base to its apex, the characteristics change in the longitudinal direction by its varying cross-sections. Hence, the apex will be more prone to rupture, thus prior to a rupturing of the base.
• dedicated spots in the protective layer may be selected which rupture more quickly compared to other spots.
• the bases may be elliptic, or may comprise circles, triangles, rectangles or any other polygonal.
• an equal strength over the longitudinal direction may be preferred, thereby using tubular or beam-shaped protuberances.
• An alternating pattern of protuberances may thus arise and configured such that stresses originating from the tangential component are concentrated in dedicated positions of the protective layer.
• the protective layer comprises a mixture of the beads and second granules.
• the protective layer may comprise, besides the mixture of beads also second granules.
• the second granules have a different composition compared to the beads and are arranged within the protective layer.
• the granules may also be arranged within the protective layer as clusters in a predefined shape.
• the protective layer is further arranged such that the rupturing initiates at a border between the beads and the granules.
• the rupturing may be initiated at the borders thereof, thus at the interfaces between the beads and the granules.
• dedicated spots of the protective layer may be selected wherein the granules are arranged within the protective layer, such that at these borders or interfaces the rupturing is initiated when the tangential component exceeds the predefined threshold.
• the bead and granules have a diameter of around 0.5mm to around 5mm, preferable around 1 mm to around 3mm.
• the beads and the granules may have the same diameter such that the protective layer may economically be produced by compressing and fusing the beads and granules. Furthermore, since the granules have an equal diameter, the beads will not be damaged by the granules while compressing and fusing.
• the beads have a first density between 50 and 70m 3 . kg, preferably 60m 3 . kg; and the granules correspond to second beads having a second density between 90 and 1 10m 3 . kg, preferably 100m 3 . kg.
• the protective layer may also be assembled using a mixture of beads with different densities, namely a first density of preferably 60m 3 . kg and a second density of preferably 100m 3 . kg. The mixture of beads is then compressed and fused, thereby shaping the protective layer.
• the mixture comprises between 25 and 75 weight percent, preferably 50 weight percent of the beads with the first density.
• the weight percent of the beads with the second density is then determined by the weigh density of the beads with the first density.
• FIG. 1A illustrates a helmet according to an illustrative embodiment of the invention.
• Fig. 1 B illustrates the helmet of Fig. 1 A with a cross-sectional view
• Fig. 2A illustrates a protective layer according to a first illustrative embodiment of the invention comprising a first and second layer and protuberances
• Fig. 2B illustrates the protective layer of Fig. 2B comprising ruptured protuberances
• Fig. 3A illustrates a protective layer according to a second illustrative embodiment of the invention comprising a first and second layer and protuberances;
• Fig. 3B illustrates a protective layer similar to the illustrative embodiment of Fig. 3A comprising protuberances that are reversely oriented;
• FIG. 4A illustrates a protective layer according to a third illustrative embodiment of the invention comprising a first and second layer and protuberances;
• Fig. 4B illustrates a protective layer according to a fourth illustrative embodiment of the invention comprising a first and second layer and protuberances;
• Fig. 5A illustrates a protective layer according to a fifth illustrative embodiment of the invention comprising a first layer and protuberances;
• Fig. 5B illustrates the protective layer of Fig. 5A comprising ruptured protuberances
• Fig. 6 illustrates a protective layer according to a sixth illustrative embodiment of the invention.
• FIG. 1A illustrates a helmet according to an illustrative embodiment of the invention and Fig. 1 B illustrates the same helmet with a cross-sectional view.
• the helmet 100 is suitable to be worn during sporting activities like, for example, cycling or skiing. When the helmet 100 is worn, the wearer’s head is in the position 107.
• the helmet 100 may comprise a clasp or buckle 1 10 which can be wrapped around the wearer’s chin when worn to secure a safe wearing of the helmet 100 on the head during activities.
• the helmet 100 may further comprise an outer shell 101 , and ventilation holes 1 1 1 .
• the outer shell 101 may function as a protective layer against external conditions, such as wind or rain, and the ventilation holes may function to manage a heat regulation of the wearer’s head, and/or for reasons of aerodynamics, and/or aesthetics. It should be further understood that these functionalities 1 10 and 1 1 1 are illustrative and may vary on the type of activity for which the helmet is designed for, or even may be absent.
• the helmet 100 comprises a protective layer 106, which is illustrated in the cross-sectional view 120 in Fig. 1 B.
• the protective layer 106 has a curved surface 1 12 on the outside and it may further be covered by the outer shell 101 .
• the curved surface 1 12 of the protective layer 106 may itself comprise the outer layer of the helmet 100, meaning that there is no outer shell 101 .
• the helmet 100 may be impacted by a force, illustrated by the impacted force 105.
• This force may, for example, originate from a fall on the ground, or from a hit by an object.
• the magnitude and direction of the impacted force 105 is a prior not known but may be presented by a vector 105 comprising a normal component 102 and a tangential component 103.
• the vector 105 further points to point 104 which represents the point of impact. It should be however further understood that the point of impact may also comprise an area or zone of impact depending on the surface whereupon the wearer of the helmet 100 falls, or the shape and size of the object that hits the helmet 100.
• the impacted force 105 is further illustrated in Fig. 2A that illustrates the protective layer 106 comprising a first or outer layer 200 and a second or inner layer 201 .
• the protective layer 106 in this first illustrative embodiment further comprises protuberances 202 extending from both layers 200 and 201 and connecting the layers 200 and 201 with each other.
• the force 105 impacts the protective layer 106 at the outside therefrom thus at the curved surface 1 12, and the tangential component 103 thereof is transferred to the other zones of the protective layer 106.
• the normal component 102 is transferred as well to the other zones of the protective layer 106.
• the impacted force 105 first impacts the outer shell 101 , and the force 105 is subsequently transferred to the protective layer 106.
• the normal component 102 is absorbed by the protective layer 106 through compression.
• the protective layer 106 compresses such that the outer layer 200, the protuberances 202 and the inner layer 201 come closer together during compression, and afterwards, when the impacted force 105 is no longer present, the layers 200 and 201 and protuberances 202 may return to their initial shape, or may be deformed plastically, depending on the magnitude of the normal component 102 with respect to the modulus of elasticity of the protective layer 106, yet without breaking or rupturing.
• the tangential component 103 is transferred to the body of the protective layer 106, which is illustrated by arrow 210.
• Arrow 210 thus illustrates that, due to the tangential component 103 of the impacted force 105, that a relative movement of the outer layer 200 with respect to the protuberances 202 and/or the inner layer 201 occurs.
• the protuberances 202 of the protective layer 106 are configured to rupture. The rupturing is thus initiated by the tangential component 103 of the impacted force 105 and depends on the angle under which the impacted force 105 hits 104 the protective layer 106 and the magnitude thereof.
• the rupturing of the protuberances 202 is illustrated by ruptures 21 1 and rupture 212.
• the protuberances 202 in this first illustrative embodiment comprises tubular or beam-shaped protuberances. Because of this the strength characteristics of the protuberances remain equal over their respective longitudinal direction. This means that the protuberances will rupture at a spot where its cross-section is no longer resistant to the predefined threshold. This may, for example, be at the middle of a protuberances, as illustrated by ruptures 21 1 , or at an extremity as illustrated by rupture 212. The position will thus be determined by the location 104 of the impacted force 105 and the way it is transferred 210 to the protuberances 202. Depending on the magnitude and direction of the impacted force 105, a rupturing may also occur at the layer 200, as illustrated by rupture 213.
• the outer layer 200 is detached 203 from the inner layer 201 . It may further occur that only a part of the protuberances is ruptured. In other words, the rotational impact or acceleration originating from the impacted force 105 and more in particular the tangential component 103 thereof is then absorbed by the rupturing of a part of the protuberances, while other protuberances remain intact.
• the protuberances may also comprise other shapes compared to a tubular or beam-shapes.
• a second illustrative embodiment of the invention is illustrated comprising conical protuberances 300 such as cone 302.
• a cone is a three-dimensional geometric shape tapering smoothly from a base to an apex, wherein the base and the apex may be circular, but may also comprises any other polygonal shape.
• the protuberances 300 may thus also for example comprise pyramids.
• the conical protuberances 300 are connected to the outer layer 200 by their respective apex, as illustrated by apex 31 1 , and by their respective base to the inner layer 201 , such as base 310.
• the configuration may also be reverse, this is the bases are connected to the outer layer 200 and the apexes to the inner layer 201 , as illustrated by protuberances 301 of Fig. 3B.
• the strength characteristics vary because of the varying cross-sections.
• stresses originating therefrom may be concentrated at the apex of the conical protuberances, such that the rupturing is initiated at these apexes. This is illustrated by rupture 312 at the outer layer 200, and by rupture 313 at the inner layer 201 .
• a rupturing may also occur at the outer layer 200, as illustrated by rupture 314.
• the conical protuberances may also be arranged in an alternating pattern as illustrated in Fig. 4A by protuberances 400.
• the direction of the tapered configuration may be altered, and the embodiment may further comprise beam-shaped and/or tubular protuberances.
• the pattern of the protuberances may be adapted such that it comprises a variety of shapes, cross-sections and/or arrangement.
• a part of the protuberances 400 may also extend from the outer layer 200, while the other part extends from the inner layer 201 , whereby the outer 200 and inner 201 layer are connected to each other by the protuberances.
• the protuberances of both layers 200 and 201 may also be interlinked as illustrated in Fig. 4B by a fourth illustrative embodiment of the protective layer 106.
• the protuberances 401 are shaped in such a way that they interlink or clasp with opposite protuberances.
• protuberance 403 extending from the outer layer 200 clasps with protuberance 402 extending from the inner layer 201 .
• a pattern of interlinked protuberances 401 together with the inner 201 and outer 200 layer forms the protective layer 106.
• the protective layer 106 may comprise one layer with protuberances extending therefrom, as illustrated in Fig. 5A and Fig. 5B.
• the layer 500 from where the protuberances 502 extend may be the outer layer of the helmet 100, or may be the inner layer, thus where the wearer’s head 107 is located when worn.
• the impacted force 105 is then either transferred 503 to the protuberances 502, or the protuberances 502 are directly impacted by the force.
• the protuberances 502 are likewise configured to rupture when the tangential component 103 of the impacted force 105 exceeds the predefined threshold. This is illustrated by ruptures 510 in Fig. 5B.
• the protective layer 106 may also, according to a sixth embodiment, comprise one whole shape 600, for example, an in-mold expanded polystyrene comprising expanded beads and granules 602.
• the granules 602 are arranged such that the rupturing, when the tangential component 103 exceeds the predefined threshold, is initiated at the borders of the granules 602. The rupturing may then result in a rupture 601 over a whole length of the protective layer 106.
• the protective layer as illustrated in Fig. 6A may also comprises one whole shape without the granules 602 but comprising a mixture of beads with different densities.
• top, bottom, over, under, and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

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• 2018
  • 2018-10-16 EP EP21174467.7A patent/EP3903616B1/en active Active
  • 2018-10-16 PT PT182008359T patent/PT3590375T/pt unknown
  • 2018-10-16 ES ES18200835T patent/ES2887074T3/es active Active
  • 2018-10-16 EP EP18200835.9A patent/EP3590375B1/en active Active
• 2019
  • 2019-09-30 AU AU2019363059A patent/AU2019363059A1/en active Pending
  • 2019-09-30 CN CN201980067908.5A patent/CN112839538A/zh active Pending
  • 2019-09-30 JP JP2021520978A patent/JP2022505077A/ja active Pending
  • 2019-09-30 US US17/285,014 patent/US20210315307A1/en active Pending
  • 2019-09-30 WO PCT/EP2019/076385 patent/WO2020078700A1/en active Application Filing

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