Classifications

• • 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
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
• • 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
• • A—HUMAN NECESSITIES
  • A42—HEADWEAR
  • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
  • A42C1/00—Manufacturing hats
  • A42C1/02—Making hat-bats; Bat-forming machines; Conical bat machines; Bat-forming tools
• • A—HUMAN NECESSITIES
  • A42—HEADWEAR
  • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
  • A42C2/00—Manufacturing helmets by processes not otherwise provided for
  • A42C2/005—Forming from solid sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/16—Cooling
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
  • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two-dimensional [2D] structure
  • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two-dimensional [2D] structure the structure being shaped to form a three dimensional configuration
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
  • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
  • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
  • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01C—MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
  • G01C21/00—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00
  • G01C21/10—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration
  • G01C21/12—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning
  • G01C21/16—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning by integrating acceleration or speed, i.e. inertial navigation
  • G01C21/165—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning by integrating acceleration or speed, i.e. inertial navigation combined with non-inertial navigation instruments
  • G01C21/1656—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning by integrating acceleration or speed, i.e. inertial navigation combined with non-inertial navigation instruments with passive imaging devices, e.g. cameras
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
  • G01S19/00—Satellite radio beacon positioning systems; Determining position, velocity or attitude using signals transmitted by such systems
  • G01S19/38—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system
  • G01S19/39—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system the satellite radio beacon positioning system transmitting time-stamped messages, e.g. GPS [Global Positioning System], GLONASS [Global Orbiting Navigation Satellite System] or GALILEO
  • G01S19/42—Determining position
  • G01S19/45—Determining position by combining measurements of signals from the satellite radio beacon positioning system with a supplementary measurement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/56—After-treatment of articles, e.g. for altering the shape
  • B29C44/5681—Covering the foamed object with, e.g. a lining
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
  • B29K2025/04—Polymers of styrene
  • B29K2025/06—PS, i.e. polystyrene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
  • B29K2067/003—PET, i.e. poylethylene terephthalate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/48—Wearing apparel
  • B29L2031/4807—Headwear
  • B29L2031/4814—Hats
  • B29L2031/4821—Helmets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/48—Wearing apparel
  • B29L2031/4842—Outerwear
  • B29L2031/4864—Gloves
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/768—Protective equipment
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
  • G01S19/00—Satellite radio beacon positioning systems; Determining position, velocity or attitude using signals transmitted by such systems
  • G01S19/38—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system
  • G01S19/39—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system the satellite radio beacon positioning system transmitting time-stamped messages, e.g. GPS [Global Positioning System], GLONASS [Global Orbiting Navigation Satellite System] or GALILEO
  • G01S19/396—Determining accuracy or reliability of position or pseudorange measurements

Definitions

• the present invention concerns the field of methods for manufacturing body protections composed of a structural shell and a layer of expanded polystyrene, and the body protections resulting from said method.
• the carcass is the outermost layer of the body protection, that is, the one that receives the impacts in the first place.
• a structural casing is a hard element designed to offer substantial protection against impacts and to distribute stresses over an area greater than that of the impact surface, thus reducing local pressures and therefore reducing the possible direct damage that such impact could. cause on a part of the user's body protected by said body protection.
• Said body protection can be a protection for joints, such as ankles, knees, elbows or shoulders, it can be a protection for long bones of the legs or arms, of extremities such as parts of boots or gloves, or it can be a protection for parts of the torso, although the preferred use for said body protection will be in the form of a helmet for the protection of the head of a user.
• a layer of expanded polystyrene is usually placed that absorbs the energy of large impacts to protect the head contained in the helmet.
• the distribution of forces in a larger area allows a larger section of the expanded polystyrene layer to work on decelerating the impact, thus homogenizing the mechanical response of the assembly to impacts with surfaces of reduced area.
• the structural carcass also has other functions, such as resisting abrasion.
• the proposed body protection can be for example an automotive helmet for a car, motorcycle or other vehicle, bicycle helmets, ski helmets, helmets for adventure activities such as climbing, parachuting, paragliding, sports helmets for example for hockey, baseball, football.
• American, work helmets such as construction helmets, mining helmets, as well as other body protections such as an elbow, a wrist strap, a knee brace, a ankle brace, a shoulder pad, at least part of a boot or a glove, a shin guard, an arm or forearm protection, a cuff, a chest or back protection, etc.
• Body protections which include a shell with a layer of expanded polystyrene adhered to its interior for shock absorption.
• Non-structural housings tend to have a very limited thickness, typically less than 1mm. Commonly these non-structural housings are produced by thermoforming molding from flat, thin sheets. These types of non-structural shells delegate structural impact resistance to an underlying layer of the helmet made of a material suitable for shock absorption, typically expanded polystyrene or Styrofoam.
• Said non-structural casing is often also made of polycarbonate, which has a melting temperature much higher than the temperature reached during the expanded polystyrene overmolding process, so the material is not altered during the overmolding process, but the The adherence of expanded polystyrene to polycarbonate is limited and they often separate over time.
• Structural housings tend to be very thick, several millimeters.
• the structural casing is made of a plastic material, normally a thermoplastic, which can be easily manufactured by injection, achieving an economical and fast manufacturing, but which requires considerable thicknesses to achieve sufficient structural strength, producing structural casings. heavy weights that can be uncomfortable to wear for extended periods of time, or are a disadvantage in competitive sports or high performance situations.
• structural casings made of composite are known, which provide sufficient structural protection with lower thicknesses and therefore less weight.
• thermosetting materials for example epoxy, polyester or vinyl ester resins. Said thermosetting materials cannot be melted or softened by the application of heat once cured, therefore, if these structural shells are used in overmolding processes of expanded polystyrene, they are not altered either, although the adhesion achieved with the thermosetting matrix is not very high. separations may occur.
• the mechanical properties of the set formed by the structural casing plus the impact absorption material is that of a system made up of the two superimposed materials, without any connection to each other.
• the insertion and adhesion process of the two components cannot be automated, thus increasing the final cost of the helmet.
• the present invention concerns, according to a first embodiment, a method of manufacturing a body protection comprising, in a manner known per se in the state of the art, the following steps:
• the structural carcass is the outermost layer of the body protection, which receives impacts directly in the event of an accident.
• Said structural shell defines a concave interior, corresponding to the interior of the helmet intended to house the part of the user's body to be protected.
• a layer of expanded polystyrene is superimposed on said concave interior, which will remain surrounding the part of the user's body, below the structural casing.
• Said layer of expanded polystyrene will suffer deformations and crushing in the event of severe impact, absorbing energy that will not be transferred to the user's body part, likewise, managing the deceleration stroke in such a way as to reduce the maximum acceleration suffered by the head and therefore protecting it.
• the manufacturing stage, by over-molding, of said expanded polystyrene layer on the intrados of the structural shell produces the adhesion of said expanded polystyrene layer to the concave interior of the structural shell through close contact, that is to say that all outer surface of the layer of expanded polystyrene that is facing and attached to the concave interior of the structural casing without the slightest gap or separation between said surfaces or any interposed material such as adhesives, integrating the layer of expanded polystyrene within any nook, relief or texture existing in the concave soffit of the structural casing.
• This close contact is achieved through the process of over-molding the expanded polystyrene layer on the soffit of the structural carcass.
• This process comprises manufacturing manufacture the structural casing, inserting it into a mold, closing the mold, introducing the material constituting the polystyrene pre-expanded and steam at a temperature between 100 and C 130 and C inside said closed mold causing, via an expanding agent, the expansion of the expanded polystyrene that will be shaped by molding against the concave intrados of the structural casing and therefore remaining adhered to it by close contact, without adhesives.
• the close union between both elements also allows them to collaborate structurally, which allows increasing the final resistance of the helmet, improving its functionality, or allows reducing the thickness of the structural shell without losing strength thanks to the structural reinforcement provided by the close union with the layer of expanded polystyrene, which reduces material and weight, reducing costs and improving performance, especially for competition or high-performance uses.
• the present invention proposes, in a way not known in the state of the art, that the stage of manufacturing the structural shell includes the distributed placement, in a mold, of a mixture of thermoplastic material and stable reinforcing fibers at equal temperatures and lower than the melting temperature of the thermoplastic, the closing and heating of the mold above the melting temperature of the thermoplastic, causing the melting of the thermoplastic material without damaging the reinforcing fibers, and subsequent cooling of the mold, hardening the thermoplastic material with the reinforcing fibers embedded in its interior forming a composite material.
• thermoplastics that is, plastics that can be repeatedly melted by heat, have great adhesion to expanded polystyrene, so using this type of thermoplastics greatly improves the structural integrity of the helmet.
• the reinforcing fibers increase the strength of the structural carcass, which again makes it possible to increase the strength of the structural carcass or to maintain the strength by reducing the thickness of the structural carcass, making it lighter and cheaper. Therefore, the combination of the use of a structural shell made of a composite material that includes thermoplastic and reinforcing fibers, together with the use of an expanded polystyrene layer adhered by close contact to the concave interior of the structural shell, provides a helmet with better performance and at a better price than the helmets known in the state of the art, since it allows to obtain a helmet with the same resistance as other known helmets but with a thinner and lighter structural shell, or it allows to obtain a helmet that is more resistant than other known helmets with equal weight, all at moderate manufacturing costs.
• thermoplastic material is introduced into the mold in the form of strands and / or in the form of a coating of the reinforcing fibers.
• thermoplastic material and the reinforcing fibers are introduced into the mold integrated in a fabric-fabric or in a non-woven fabric.
• Said fabric-fabric and / or non-woven fabric can be introduced into the mold forming superimposed layers.
• at least the layers that make up the extrados of the structural shell are made up only of strands of thermoplastic material, a structural shell producing a higher density of reinforcing fibers in its concave interior than in its convex exterior.
• the reinforcing fibers will preferably be long fibers, or long fibers with a length greater than 30mm.
• the reinforcing fibers are preferably selected from glass fiber, carbon fiber, aramid fiber, or a combination of the above.
• thermoplastic is preferably polyethyleneterephthalate, polyethyleneterephthalate low degree of fusion, or polyethyleneterephthalate low grade with a melting temperature comprised between 165 and melting and 190 e.
• the reinforcing fibers account for between 45% and 65%, by total weight, of the structural carcass.
• the part of the mold that defines the concave interior is extracted, it is replaced by a new mold part that defines, together with the part of the mold that has formed the convex exterior of the structural shell, an over-molding chamber that contains the structural shell, and the polystyrene layer is over-molded expanded over the concave interior of the structural casing in said overmolding chamber.
• the present invention concerns, according to a second aspect of the present invention, a body protection, obtained by the method described above, comprising, in a manner known per se:
• the proposed body protection also includes, in a way not known in the state of the art, the following characteristics: the structural shell is made of a composite material comprising a thermoplastic with a certain melting temperature and reinforcing fibers embedded in its Stable interior at temperatures equal to and lower than the melting temperature of thermoplastic.
• the structural carcass can have a higher density of reinforcing fibers in its concave interior than in its convex exterior. This allows the reinforcing fibers to be exposed on the surface of the concave interior, or at least affect the surface finish of said concave interior, producing tiny projections or cavities that improve the adherence of the expanded polystyrene layer, while said imperfections are avoid on the convex exterior of the structural casing.
• the thermoplastic is polyethylene terephthalate, commonly known by the acronym PET.
• a low melting degree polyethylene terephthalate will be used, for example, one that has a melting temperature between 165 e and 190 e , which is beneficial for the carcass molding process and its manufacture is accelerated, reducing its costs.
• a structural casing made of polyethylene terephthalate or polyethylene terephthalate with a low melting degree would present deformations due to the heat applied during the overmolding process of the expanded polystyrene layer, necessary to obtain a close contact joint.
• the inclusion of reinforcing fibers within said thermoplastic prevents this problem and therefore makes it possible to use this thermoplastic material in combination with a layer of expanded polystyrene bonded by close contact without intervening adhesives.
• the reinforcing fibers may preferably be selected from glass fiber, carbon fiber, aramid fiber or a combination of the above. This type of fibers remain unaltered even during the manufacturing process of the structural carcass, which requires the fusion of the thermoplastic where said reinforcing fibers are embedded within a mold for the conformation of the structural carcass.
• said reinforcing fibers will be long fibers, for example, with a length greater than 30mm, which offers a greater reinforcement of the structural carcass.
• the reinforcing fibers will form a weave-weave, that is to say a weave with a warp and mesh structure, therefore, the opposite of a nonwoven fabric.
• a non-woven fabric is also contemplated.
• Said fabric will be the one that will be deposited inside the mold before proceeding to close it and heat it to obtain the structural casing.
• said fabric whether woven-woven or non-woven, includes, in addition to reinforcing fibers, thermoplastic fibers or a thermoplastic coating of the reinforcing fibers before proceeding to close and heat the mold for the manufacture of the carcass. structural.
• thermoplastic fibers or a thermoplastic coating of the reinforcing fibers before proceeding to close and heat the mold for the manufacture of the carcass. structural.
• the thermoplastic that will melt forming the structural casing is also placed, leaving the reinforcing fibers embedded.
• the reinforcing fibers account for between 45% and 65% by total weight of the structural carcass.
• the expanded polystyrene layer will have a minimum thickness of 10mm, preferably at least 15mm.
• the proposed body protection is a helmet, or a full face helmet, an elbow brace, a wrist brace, a knee brace, an ankle brace, a shoulder pad, at least part of a boot or a glove, a shin guard, an arm or forearm protection. , a coquera, a chest or back protection.
• Fig. 1 shows a perspective view of a structural shell such as the one proposed according to an embodiment in which the helmet is a full face helmet
• Fig. 2 shows a sectional view of a full face helmet formed by a structural shell as shown in Fig. 1, with a layer of expanded polystyrene bonded by close contact on the concave interior of the structural shell.
• a structural shell 10 is shown in Fig. 1, which in this example is a structural shell for a full face helmet that includes a lower opening for inserting the wearer's head therethrough, and a front visor opening for the user can see through.
• the structural shell 10 defines a concave interior 11, intended to face and at least partially surround the head of the helmet user, and a convex exterior 12, which will be exposed and will receive the impacts in the first place.
• the structural casing 10 is made of a composite material, that is to say a composite material, which integrates a thermoplastic within which reinforcing fibers are embedded.
• the proposed helmet also includes an expanded polystyrene layer 20 located within the structural shell 10, as shown in Fig. 2.
• the expanded polystyrene layer 20 is attached to the concave interior 11 of the structural shell 10 by means of a tight joint devoid of interposed adhesives, that is, there is no play, space or separation between the structural shell 10 and the expanded polystyrene layer. 20. This is accomplished by over-molding the expanded polystyrene layer 20 onto the structural shell 10.
• the structural casing has a thickness between 2 mm and 4 mm.
• the thermoplastic that integrates the structural shell 10 will be polyethylene terephthalate, commonly known as PET, and the reinforcing fibers will be long glass, carbon or aramid fibers, or even a mixture of the above.
• the polyethylene terephthalate is inexpensive, strong, durable and easy to manufacture, and also allows an excellent bond by close contact with the layer of expanded polystyrene 20.
• the reinforcing fibers embedded within the polyethylene terephthalate increase its structural strength, while preventing it from suffering. deformations during the overmolding process of the expanded polystyrene layer due to heat.
• polyethylene terephthalate of low degree of fusion which is a thermoplastic selected to have a temperature comprised fusion between 165 and and 190 and C.
• This low melting temperature allows reducing and speed manufacturing without compromising endurance. Thanks to the stability provided by the reinforcing fibers, the low-melting polyethylene terephthalate will not deform during the application of the expanded polystyrene layer 20.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Radar, Positioning & Navigation (AREA)
• Remote Sensing (AREA)
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• Thermal Sciences (AREA)
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• General Physics & Mathematics (AREA)
• Automation & Control Theory (AREA)
• Computer Networks & Wireless Communication (AREA)
• Helmets And Other Head Coverings (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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• 2019
  • 2019-11-04 ES ES201931804U patent/ES1239399Y/es active Active
• 2020
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