U.S. patent application number 13/990672 was filed with the patent office on 2013-12-26 for impact core for insertion inside an outer shell of a helmet.
This patent application is currently assigned to EGG International B.V.. The applicant listed for this patent is Lars Dekker, Rick Adriaan Keijzer. Invention is credited to Lars Dekker, Rick Adriaan Keijzer.
Application Number | 20130340146 13/990672 |
Document ID | / |
Family ID | 44201206 |
Filed Date | 2013-12-26 |
United States Patent
Application |
20130340146 |
Kind Code |
A1 |
Dekker; Lars ; et
al. |
December 26, 2013 |
IMPACT CORE FOR INSERTION INSIDE AN OUTER SHELL OF A HELMET
Abstract
The invention relates to an impact core for insertion inside an
outer shell of a helmet. The impact core comprises a shock-proof
material and is substantially dome-shaped having cut outs to
increase the flexibility of the impact core. The cut out makes the
impact core deformable and as a result the impact core can be
adjusted according to different head shapes and sizes. The impact
core comprises a substantially star-shaped cut out at a top and a
plurality of elongated edge cut outs near an edge of said impact
core. Further, each of a plurality of arms of said star-shaped cut
out extends downward between two neighboring edge cut outs at the
edge.
Inventors: |
Dekker; Lars; (Den Haag,
NL) ; Keijzer; Rick Adriaan; (Den Haag, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dekker; Lars
Keijzer; Rick Adriaan |
Den Haag
Den Haag |
|
NL
NL |
|
|
Assignee: |
EGG International B.V.
Den Haag
NL
|
Family ID: |
44201206 |
Appl. No.: |
13/990672 |
Filed: |
December 1, 2011 |
PCT Filed: |
December 1, 2011 |
PCT NO: |
PCT/NL2011/050825 |
371 Date: |
August 16, 2013 |
Current U.S.
Class: |
2/411 ;
428/36.92 |
Current CPC
Class: |
A42B 3/12 20130101; Y10T
428/1397 20150115; A42B 3/125 20130101; A42B 3/324 20130101 |
Class at
Publication: |
2/411 ;
428/36.92 |
International
Class: |
A42B 3/12 20060101
A42B003/12 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 1, 2010 |
NL |
2005798 |
Claims
1. An apparatus comprising: an impact core for insertion inside an
outer shell of a helmet, wherein the impact core comprises a shock
proof material and is substantially dome-shaped having cut outs to
increase the flexibility of the impact core, wherein the impact
core comprises a substantially star-shaped cut out at a top of the
impact core and a plurality of elongated edge cut outs near an edge
of the impact core, and wherein each of a plurality of arms of the
star-shaped cut out extends downward between two neighboring edge
cut outs.
2. The impact core according to claim 1, wherein the star-shaped
cut out is a cross-shaped cut out.
3. The impact core according to claim 1, wherein the elongated cut
outs near the edge extend from the edge in a substantially upward
direction.
4. The impact core according to claim 1, wherein each of the arms
extends from the top of the impact core downwardly towards a
respective point located above the edge, and wherein each of the
elongated cut outs extends from the edge upwardly towards a
respective point located below the top of the impact core.
5. The impact core according to claim 1, wherein each arm extends
downwardly to such extent that a lower part of the respective arm
is at least partly located between two neighboring elongated edge
cut outs.
6. The impact core according to claim 1, wherein the impact core is
substantially serpentine-shaped, following a substantially
serpentine-shaped path extending in a circumferential direction of
the impact core, the path running above upper ends of the elongated
edge cut outs and running below lower ends of the arms.
7. The impact core according to claim 1, wherein the impact core
comprises expanded polypropylene.
8. The impact core according to claim 1, wherein the impact core
comprises expanded polyurethane.
9. The impact core according to claim 1, wherein the impact core is
molded.
10. A helmet comprising: an impact core for insertion inside an
outer shell of the helmet, wherein the impact core comprises a
shock proof material and is substantially dome-shaped having cut
outs to increase the flexibility of the impact core, wherein the
impact core comprises a substantially star-shaped cut out at a top
of the impact core and a plurality of elongated edge cut outs near
an edge of the impact core, and wherein each of a plurality of arms
of the star-shaped cut out extends downward between two neighboring
edge cut outs, the helmet further comprising an outer shell, the
impact core being arranged in the outer shell.
11. The helmet according to claim 10, wherein the outer shell
comprises acrylonitrile butadiene styrene (ABS).
12. The helmet according to claim 10, wherein the outer shell has a
thickness of between 0.5-3.5 mm, more preferably between 1.8-2.2
mm.
13. The helmet according to claim 10, wherein the helmet further
comprises a comfort core comprising a substantially helmet shaped
layer arranged at least partly inside the impact core.
14. The helmet according to claim 13, wherein the comfort core
comprises EVA rubber.
15. The helmet according to claim 13, wherein the comfort core
comprises an upper portion being substantially dome-shaped and a
lower portion for surrounding a lower part of the skull of a
user.
16. The helmet according to claim 15, wherein the upper portion of
the comfort core is less thick than the lower part so as to
accommodate the impact core.
Description
FIELD OF THE INVENTION
[0001] The invention relates to helmets and, more particularly, to
impact cores and safety helmets having an impact core.
BACKGROUND OF THE INVENTION
[0002] Typically, a safety helmet provides a user or a wearer
protection from head injury or damage in case of an accident. There
is a wide variety of safety helmets available in the market.
Various examples of safety helmets may include, but are not limited
to, bicycle helmets, motor bike helmets, and racing car
helmets.
[0003] Different users may have different head sizes. Generally, a
shopkeeper measures the size of the user's head with the help of a
measuring instrument, and accordingly provides a helmet from the
variety of helmets present in the shop. The user selects a helmet
after taking numerous fitting trials depending on the ease and
comfort of its fit.
[0004] However, the disadvantage associated with the abovementioned
methods for selecting the best fit safety helmet is that only the
size of the head is taking into.
[0005] Because apart from size, different users also have different
head shapes, a helmet does not fit perfectly around the head. The
user normally chooses a helmet that is comfortable but that does
not fit perfectly. In fact, most often a helmet is chosen which is
too spacious. This may lead to unnecessary injuries when being
involved in an accident.
[0006] In light of the foregoing, there is a need for a comfortable
fit safety helmet according to various head sizes and shapes of
different users.
OBJECT AND SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide a helmet and/or
an impact core that fits better on different heads as compared to
the known helmets and/or impact cores.
[0008] In a first aspect, the invention relates to an impact core
for insertion inside an outer shell of a helmet. The impact core
comprises a shock proof material. The impact core is substantially
dome-shaped and comprises cut outs. The cut outs increases the
flexibility of the impact core. The impact core comprises a
substantially star-shaped cut out at a top of said impact core and
a plurality of elongated edge cut outs near an edge of said impact
core. Each of a plurality of arms of said star-shaped cut out
extends downward between two neighboring cut outs at the edge, or
so called edge cut outs. Further, the flexible impact core can
provide for a deformable and an adjustable helmet for different
head shapes. The plurality of edge cut outs makes the impact core
flexible.
[0009] In an embodiment, the star-shaped cut out is a cross-shaped
cut out. For example, the cross may consist of two substantially
perpendicularly crossing lines. Alternatively, the cross may for
example comprise two lines crossing each other at an angle smaller
than about 90 degrees.
[0010] It is noted that the arms of the star-shape may have
substantially the same length. However, alternatively the length of
the arms may differ from each other.
[0011] In an embodiment, the elongated cut outs near the edge
extend from said edge in a substantially upward direction.
[0012] In an embodiment, each of the arms extends from the top of
the impact core downwardly towards a respective point located above
said edge, and wherein each of the elongated cut outs extends from
the edge upwardly towards a respective point located below the top
of the impact core.
[0013] In an embodiment, each arm extends downwardly to such extent
that a lower part of the respective arm is at least partly located
between two neighboring elongated edge cut outs.
[0014] In an embodiment, the impact core is substantially
serpentine-shaped, following a substantially serpentine-shaped path
extending in a circumferential direction of said impact core, the
path running above upper ends of the elongated edge cut outs and
running below lower ends of the arms. Accordingly, the
serpentine-shaped impact core is deformable in different
directions. Thus, the impact core deforms in different directions
to adjust various head sizes and may provide the best fit helmet to
the user.
[0015] In an embodiment, each of a plurality of arms of the
star-shaped cut out extends vertically downward between two
neighboring cut outs at the edge. With the word `downward` is meant
`towards the edge` of the impact core. A combination of arms of a
top cut out alternating with the edge cut outs, or so called bottom
cut outs, can result in a serpentine-shaped impact core.
[0016] Preferably, the impact core is integrally formed.
Advantageously, the material of the impact core is homogeneous.
[0017] In an embodiment, the impact core comprises expanded
polypropylene. The expanded polypropylene is a multi-impact
material and also flexible. The combination of the expanded
polypropylene being flexible together with the cut outs, results in
a deformable impact core. Since expanded polypropylene is a
multi-impact material, it increases the durability of the helmet.
Alternatively, the impact core is made from another flexible
material or another flexible material composition.
[0018] In an embodiment, the impact core is produced using a
moulding technique. The moulding technique can use a single mold
which considerably reduces the manufacturing time and makes the
overall process simple.
[0019] The invention further relates to a helmet comprising an
impact core as described above. The helmet further comprises an
outer shell, the impact core being arranged in said outer shell.
Preferably, the helmet is a safety helmet.
[0020] In an embodiment, the outer shell of the helmet is made of
acrylonitrile butadiene styrene (ABS). An outer shell of ABS
material is impact resistant, and when it is not excessively thick,
is also slightly flexible, which makes it a preferred material for
the outer shell. Further, in a preferred embodiment, the outer
shell has a thickness in the range of about 0.5 mm to about 3.5 mm,
and more preferably in the range of about 1.8 mm to about 2.2 mm.
The abovementioned thickness of the outer shell helps in achieving
a deformity which results in expansion of the impact core to fit
different head shapes. Additionally, it is easier to wear and
remove the helmet with the abovementioned thickness of the outer
shell. Instead of using ABS, alternative materials may be used for
the outer shell, e.g. Polycarbonate.
[0021] In an embodiment, the helmet furthermore comprises a comfort
core, and in a particular embodiment, the comfort core is
substantially helmet-shaped layer arranged at least partly inside
the impact core. The comfort core is made of Ethylene vinyl acetate
(EVA) rubber. Also, the comfort core comprises an upper portion and
a lower portion. The upper portion is substantially dome-shaped.
The dome shape of the upper portion facilitates a base support to
the impact core. Further, the lower portion surrounds a lower part
of the skull of the user. In a particular embodiment, to provide a
proper fit to the impact core when the comfort core is inserted in
it, the upper portion of the comfort core is less thick than its
lower portion.
[0022] It is noted that, in a preferred embodiment, the helmet
comprises tree layers, substantially placed one inside the other.
The three layered helmet may thus comprise: the outer shell, the
substantially dome-shaped impact core substantially placed in said
outer shell, and the comfort core arranged at least partly inside
said impact core.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention and embodiments thereof will now be further
elucidated by means of figures, wherein:
[0024] FIG. 1 schematically shows a representation of a helmet
according to an embodiment of the present invention; and
[0025] FIGS. 2a, 2b, 2c, 2d, and 2e depicts a top-view, a
side-view, a front-view, a first perspective view, and a second
perspective view, respectively, of the embodiment of FIG. 1.
DESCRIPTION OF THE EMBODIMENTS
[0026] FIG. 1 schematically shows a representation of an embodiment
of a helmet 1 according to an aspect of the invention. The helmet
comprises three layers--a comfort core 2, an impact core 3
according to an aspect of the invention, and an outer shell 4. The
arrangement of the three layers of the helmet 1 is in a manner such
that, the comfort core 2 can be arranged at least partly inside the
impact core 3, and the impact core 3, along with the comfort core
2, can be arranged inside the outer shell 4.
[0027] It is noted that the helmet may be a so called safety
helmet.
[0028] In an embodiment, the comfort core 2 is made of foam or
expanded rubber, such as Ethylene vinyl acetate (EVA) rubber. In
the embodiment of FIG. 1, the comfort core 2 is substantially a
helmet-shaped layer and comprises an upper portion 5 and a lower
portion 6. The upper portion 5 is substantially dome-shaped which
facilitates a base support to the impact core 3. Thus, the impact
core 3 gets the base support from the comfort core 2, and both are
closely fit into the outer shell 4 of the helmet 1. Further, the
lower portion 6 surrounds a lower part of the skull of a user. In a
particular embodiment, the upper portion 5 is less thick than the
lower portion 6 to properly accommodate the impact core 3.
[0029] Further, the outer shell 4 is preferably made of a
shock-proof and a flexible thermoplastic, for example,
acrylonitrile butadiene styrene (ABS). The flexible outer shell 4
easily accommodates the impact core 4 along with the partly fit
comfort core 2. Further, the impact core 3 deforms easily when the
outer shell 4 is flexible. In a particular embodiment, the outer
shell 4 has a thickness in the range of about 0.5 mm to about 3.5
mm, and more preferably in the range of about 1.8 mm to about 2.2
mm. The outer shell 4 is preferably made thin, so that the outer
shell 4 is deformable to fit different head shapes and sizes apart
from being only strong. Additionally, the helmet 1 is easier to
wear and remove from the head.
[0030] Furthermore, the second layer, i.e, the impact core 3 of the
helmet 1 is substantially dome-shaped and comprises a shock-proof
material. The shock-proof material in the impact core 3 makes the
helmet 1 robust and protects the user in case of accidents. In an
embodiment, the impact core 3 comprises a number of edge cut outs,
or so called bottom cut outs, such as 7, 8, 9, and 10. It should be
noted that four edge cut outs, i.e., 7, 8, 9, and 10 have been
depicted in FIG. 1 only for exemplary purposes. However, the impact
core 3 may have any multiple number of edge cut outs to provide
proper fit to the different head shapes and sizes of the users, for
example three or four edge cut outs.
[0031] Additionally, each of the edge cut outs 7, 8, 9, and 10
extends from the edge in a substantially upward direction. This is,
each edge cut out 7, 8, 9, and 10 starts from an edge of the impact
core 3. It may be apparent to any person skilled in the art that
the edge may be defined as the circumferential boundary of the
surface of the substantially dome-shaped impact core 3. It may be
also appreciated by a person skilled in the art that the edge cut
outs 7, 8, 9 and 10 provide sufficient space for expansion of the
impact core 3 to adjust according to the different head shapes of
different users.
[0032] FIGS. 2a, 2b, 2c, 2d, and 2e depicts a top-view, a
side-view, a front-view, a first perspective view, and a second
perspective view, respectively, of the embodiment of FIG. 1.
[0033] FIG. 2a depicts the top view of the impact core 3 of FIG. 1.
In this embodiment, four cut outs 11, 12, 13, and 14 are arranged
at top of the impact core 3. These cut outs 11, 12, 13, and 14 are
slit-shaped and combine together to form a substantially
star-shaped cut out at the top of the impact core 3 and can
alternatively be referred to as the arms of the star-shaped cut
out. Additionally, the impact core 3 comprises numerous other
elongated cut outs, i.e. the edge cut outs 7, 8, 9, and 10 near the
edge of the impact core 3 (as shown in FIG. 2a). In this
embodiment, the arms 11, 12, 13, and 14 of the star-shaped cut out
extends vertically downward between two neighboring cut outs from
the cut outs 7, 8, 9, and 10 at the edge. It should be noted that
these cut outs will be collectively referred as 7-14 in the
subsequent paragraphs.
[0034] It may be apparent to any person skilled in the art that,
although the star-shaped cut out is cross-shaped in the shown
embodiment, the star-shaped cut out can alternatively have another
star-shape, and may for instance have three or five arms.
[0035] The cut outs 7-14 are of predefined length and width to
provide maximum flexibility to the impact core 3. In the example of
FIG. 2a, the width of each of the slits 7-14 is about 10 mm.
Furthermore, the pre-defined angle of separation between two
subsequent cut outs at the edge 7 and 10 is preferably about 90
degrees. However, other angles of separation are possible, such as
about 45, 72, 75 or 120 degrees. Typical dimensions of the impact
core 3 are shown in FIG. 2a. It is noted that other dimension are
possible.
[0036] As will be appreciated by the skilled person, the edge cut
outs may be evenly distributed around the impact core 3. However,
the edge cut outs 7, 8, 9, and 10 may be placed closer to each
other at a first part of the impact core than at another part of
said impact core. For example, the angle of separation may be
smaller at a back side than at a front side of said impact core, or
vice versa.
[0037] As will be appreciated by the skilled person, the cut-outs
can be of varying shapes, and the invention is by no means limited
to the use of slit-shaped cut outs. It should however be noted that
the cut-outs can not be too wide, since then, the protection of the
head will be compromised.
[0038] FIGS. 2b, 2c, 2d, and 2e depict the side-view, the
front-view, the first perspective view, and the second perspective
view, respectively, of the impact core 3. As shown in FIGS. 1, 2a,
2b, 2d, and 2e, the arm 12 of the star-shaped cut out extends
vertically downward between two neighboring cut outs 7 and 8 at the
edge. The combination of the top cut outs (or arms of the
star-shaped cut out) 11, 12, 13, and 14 alternating with the bottom
cut outs 7, 8, 9, and 10 results here in a serpentine-shaped impact
core 3 which is deformable in different directions.
[0039] Although the arms 11-14 and the edge cuts outs 7-10 are
preferably alternating, it may be apparent to any person skilled in
the art that, instead of one intermediate edge cut out 8, a
multiple number of edge cut outs may be provided between two
subsequent arms 12 and 13 of the top cut out.
[0040] As best can be seen in FIG. 2d, each of the arms 11-14 of
the top cut out can extend from the top of the impact core 3
downwardly towards a respective point 12b and 13b located above
said edge. In other words, each of the arms 11-14 of the top cut
out can start at said top, can extends downwardly towards the edge
of the impact core 3, and can come to an end before reaching said
edge.
[0041] Further, each of the elongated cut outs can extend from the
edge upwardly towards a respective point 7b, 8b, and 9b located
below the top of the impact core 3. In other words, each of the
elongated edge cut outs 7-10 can start at the edge, can extend
upwardly towards the top and can come to an end before connecting
with the arms 11-14.
[0042] In the shown embodiment, each arm 11-14 extends downwardly
to such extent that a lower part 13a of the respective arm 13 is at
least partly located between two neighboring elongated edge cut
outs 8 and 9.
[0043] In the shown embodiment, the impact core 3 is further
substantially serpentine-shaped, following a substantially
serpentine-shaped path extending in a circumferential direction of
said impact core. The path, schematically shown in FIG. 2d with
dotted line 15, is running above upper ends 7', 8', and 9' of the
elongated edge cut outs and is running below lower ends 12' and 13'
of the arms. Therefore, the path 15 is circumventing said lower
ends of the arms and said upper ends of the edge cut outs.
[0044] The serpentine-shaped path 15 may be substantially
sinus-shaped. Alternatively or additionally, the path 15 may be
formed as a concatenation of semi-circular path sections and/or
substantially apex-shaped path sections.
[0045] Preferably, the path forms a loop. This is, said path may be
endless.
[0046] As best can be seen in FIG. 2e, the impact core 3 can
further comprise air channels formed as air guiding grooves 110,
120, 130, and 140. In the shown embodiment, the air guiding grooves
110-140 are substantially laying in line with the arms 11-14 of the
top cut out. Besides, the edge cuts outs 7-10 may serve as further
air channels.
[0047] Preferably, the impact core 3 is integrally formed, as a
single piece. Further, the impact core 3 may include a single
material or a single material composition.
[0048] In a preferred embodiment, the impact core 3 comprises
expanded polypropylene material (EPP). This material has
advantageous properties, such as the material being multi-impact
and flexible. The combination of the expanded polypropylene
material with the arrangement of the cut outs 7-14 results in a
deformable impact core 3 which is highly durable.
[0049] In an embodiment, the density of the EPP material used for
the impact core 3 lays between 20 and 100 kg/m3, and preferably is
about 60 kg/m3. These densities showed good results during impact
tests.
[0050] Alternatively, the impact core may comprise expanded
Polyurethane (PU) or another flexible material or another flexible
material composition.
[0051] The impact core 3 may be made using moulding technique. The
moulding technique preferably uses a single mold which considerably
reduces the manufacturing time and makes the overall process
simple.
[0052] Instead of using Ethylene vinyl acetate (EVA) rubber, the
comfort core 5 may comprise relative low density EPP or EPS. A
typical density for an EVA rubber comfort core could be about 30
kg/m3.
[0053] Alternatively, the comfort core 5 could comprise textile,
PU, rubber or Neoprene or a combination thereof. With Neoprene for
example, several sheets can be sewed together to form the comfort
core.
[0054] It is emphasized that the present invention can be varied in
many ways, of which the alternative embodiments as presented are
just a few examples. A person skilled in the art will readily
appreciate that various features disclosed in the description may
be modified and that various embodiments disclosed and/or claimed
may be combined without departing from the scope of the invention.
These different embodiments are, hence, non-limiting examples. The
scope of the present invention, however, is only limited by the
subsequently following claims.
* * * * *