U.S. patent application number 15/713517 was filed with the patent office on 2019-03-28 for interlocking co-molded helmet energy management liner.
The applicant listed for this patent is Bell Sports, Inc.. Invention is credited to Samuel J. Shaffer.
Application Number | 20190090574 15/713517 |
Document ID | / |
Family ID | 63556255 |
Filed Date | 2019-03-28 |
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United States Patent
Application |
20190090574 |
Kind Code |
A1 |
Shaffer; Samuel J. |
March 28, 2019 |
INTERLOCKING CO-MOLDED HELMET ENERGY MANAGEMENT LINER
Abstract
A helmet includes a helmet body with an outer shell and an
in-molded energy management liner inside the outer shell. The
in-molded energy management liner may include an inner liner of a
first material and an outer liner of a second material different
from the first material, with at least one hole through the inner
liner, an inside surface, an outside surface, and sides connecting
the inside surface with the outside surface. The outer liner formed
around the inner liner such that the outer liner extends through
the at least one hole and around at least two of the sides of the
inner liner, covering a majority of the outside surface and at
least a portion of the inside surface, and both the inner liner and
the outer liner are exposed on an inside of the in-molded energy
management liner.
Inventors: |
Shaffer; Samuel J.; (Santa
Cruz, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bell Sports, Inc. |
Scotts Valley |
CA |
US |
|
|
Family ID: |
63556255 |
Appl. No.: |
15/713517 |
Filed: |
September 22, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/08 20130101; A42C
2/002 20130101; A42B 3/063 20130101; A42B 3/066 20130101; A42B
3/125 20130101; A42B 3/128 20130101 |
International
Class: |
A42B 3/06 20060101
A42B003/06; A42C 2/00 20060101 A42C002/00; A42B 3/12 20060101
A42B003/12; A42B 3/08 20060101 A42B003/08 |
Claims
1. A helmet comprising: a helmet body having an outer shell and an
in-molded energy management liner inside the outer shell, wherein
the in-molded energy management liner includes: an inner liner of
expanded polypropylene (EPP) having at least one hole through the
inner liner, an inside surface, an outside surface, and sides
connecting the inside surface with the outside surface; and an
outer liner of expanded polystyrene (EPS) formed around the inner
liner such that the outer liner extends through the at least one
hole and around at least two of the sides of the inner liner,
covering a majority of the outside surface and at least a portion
of the inside surface; and a fit system disposed within the
in-molded energy management liner and coupled to the helmet
body.
2. The helmet of claim 1, wherein the inner liner comprises one or
more standoffs extending outward through the outside surface of the
outer liner.
3. The helmet of claim 1, wherein both the inner liner and the
outer liner are exposed on an inside of the in-molded energy
management liner.
4. The helmet of claim 1, wherein the outer liner engages the inner
liner mechanically and without a chemical bond.
5. The helmet of claim 1, wherein the outer liner extends at least
partially around all of the sides of the inner liner.
6. An in-molded energy management liner comprising: an inner liner
of expanded polypropylene (EPP) having at least one hole through
the inner liner, an inside surface, an outside surface, and sides
connecting the inside surface with the outside surface; and an
outer liner of expanded polystyrene (EPS) formed around the inner
liner such that the outer liner extends through the at least one
hole and around at least two of the sides of the inner liner,
covering a majority of the outside surface and at least a portion
of the inside surface.
7. The in-molded energy management liner of claim 6, wherein the
inner liner comprises one or more standoffs extending outward
through the outside surface of the outer liner.
8. The in-molded energy management liner of claim 6, wherein both
the inner liner and the outer liner are exposed on an inside of the
in-molded energy management liner.
9. The in-molded energy management liner of claim 6, wherein the
outer liner engages the inner liner mechanically and without a
chemical bond.
10. The in-molded energy management liner of claim 6, wherein the
outer liner extends at least partially around all of the sides of
the inner liner.
11. A method of assembling a multi-liner helmet, comprising:
injecting a first material into an inner-liner mold to form an
inner liner; placing the inner liner in an outer-liner mold; and
injecting a second material different from the first material into
the outer-liner mold to form an outer liner around the inner liner;
wherein the outer liner extends through at least one hole in the
inner liner and around at least two of sides of the inner liner,
covering a majority of an outside surface of the inner liner, and
both the outer liner and the inner liner are exposed on an inside
of an in-molded energy management liner comprising the inner liner
and the outer liner.
12. The method of claim 11, wherein the first material is expanded
polypropylene (EPP) and the second material is expanded polystyrene
(EPS).
13. The method of claim 11, wherein the inner liner comprises
standoffs extending outward and injecting a second material
comprises injecting the second material such that the standoffs
extend outward through an outside surface of the outer liner.
14. A helmet comprising: a helmet body having an outer shell and an
in-molded energy management liner inside the outer shell, wherein
the in-molded energy management liner includes: an inner liner of a
first material having at least one hole through the inner liner, an
inside surface, an outside surface, and sides connecting the inside
surface with the outside surface, and an outer liner of a second
material different from the first material formed around the inner
liner such that the outer liner extends through the at least one
hole and around at least two of the sides of the inner liner,
covering a majority of the outside surface and at least a portion
of the inside surface, and both the inner liner and the outer liner
are exposed on an inside of the in-molded energy management
liner.
15. The helmet of claim 14, further comprising a fit system
disposed within the in-molded energy management liner and coupled
to the helmet body.
16. The helmet of claim 14, wherein the first material is EPP and
the second material is EPS.
17. The helmet of claim 14, wherein the inner liner comprises one
or more standoffs extending outward through the outside surface of
the outer liner.
18. The helmet of claim 14, wherein the outer liner engages the
inner liner mechanically and without a chemical bond.
19. The helmet of claim 14, wherein the outer liner extends at
least partially around all of the sides of the inner liner.
Description
TECHNICAL FIELD
[0001] Aspects of this document relate generally to assembling
multiple helmet liners, and more specifically to a helmet
comprising a co-molded energy management liner and methods for
assembling such a helmet.
BACKGROUND
[0002] Protective headgear and helmets have wide uses. Multiple
liners are used for comfort and protection. To assemble a
multi-liner helmet, the liners are glued together or fastened
together through components like plastic parts or pins, which
requires additional manufacturing parts and steps. Further, the
glue or the fastening components may deteriorate with time or use
and lose its strength in holding the liners together. As a result,
the multiple liners may separate and fall apart.
SUMMARY
[0003] According to an aspect of the disclosure, a helmet may
comprise a helmet body and a fit system, an outer shell and an
in-molded energy management liner inside the outer shell. The
in-molded energy management liner may include an inner liner of
expanded polypropylene (EPP) and an outer liner of expanded
polystyrene (EPS) with at least one hole through the inner liner,
an inside surface, an outside surface, and sides connecting the
inside surface with the outside surface. The outer liner may be
formed around the inner liner such that the outer liner extends
through the at least one hole and around at least two of the sides
of the inner liner, covering a majority of the outside surface and
at least a portion of the inside surface. The fit system is
disposed within the in-molded energy management liner and coupled
to the helmet body.
[0004] Particular embodiments may comprise one or more of the
following features. One or more standoffs extending outward through
the outside surface of the outer liner. Both the inner liner and
the outer liner may be exposed on an inside of the in-molded energy
management liner. The outer liner may engage the inner liner
mechanically and without a chemical bond. The outer liner extending
at least partially around all of the sides of the inner liner.
[0005] According to an aspect, an in-molded energy management liner
may comprise an inner liner of expanded polypropylene (EPP) and an
outer liner of expanded polystyrene (EPS). The inner liner of
expanded polypropylene (EPP) may have at least one hole through the
inner liner, an inside surface, an outside surface, and sides
connecting the inside surface with the outside surface. The outer
liner of expanded polystyrene (EPS) may be formed around the inner
liner such that the outer liner extends through the at least one
hole and around at least two of the sides of the inner liner,
covering a majority of the outside surface and at least a portion
of the inside surface.
[0006] Particular embodiments may comprise one or more of the
following features. One or more standoffs extending outward from
the inner liner through the outside surface of the outer liner.
Both the inner liner and the outer liner may be exposed on an
inside of the in-molded energy management liner. The outer liner
may engage the inner liner mechanically and without a chemical
bond. The outer liner may extend at least partially around all of
the sides of the inner liner.
[0007] According to an aspect, a method of assembling a multi-liner
helmet may comprise injecting a first material into an inner-liner
mold to form an inner liner, placing the inner liner in an
outer-liner mold, and injecting a second material different from
the first material into the outer-liner mold to form an outer liner
around the inner liner, wherein the outer liner extends through at
least one hole in the inner liner and around at least two of sides
of the inner liner, covering a majority of an outside surface of
the inner liner, and both the outer liner and the inner liner are
exposed on an inside of an in-molded energy management liner
comprising the inner liner and the outer liner.
[0008] Particular embodiments may comprise one or more of the
following features. The first material may be expanded
polypropylene (EPP) and the second material may be expanded
polystyrene (EPS). The inner liner may comprise standoffs extending
outward and injecting a second material comprises injecting the
second material such that the standoffs extend outward through an
outside surface of the outer liner.
[0009] According to an aspect, a helmet may comprise a helmet body
with an outer shell and an in-molded energy management liner inside
the outer shell that includes an inner liner of a first material
and an outer liner of a second material different from the first
material. The inner liner may have at least one hole through the
inner liner, an inside surface, an outside surface, and sides
connecting the inside surface with the outside surface. The outer
liner may be formed around the inner liner such that the outer
liner extends through the at least one hole and around at least two
of the sides of the inner liner, covering a majority of the outside
surface and at least a portion of the inside surface, and both the
inner liner and the outer liner are exposed on an inside of the
in-molded energy management liner.
[0010] Particular embodiments may comprise one or more of the
following features. A fit system disposed within the in-molded
energy management liner and coupled to the helmet body. The first
material may be EPP and the second material may be EPS. The inner
liner may comprise one or more standoffs extending outward through
the outside surface of the outer liner. The outer liner may engage
the inner liner mechanically and without a chemical bond. The outer
liner may extend at least partially around all of the sides of the
inner liner.
[0011] Aspects and applications of the disclosure presented here
are described below in the drawings and detailed description.
Unless specifically noted, it is intended that the words and
phrases in the specification and the claims be given their plain,
ordinary, and accustomed meaning to those of ordinary skill in the
applicable arts. The inventors are fully aware that they can be
their own lexicographers if desired. The inventors expressly elect,
as their own lexicographers, to use only the plain and ordinary
meaning of terms in the specification and claims unless they
clearly state otherwise and then further, expressly set forth the
"special" definition of that term and explain how it differs from
the plain and ordinary meaning. Absent such clear statements of
intent to apply a "special" definition, it is the inventors' intent
and desire that the simple, plain, and ordinary meaning to the
terms be applied to the interpretation of the specification and
claims.
[0012] The inventors are also aware of the normal precepts of
English grammar. Thus, if a noun, term, or phrase is intended to be
further characterized, specified, or narrowed in some way, such
noun, term, or phrase will expressly include additional adjectives,
descriptive terms, or other modifiers in accordance with the normal
precepts of English grammar. Absent the use of such adjectives,
descriptive terms, or modifiers, it is the intent that such nouns,
terms, or phrases be given their plain, and ordinary English
meaning to those skilled in the applicable arts as set forth
above.
[0013] Further, the inventors are fully informed of the standards
and application of the special provisions of 35 U.S.C. .sctn. 112,
6. Thus, the use of the words "function," "means" or "step" in the
Detailed Description or Description of the Drawings or claims is
not intended to somehow indicate a desire to invoke the special
provisions of 35 U.S.C. .sctn. 112, 6, to define the invention. To
the contrary, if the provisions of 35 U.S.C. .sctn. 112, 6 are
sought to be invoked to define the inventions, the claims will
specifically and expressly state the exact phrases "means for" or
"step for", and will also recite the word "function" (i.e., will
state "means for performing the function of [insert function]"),
without also reciting in such phrases any structure, material, or
acts in support of the function. Thus, even when the claims recite
a "means for performing the function of . . . " or "step for
performing the function of . . . ," if the claims also recite any
structure, material, or acts in support of that means or step, or
to perform the recited function, it is the clear intention of the
inventors not to invoke the provisions of 35 U.S.C. .sctn. 112, 6.
Moreover, even if the provisions of 35 U.S.C. .sctn. 112, 6, are
invoked to define the claimed aspects, it is intended that these
aspects not be limited only to the specific structure, material, or
acts that are described in the preferred embodiments, but in
addition, include any and all structures, material, or acts that
perform the claimed function as described in alternative
embodiments or forms in the disclosure, or that are well-known
present or later-developed, equivalent structures, material, or
acts for performing the claimed function.
[0014] The foregoing and other aspects, features, and advantages
will be apparent to those artisans of ordinary skill in the art
from the DETAILED DESCRIPTION and DRAWINGS, and from the
CLAIMS.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Implementations will hereinafter be described in conjunction
with the appended drawings, where like designations denote like
elements, and:
[0016] FIG. 1 is a perspective view of a multi-liner helmet;
[0017] FIG. 2 is a front perspective view of an energy management
liner;
[0018] FIG. 3 is a cross-sectional side view of the energy
management liner shown in FIG. 2, where the outer liner is shown as
transparent;
[0019] FIG. 4 is the cross-sectional side view of the energy
management liner shown in FIG. 2, where the outer liner is shown as
solid;
[0020] FIG. 5 is a flow chart of a method for assembling a
multi-liner helmet.
DETAILED DESCRIPTION
[0021] While this disclosure includes embodiments in many different
forms, they are shown in the drawings and will herein be described
in detailed particular embodiments with the understanding that the
present disclosure is to be considered as an exemplification of the
principles of the disclosed methods and systems, and is not
intended to limit the broad aspect of the disclosed concepts to the
embodiments illustrated.
[0022] Protective head gear and helmets have been used in a wide
variety of applications and across a number of industries including
recreation, sports, athletics, construction, mining, military
defense, and others, to prevent damage to users' heads and brains.
Damage and injury to a user can be prevented or reduced by
preventing hard objects, sharp objects, or both, from directly
contacting the user's head, and also by absorbing, distributing, or
otherwise managing energy of an impact between the object and the
user's head. Straps or webbing are typically used to allow a user
to releasably wear their helmet, and to ensure the helmet remains
on the user's head during an impact.
[0023] Protective headgear or helmets can be used for a snow skier,
a cyclist, football player, hockey player, baseball player,
lacrosse player, polo player, climber, auto racer, motorcycle
rider, motocross racer, snowboarder or other snow or water athlete,
sky diver or any other athlete, recreational or professional, in a
sport. Other non-athlete users such as workers involved in
industry, including without limitation construction workers or
other workers or persons in dangerous work environments can also
benefit from the protective headgear described herein, as well as
the system and method for providing the protective head gear.
[0024] Helmets function to provide protection while minimizing
interference with an activity. The shape of a helmet may be adapted
to provide both protection and comfort (e.g. ventilation, size,
etc.). Some helmets are made of two or more bodies of
energy-absorbing material formed in shapes that would be difficult,
if not impossible, to achieve in a single molded piece.
[0025] Various implementations and embodiments of protective
helmets according to this disclosure comprise a protective shell.
The protective shell may be formed of an energy absorbing material
such as expanded polystyrene (EPS), expanded polyurethane (EPU),
expanded polyolefin (EPO), expanded polypropylene (EPP), or other
suitable material. The energy absorbing material can be used as
part of a hard-shell helmet such as skate bucket helmets,
motorcycle helmets, snow sport helmets, football helmets, batting
helmets, catcher's helmets, or hockey helmets, and include an
additional outer protective shell disposed outside, or over, the
protective shell. In hard shell applications, the energy absorbing
material may comprise one or more layers of EPP and provide more
flexibility. Alternatively, the energy absorbing material may be
part of an in-molded helmet such as a bicycle helmet or cycling
helmet. An outer shell layer, such as a layer of stamped
polyethylene terephthalate or a polycarbonate shell, may be
included on an outer surface of the protective shell of the helmet
and be bonded directly to the energy management liner.
[0026] Contemplated as part of this disclosure is a multi-liner
helmet having a co-molded energy management liner, as well as a
method of assembling such a helmet.
[0027] A helmet 100 comprises a helmet body 102 (FIG. 1). A helmet
100 may further comprise a fit system 400. The helmet body 102
comprises an outer shell 104 and an in-molded or co-molded energy
management liner, energy absorbing liner, or impact liner 200
inside the outer shell 104. The fit system 400 may be disposed
within the in-molded energy management liner 200 and coupled to the
helmet body 102.
[0028] The in-molded energy management liner 200 comprises an inner
liner 202 and an outer liner 300 (FIGS. 2 and 3). In FIG. 3, the
outer liner 300 is depicted as transparent to show the structure of
the inner liner 202. The inner liner 202 and the outer liner 300
may be formed by molding. The inner liner 202 comprises an inside
surface 210, an outside surface 212, and sides 214 connecting the
inside surface 210 with the outside surface 212. The inner liner
202 comprises at least one hole 208 through the inner liner 202.
The outer liner 300 may be formed around the inner liner 202 such
that the outer liner 300 extends through the holes 208 and around
at least two of the sides 214 of the inner liner 202, covering a
majority of the outside surface 212 and at least a portion of the
inside surface 210. In some embodiments, the outer liner 300
extends at least partially around all of the sides 214 of the inner
liner 202. In some embodiments, both the inner liner 202 and the
outer liner 300 are exposed on the inside 216 of the in-molded
energy management liner 200 (FIG. 4). In FIG. 4, the inner liner
202 is depicted in light gray and the outer liner 300 is depicted
in dark gray.
[0029] The inner liner 202 is made of a first material. The outer
liner 300 is made of a second material. The first material and
second materials may be different. The first and second materials
may be of any types of material used to manage energy impact to the
helmet 100. The first and second materials may be any types of
material that can be expanded and, during the process of molding,
formed into bigger objects. The pre-expanded materials are also
called beads. For example, the first or second material may be EPS,
EPP, EPU, or EPO. In some embodiments, the first material is EPP
and the second material is EPS.
[0030] The inner liner may further comprise one or more standoffs
204. In some embodiments, the standoffs 204 extend outward through
the outside surface 302 of the outer liner 300. For example, as
shown in FIG. 2, the standoffs 204 can be seen extending outward
through the outside surface 302 of the outer liner 300. The
standoffs may extend from the sides of the inner liner through the
sides of the outer liner (not shown). The standoffs help hold the
inner liner in place inside an outer-liner mold when the second
materials are injected, often at a high speed, into the outer liner
mold. The inner liner may be held in place in an outer-liner mold
through other methods or structures, such as adhesive tapes and
hooks-and-loops fasteners.
[0031] To assemble a multi-liner helmet, a method 500 may be used
(FIG. 5). Method 500 comprises injecting a first material into an
inner-liner mold to form an inner liner (502), placing the inner
liner in an out-liner mold (504), and injecting a second material
different from the first material into the outer-liner mold to form
an outer liner around the inner liner (506). The outer liner formed
by the method 500 may extend through at least one hole in the inner
liner and around at least two sides of the inner liner, covering a
majority of an outside surface of the inner liner, and both the
inner liner and the outer liner are exposed on an inside of an
in-molded energy management liner comprising the inner liner and
the outer liner. In some embodiments, the first material is EPP and
the second material is EPS. In some embodiments, the inner-liner
comprises one or more standoffs extending outward and injecting a
second material further comprises injecting the second material
such that the standoffs extend outward through an outside surface
of the outer liner.
[0032] When the inner liner and the outer liner are made of
different materials, such as having different densities or
chemicals, the two materials may stay separate and not form a
chemical bond under heat and pressure during molding. The holes 208
of the inner liner 202 allow the second material for the outer
liner to flow through and accumulate on the inside surface 210 of
the inner liner 202 (FIGS. 3 and 4). As a result, the outer liner
300 is formed around, through, and under the inner liner 202 during
the molding, and the two liners 202 and 300 are interlocked and
held together by mechanical forces. No additional manufacturing
parts or steps are required to hold the liners in the energy
management liner together. Because the liners in the energy
management liner are co-molded, the multi-liner helmets made in
this manner are also more compact and lighter than those
manufactured with a conventional method. Further, the design of the
liners, such as the geometries of the liners, is not constrained by
the fastening components used to fasten them together and, thus,
more design freedom is provided.
[0033] This disclosure, its aspects and implementations, are not
limited to the specific components or assembly procedures disclosed
herein. Many additional components and assembly procedures known in
the art consistent with the intended helmets, co-molded energy
management liners, and methods of assembling a multi-liner helmet
will become apparent for use with implementations of the apparatus
and methods in this disclosure. In places where the description
above refers to particular implementations of protective helmets,
it should be readily apparent that a number of modifications may be
made without departing from the spirit thereof and that these
implementations may be applied to other protective helmets. The
presently disclosed implementations are, therefore, to be
considered in all respects as illustrative and not restrictive, the
scope of the disclosure being indicated by the appended claims
rather than the foregoing description. All changes that come within
the meaning of and range of equivalency of the description are
intended to be embraced therein. Accordingly, for example, although
particular helmets, co-molded energy management liners, and methods
of assembling a helmet are disclosed, such apparatus, methods, and
implementing components may comprise any shape, size, style, type,
model, version, class, grade, measurement, concentration, material,
quantity, the like as is known in the art for such apparatus,
methods, and implementing components, and/or the like consistent
with the intended operation of the helmet, co-molded energy
management liners, and methods of assembling a helmet may be
used.
[0034] The word "exemplary," "example," or various forms thereof
are used herein to mean serving as an example, instance, or
illustration. Any aspect or design described herein as "exemplary"
or as an "example" is not necessarily to be construed as preferred
or advantageous over other aspects or designs. Furthermore,
examples are provided solely for purposes of clarity and
understanding and are not meant to limit or restrict the disclosed
subject matter or relevant portions of this disclosure in any
manner. It is to be appreciated that a myriad of additional or
alternate examples of varying scope could have been presented, but
have been omitted for purposes of brevity.
* * * * *