U.S. patent application number 16/486492 was filed with the patent office on 2020-07-23 for climate controlled headgear apparatus.
The applicant listed for this patent is Steve Feher. Invention is credited to Steve Feher.
Application Number | 20200229530 16/486492 |
Document ID | / |
Family ID | 63169621 |
Filed Date | 2020-07-23 |
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United States Patent
Application |
20200229530 |
Kind Code |
A1 |
Feher; Steve |
July 23, 2020 |
CLIMATE CONTROLLED HEADGEAR APPARATUS
Abstract
A headgear apparatus for delivering temperature conditioned air
including passively or actively cooled, heated, or ventilated air
to the interior of a shell is disclosed. A device housing which
enshrouds a device for providing temperature conditioned air is
placed on a rear portion of the shell. The device housing has air
inlets and air rejector vents for delivering fresh air to and
removing heated air from the device, and is configured to reduce
the heated air from re-entering the device through the air inlets.
The headgear apparatus is designed to withstand impact forces
without injuring the wearer.
Inventors: |
Feher; Steve; (Beverly
Hills, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Feher; Steve |
Beverly Hills |
CA |
US |
|
|
Family ID: |
63169621 |
Appl. No.: |
16/486492 |
Filed: |
February 14, 2018 |
PCT Filed: |
February 14, 2018 |
PCT NO: |
PCT/US18/18260 |
371 Date: |
August 15, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62459563 |
Feb 15, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/286 20130101;
A42B 3/285 20130101 |
International
Class: |
A42B 3/28 20060101
A42B003/28 |
Claims
1. A headgear apparatus, comprising: a shell including a first
opening of such dimensions as to permit receipt onto the head of a
wearer, the shell having a top portion shaped to fit over the upper
scalp of the wearer, and a rear portion shaped to fit over at least
a portion of the back of the head of the wearer; a device housing
positioned on the rear portion of the shell, the device housing
comprising a generally curved surface that emerges from an upper
part of the device housing in contact with and emerging away from
the shell extending downward toward the first opening of the shell,
in which the device housing has two generally vertical side-walls
nearly perpendicular from the curved surface, the device housing
forming a cavity between the shell and an outer surface of the
device housing in which an at least one air inlet is formed in the
device housing, the device housing configured for detachment from
the shell upon impact of the headgear apparatus; an air conducting
layer distributed about substantially an entire interior of the
shell; and, a device for producing a pressurized stream of air, the
device receiving intake air from the at least one air inlet of the
device housing and producing a pressurized stream of air in fluid
communication with the air conducting layer.
2. The headgear apparatus of claim 1, in which the at least one air
inlet is formed in both of the two generally vertical side-walls of
the device housing.
3. The headgear apparatus of claim 1, in which the device and the
device housing are configured to deform and absorb energy during an
impact to the headgear apparatus.
4. The headgear apparatus of claim 1, in which the device housing
is removably coupled to the shell.
5. The headgear apparatus of claim 1, in which the device is
detachably coupled to the shell with a hook and loop fastener.
6. The headgear apparatus of claim 2, in which the device housing
further comprises a rejector air outlet for exiting heated air, in
which the rejector air outlet is positioned to prevent the exiting
heated air from entering the at least one air inlet.
7. The headgear apparatus of claim 6, in which the rejector air
outlet is formed in the generally curved surface of the device
housing.
8. The headgear apparatus of claim 6, in which the device is a heat
pump, in which the air moving past a hot place of the heat pump is
exited to the rejector air outlet of the device housing.
9. The headgear apparatus of claim 8 is configured such that air
moving past a cold place of the heat pump is caused to flow forward
through the air conducting layer adjacent the scalp of the
wearer.
10. The headgear apparatus of claim 1. in which the device is a
Positive Coefficient Temperature type resistive heating
element.
11. A headgear apparatus, comprising: a shell including a first
opening of such dimensions as to permit receipt onto the head of a
wearer, the shell having a top portion shaped to fit over the upper
scalp of the wearer, and a rear portion shaped to fit over at least
a portion of the back of the head of the wearer; a device housing
positioned on the rear portion of the shell, an upper part of the
device housing in contact with and emerging away from the shell
extending downward toward the first opening of the shell, the
device housing forming a cavity between the shell and an outer
surface of the device housing, the device housing having at least
one air inlet, the device housing configured for detachment from
the shell upon impact of the headgear apparatus; an air conducting
layer distributed about substantially an entire interior of the
shell; and, a device for producing a pressurized stream of air, the
device receiving intake air from the at least one air inlet of the
device housing and producing a pressurized stream of air in fluid
communication with the air conducting layer.
12. The headgear apparatus of claim 11, in which the device and the
device housing are configured to deform and absorb energy during an
impact to the headgear apparatus.
13. The headgear apparatus of claim 11, in which the device housing
is removably coupled to the shell.
14. The headgear apparatus of claim 11, in which the device is
detachably coupled to the shell with a hook and loop fastener.
15. The headgear apparatus of claim 11, in which the device housing
further comprises a rejector air outlet for exiting heated air, in
which the rejector air outlet is positioned to prevent the exiting
heated air from entering the at least one air inlet.
16. The headgear apparatus of claim 15, in which the device is a
heat pump, in which the air moving past a hot place of the heat
pump is exited to the rejector air outlet of the device
housing.
17. A headgear apparatus, comprising: a shell including a first
opening of such dimensions as to permit receipt onto the head of a
wearer, the shell having a top portion shaped to fit on the upper
scalp of the wearer, and a rear portion shaped to fit on at least a
portion of the back of the head of the wearer; a device housing
positioned on the rear portion of the shell, the device housing in
contact with and emerging away from the shell extending downward
toward the first opening of the shell, the device housing forming a
cavity between the shell and an outer surface of the device
housing, the device housing having at least one air inlet, the
device housing configured for detachment from the shell upon impact
of the headgear apparatus; and, a device for cooling the scalp of
the wearer, the device receiving air from the at least one air
inlet.
18. The headgear apparatus of claim 17, in which the device and the
device housing are configured to deform and absorb energy during an
impact to the headgear apparatus.
19. The headgear apparatus of claim 17, in which the device housing
further comprises a rejector air outlet for exiting heated air, in
which the rejector air outlet is positioned to prevent the exiting
heated air from entering the at least one air inlet.
20. The headgear apparatus of claim 19, in which the device is a
heat pump, in which the air moving past a hot place of the heat
pump is exited to the rejector air outlet of the device housing.
Description
RELATED APPLICATION INFORMATION
[0001] The present application claims priority under 35 U.S.C.
Section 119(e) to U.S. Provisional Patent Application Ser. No.
62/459,563 filed Feb. 15, 2017 entitled "Air Conditioned Helmet,
(ACH) & Convective Headgear," along with PCT App. No.
PCT/US18/18260, filed Feb. 15, 2018, of the same title, the
disclosure of both which are incorporated herein by reference in
their entirety.
BACKGROUND
1. Field
[0002] The present application relates in general to headgear. More
particularly, the present application is directed to air
conditioned and convective helmets and other headgear.
2. Description of the Related Art
[0003] There are many situations, both work oriented and sport, in
which the wearing of a helmet is necessary or highly desirable.
Exemplary of but a few instances where wearing a helmet for a
relatively long period of time is required are a motorcycle police
officer; race car driver; and a military tank driver. Considerable
discomfort can result from wearing a helmet, especially the
full-face type, for even a short period of time particularly in
warm or humid weather.
[0004] Accordingly, a need exists to provide a temperature
controlled helmet and convective headgear.
SUMMARY
[0005] In one or more embodiments, the device is either a
thermoelectric Peltier cooler or a resistive heater, preferably of
the PTC type, designed into a housing with air movers, condensation
control, and an air input adapter in the headgear. In one or more
embodiments, the system housing may be exposed on the rear of the
headgear, but the preferred embodiment is to fair it smoothly into
the headgear and cover it with a cover that has two openings in it
for ambient air to enter, and in the case of a thermoelectric
system, for heated rejector air to exhaust out. In an embodiment,
the device is preferably a Positive Coefficient Temperature ("PTC")
type resistive heating element for warming, and a Peltier
thermoelectric device for cooling.
[0006] In one or more embodiments, the device housing is preferably
designed into the helmet shell and covered smoothly. The
detachability of the device is only desired and necessary for
certification of the system, including the device, when exposed on
the outside of the headgear.
[0007] The preferred embodiment is an arrangement where the
convector ventilating, cooling, or heating device/system/housing is
enclosed with a cover that is smoothly integrated into the headgear
outer surface to reduce or eliminate tangential impact induced
rotational moment, and for good aerodynamics, where
appropriate.
[0008] In an embodiment, the cooling system or heating system
contains a device within its housing. The housing is either exposed
on the rear of the headgear or is covered. The covers are removable
for servicing and can be configured to be knocked off if desired,
but that is not necessarily always necessary. If the system housing
is exposed, then it can be configured to breakaway in tangential
impact to reduce or eliminate rotating moments.
[0009] In one or more embodiments, when the device housing is
exposed (i.e., not covered), the device housing is configured for
detachment from the helmet upon impact on the helmet apparatus. The
device hosing is configured for detachment from the helmet so that
the air filter may be cleaned or replaced, or other servicing may
be done, and then replaced. The device cover is designed to be
firmly attached to the headgear, but is removable so that servicing
or repairs may be accomplished and then be re-installed.
[0010] In a first aspect, a helmet apparatus is disclosed. The
helmet apparatus comprises a helmet shell including a first opening
of such dimensions as to permit receipt onto the head of a wearer,
the helmet shell having a front portion shaped to protect the front
face of the wearer, and a rear portion shaped to protect the back
of the head of the wearer. The helmet apparatus further comprises a
device housing positioned on the outer rear portion of the helmet
shell, the device housing comprising a generally curved surface
that emerges from the upper part of the device housing in contact
with and emerging away helmet shell extending downward toward the
first opening of the helmet shell, in which the device housing has
two generally vertical side-walls nearly perpendicular from the
curved surface, the device housing forming a cavity between the
helmet shell and an outer surface of the device housing in which
the at least one air inlet is formed in the device housing. The
helmet apparatus further comprises an air conducting layer
distributed about substantially the entire interior of the helmet
shell, and a device for producing a pressurized stream of air, the
device receiving intake air from the at least one air inlet of the
device housing and producing a pressurized stream of air in fluid
communication with the air conditioning layer.
[0011] In a first preferred embodiment, the at least one air inlet
is formed in both of the two generally vertical side-walls of the
device housing. The at least one air inlet is preferably formed in
one of the two generally vertical side-walls of the device housing.
The device and the device housing are preferably configured to
deform and absorb energy during an impact to the rear of the helmet
apparatus. The device housing is preferably removably coupled to
the helmet shell. The device is preferably detachably coupled to
the helmet with a hook and loop fastener. The device housing
preferably further comprises a rejector air outlet for exiting
heated air, in which the rejector air outlet is positioned to
prevent the exiting heated air from entering the at least one air
inlet. The rejector air outlet is preferably formed in the
generally curved surface of the device housing. The device is
preferably a heat pump, in which the air moving past the "hot"
place of the heat pump is exited to the rejector air outlet of the
device housing. The device is preferably a Positive Coefficient
Temperature ("PTC") type resistive heating element.
[0012] In a second aspect, a helmet apparatus is disclosed. The
helmet apparatus comprises a helmet shell including a first opening
of such dimensions as to permit receipt onto the head of a wearer,
the helmet shell having a front portion shaped to protect the front
face of the wearer, and a rear portion shaped to protect the back
of the head of the wearer. The helmet apparatus further comprises a
device housing positioned on the outer rear portion of the helmet
shell, the upper part of the device housing in contact with and
emerging away helmet shell extending downward toward the first
opening of the helmet shell, the device housing forming a cavity
between the helmet shell and an outer surface of the device
housing, the device housing having at least one air inlet. The
helmet apparatus further comprises an air conducting layer
distributed about substantially the entire interior of the helmet
shell, and a device for producing a pressurized stream of air, the
device receiving intake air from the at least one air inlet of the
device housing and producing a pressurized stream of air in fluid
communication with the air conditioning layer.
[0013] In a second preferred embodiment, the device and the device
housing are preferably configured to deform and absorb energy
during an impact to the rear of the helmet apparatus. The device
housing is preferably removably coupled to the helmet shell. The
device is preferably detachably coupled to the helmet with a hook
and loop fastener. The device housing preferably further comprises
a rejector air outlet for exiting heated air, in which the rejector
air outlet is positioned to prevent the exiting heated air from
entering the at least one air inlet. The device is preferably a
heat pump, in which the air moving past the "hot" place of the heat
pump is exited to the rejector air outlet of the device
housing.
[0014] In a third aspect, a helmet apparatus is disclosed. The
helmet apparatus comprises a helmet shell including a first opening
of such dimensions as to permit receipt onto the head of a wearer,
the helmet shell having a front portion shaped to protect the front
face of the wearer, and a rear portion shaped to protect the back
of the head of the wearer, and a device housing positioned on the
outer rear portion of the helmet shell, the device housing in
contact with and emerging away helmet shell extending downward
toward the first opening of the helmet shell, the device housing
forming a cavity between the helmet shell and an outer surface of
the device housing, the device housing having at least one air
inlet. The helmet apparatus further comprises a device for cooling
the scalp of the wearer, the device receiving air from the at least
one air inlet.
[0015] In a third preferred embodiment, device and the device
housing are configured to deform and absorb energy during an impact
to the rear of the helmet apparatus. The device housing preferably
further comprises a rejector air outlet for exiting heated air, in
which the rejector air outlet is positioned to prevent the exiting
heated air from entering the at least one air inlet. The device is
preferably a heat pump, in which the air moving past the "hot"
place of the heat pump is exited to the rejector air outlet of the
device housing. These and other features and advantages of the
preferred embodiments will become more apparent with a description
of preferred embodiments in reference to the associated
drawings.
DESCRIPTION OF THE DRAWINGS
[0016] The above and other aspects, features and advantages of the
preferred embodiments will be apparent from the following more
particular description thereof, presented in conjunction with the
following drawings and tables.
[0017] FIG. 1 is a rear view of an air conditioned helmet showing
several components in an embodiment.
[0018] FIG. 1A is a rear view of helmet showing an alternative
method of ducting air into the air flow structure liner.
[0019] FIG. 1B is a side view of an air conditioned helmet showing
a Volara.RTM. insulator and lower air flow structure edge air seal
replaced with the neck roll.
[0020] FIG. 10 shows the optional type 3 air filter behind air
inlet openings and the rejecter air opening with or without
grill.
[0021] FIG. 2 is a side view of an air conditioned helmet showing a
removed cover in an embodiment.
[0022] FIG. 2A is a side view of helmet showing an alternative
method of ducting air into the air flow structure liner.
[0023] FIG. 2B shows the main impact absorbing structure and the
separate extended shell impact absorbing structure.
[0024] FIG. 2C is a side view of a helmet showing additional
details of the components such as the optional air filter type 3,
mounted behind vent openings in cover.
[0025] FIG. 3 is a plan view of a helmet showing the mounting of an
air convection assembly without blowers.
[0026] FIG. 3A is a top view of a helmet having an extended shell
that is smooth, without protrusions that could cause rotational
neck injury from tangential impact.
[0027] FIG. 4 is a plan view of a helmet having two fans.
[0028] FIG. 4A is a side view of a helmet having an extended shell
that is smooth and without protrusions.
[0029] FIG. 5 is a front elevation view of a helmet showing the air
inlet for the thermoelectric pump.
[0030] FIG. 5A illustrate alternative air channels or slots, in
foam, with an optional air permeable inner cushion layer 9
[0031] FIG. 6 illustrates a basic pattern for the convective helmet
interior air flow structure.
[0032] FIG. 7 is a side elevation view of the thermoelectric air to
air helmet thermoelectric heat pump.
[0033] FIG. 8 is a side elevation view air helmet convective system
having after heater fins in an embodiment.
[0034] FIG. 8A is a side elevation view air helmet convective
system having a two-stage Peltier cooler in an embodiment.
[0035] FIG. 8B is a side elevation view air helmet convective
system having after heater fins in an embodiment.
[0036] FIG. 9 is a plan view of a helmet having tapered,
aerodynamically smooth convective system fairings.
[0037] FIG. 10 shows a helmet with an extended shell.
[0038] FIG. 11 illustrates a side elevation view of the extended
rear cover, or fairing, which is applied to the outside surface of
a conventional helmet shell.
[0039] FIG. 12 is a heating apparatus in which a blower is coupled
to the resistive heating element.
[0040] FIG. 12A is a heating apparatus in which a blower is coupled
to the resistive heating element with widely spaced, overrated
fins.
[0041] FIG. 13 is a plan phantom view of resistive heating
elements.
[0042] FIG. 13A is an elevation view depicting the resistance
heating elements with a low efficiency, low fin density heat
exchanger.
[0043] FIG. 14 is an end elevation view of a heating module in an
embodiment.
[0044] FIG. 14A is an end elevation view of a heating module in an
embodiment, having optional baseplates.
[0045] FIG. 14B is an end elevation view of a heating module in an
embodiment, having a conflux conductive heater in an
embodiment.
[0046] FIG. 15 is a plan view of a heating module in an
embodiment.
[0047] FIG. 15A is a plan view of a heating module having a lower
density fin design in an embodiment.
[0048] FIG. 15B shows the conflux conductive elastomer or polymer
PTC heater and a housing clamping folded fin heat exchangers.
[0049] FIG. 16 illustrates a helmet with air vent holes in rear
surface of cover instead of on sides of cover.
[0050] FIG. 17 illustrates a covering for air duct for air entering
the air flow structure on the edge of the structure instead of the
rear surface of the air flow structure.
[0051] FIG. 18A is a top view of a removable lining in an
embodiment.
[0052] FIG. 18B is a representation of the air flow within the
helmet.
[0053] FIG. 18C is a perspective view of the air flow structure
with an interior trim layer as fitted into a helmet.
[0054] FIG. 19A is a top view of a removable lining having an
optional insulation layer in an embodiment
[0055] FIG. 19B is a representation of the air flow within the
helmet.
[0056] FIG. 19C is a top view of a removable lining having an
optional insulation layer in an embodiment.
[0057] FIG. 19D is a top view of a removable lining having an
insulation layer or a partial insulation layer in an
embodiment.
[0058] FIG. 20 illustrates a cooling and heating system in an
embodiment.
[0059] FIG. 20A shows thermoelectric Pellets, flexible
insulator/support planes, inner fins tapered outward, before
bending and installing in housing, and outer fins tapered inward,
before bending.
[0060] FIG. 20B shows a conventional non-flattened helmet shell
rear surface and optional curved ceramic plates.
[0061] FIG. 21 illustrates a cooling and heating system in an
embodiment.
[0062] FIG. 21A shows the conventional outside rear of helmet and
assembly above after bending, fins are straight, originating from
the same instant center.
[0063] FIG. 21B shows stamped copper or aluminum fins in a square U
shape, straight, flat, rigid non-conductive fin.
[0064] FIG. 22 illustrates the location of the helmet air outlet
vents that vent into the face area.
[0065] FIG. 22B shows double articulated TE modules with radii,
designed for small air movers for maximum compactness and a low and
high cooling mode.
[0066] FIG. 22C shows a side view of the helmet with a Tubular
Spacer Fabric ("TSF") or other air flow layer, insulation or impact
layer, an outer shell, a convective system, and a rear air inlet
TSF lower edge air seal.
[0067] FIG. 22AB shows a plastic strip stitched to 3Mesh.RTM. or
other air flow structure interior trim cover.
[0068] FIG. 23 is a perspective view of the trim molding.
[0069] FIG. 23A shows a thin flexible plastic strip stitched to
finisher and trim, soft flexible air outlet vent grill finisher,
and 3Mesh.RTM. or other air flow structure interior trim cover.
[0070] FIG. 23B shows a soft flexible air outlet vent grill
finisher and 3Mesh.RTM. or other air flow structure interior trim
cover.
[0071] FIG. 23C shows extruded or molded seal outer face.
[0072] FIG. 23D shows a closed plug, a side wall, where the plugs
are shown spaced farther apart than normal for clarity.
[0073] FIG. 23E shows a front face, air outlets, a side wall, and a
plug with opening for air outlet.
[0074] FIG. 23AB shows the helmet air flow layer interior
trim/padding layer, an optional air tight layer to seal bottom edge
of TSF or other air flow structure, and a plastic strip sewn to
interior trim to anchor trim by inserting between EPS and
shell.
[0075] FIGS. 24 and 25 are side views of a resilient mounting
system in one or more embodiment
[0076] FIG. 26 is a plan and side elevation view of an empty
grommet and a separate ball-pin.
[0077] FIG. 27 is a plan and side elevation view of a grommet
coupled to a separate ball-pin.
[0078] FIGS. 28 and 30 are plan and side elevation views
respectively of a helmet cover having a convective system cover
extended from the shell.
[0079] FIGS. 29 and 31 are plan and side elevation views
respectively of a helmet cover having a having a side air inlet and
a rejecter air outlet for thermoelectric cooling system only.
[0080] FIG. 32 illustrates a means for attaching the air system to
a helmet.
[0081] FIGS. 33 and 34 illustrate how the Velcro.RTM. strip or spot
secures the thermoelectric heat pump assembly to the helmet shell
resiliently.
[0082] FIG. 35 is a view of an air handling system.
[0083] FIG. 36 shows a TSF, or other air flow layer, where these
optional radii depend on the size of the helmet.
[0084] FIG. 36A shows an expanded view of an example of the
removable coupling/adaptor.
[0085] FIG. 37 shows an alternative convective system with smaller
fins for a closer fit to a conventional headgear shell.
[0086] FIGS. 38 through 40AA, disclose an ACH thermoelectric
assembly cover that is designed to integrate smoothly into the
shape of the back of the helmet.
[0087] FIG. 38A is a top plan view image of the helmet with a
smoothly integrated cover which eliminates increased rotational
moment from tangential impacts.
[0088] FIG. 41 is a view of a helmet shell having a foam impact
layer formed in a notch in lower back edge of helmet shell.
[0089] FIG. 42 is a cross-sectional view of the air/heating system
coupling with the helmet shell through the notch or opening in
lower back wall of helmet shell
[0090] FIG. 42A is a cross-sectional view of the air/heating system
coupling with the helmet shell through the notch or opening in
lower back wall of helmet shell to the air duct to edge of air flow
structure molded into foam layer overlapping air flow structure
edge.
[0091] FIGS. 43 and 43A are side views of a cooling/heating system
having an insert slot for coupling with a "radius insert."
[0092] FIGS. 44 and 44A are side views of a cooling/heating system
having an insert slot for coupling with a "radius insert."
[0093] FIG. 44B illustrates an air system having an
isolation/decoupling material between air mover and adaptor, a
fan/blower, an adaptor, a snap fit, a soft isolator, an air duct
extension, and a second air mover isolator between air mover
adaptor and convective housing.
[0094] FIG. 44C has a snap fit, a soft isolator, an optional EPS
liner, and an air duct extension.
[0095] FIG. 44D shows an isolation/decoupling material between fan
and adaptor, a fan/blower, an adaptor, a pliable convective system
air duct with coupling/adaptor and vibration isolator, a shell, and
an impact absorbing layer.
[0096] FIGS. 45-46 disclose a variation of the solutions disclosed
in previous drawings of the subject disclosure involving the use of
Velcro.RTM. as a semi-permanent fastener securing the convective
assembly to the helmet shell while allowing the assembly to be
readily separated from the helmet or cap in a direct tangential or
lateral impact, or for repairs or replacement
[0097] FIG. 47 depicts a thermoelectric device with a fan housing
in an embodiment.
[0098] FIG. 48 depicts a thermoelectric device with a fan housing
in an embodiment, which includes an extended helmet air duct from
the lower convective system housing.
[0099] FIG. 48A illustrates a preferred embodiment for coupling the
TE device to the helmet.
[0100] FIG. 49 is a top view of the dual Durometer fan housing and
adaptor.
[0101] FIG. 49A illustrates a preferred embodiment employing fan
frames
[0102] FIGS. 50-52 are a side elevation, a front or rear elevation,
and a plan view respectively of an aerodynamically efficient
housing for a bicycle ACH battery.
[0103] FIG. 53 is a perspective view of an ACH bicycle helmet in an
embodiment.
[0104] FIG. 53A is a top view of a battery cord with connector to
the helmet.
[0105] FIG. 53B is a side view of a bicycle helmet.
[0106] FIG. 54 discloses a unique wiring schematic for the ACH that
includes switches that provide for off, ventilate, low cool and
high cool, as well as providing accessories such as noise
cancellation and Bluetooth.RTM. in one or more embodiments.
[0107] FIGS. 54A-54C discloses the circuit diagram for a system
configured to be off, to ventilate, and to cool respectively.
[0108] FIG. 55 discloses a power cord with an optional dc-dc
convertor in-line to enable the use of the helmet with different
battery types and voltages.
[0109] FIGS. 56 through 58 disclose a variation of the novel method
for controlling the cooling and heating power of a thermoelectric
convective, or resistive convective system as used in embodiments,
in the simplest, most cost effective way.
[0110] FIGS. 59-61 are front elevation, rear elevation, and side
elevation view respectively housing holding a filter.
[0111] FIG. 61A is a perspective view of an air filter adaptor to
fans housing holding an electrostatic air filter.
[0112] FIG. 62 is a cross-sectional view of a helmet having an
extra, ultra-light weight configuration with several thin thermal
insulation and a gusset at the rear to attach to the convective
system.
[0113] FIGS. 63-65 depict equivalent electrical circuits for
cooling or heating mode, ventilation mode, and heating or cooling
mode respectively.
[0114] FIGS. 66-68 depict equivalent electrical circuits for being
off, ventilating mode, and cooling mode respectively.
[0115] FIG. 69 shows an optional snorkel for blower or fan, to
limit rain ingress and excessive air pressure in higher speed
vehicle applications, a blower(s) or fan(s), a blower adaptor to
helmet air inlet, preferably made of a medium Durometer urethane,
an air inlet for air mover assembly, and a thermoelectric hot air
outlet not necessary w/ ventilation only.
[0116] FIG. 70A illustrates a fan/blower(s), a fan/blower speed
control potentiometer, a single pole, single throw switch, or
switch can be incorporated into pot, and a power input.
[0117] FIG. 71 is a side view of a helmet showing an optional
snorkel or filter adapter FIG. 72 shows an optional movable impact
absorbing layer with variable densities or multiple movable layers,
or elastic suspension elements to provide compliance between the
user's head shell and the outer shell to reduce rotational trauma
to the neck and/or brain.
[0118] FIG. 73 shows a rear view of a resistive air convection
helmet and visor for snowmobiling for example, with optional
extended shell and rear cover.
[0119] FIG. 73A is an electrical circuit of a fan/blower speed
control including a potentiometer that controls the current flow to
the fan/blowers.
[0120] FIG. 74 illustrates a soft air deflector above forehead to
direct more warm air to the visor, and an optional thermal
impedance layer to limit head warming with higher visor air
temperatures.
[0121] FIG. 75A shows another ultra-light weight convective
headgear design depicting an outer shell, an air flow structure
layer, and an optional pad for optional Velcro.RTM. fastener for
convective system.
[0122] FIGS. 75B-75F are perspective views of a bicycle air
conditioned helmet ("BACH") in one or more embodiments.
[0123] FIGS. 75G and 75H are cross-sectional views of a bicycle air
conditioned helmet ("BACH") in one or more embodiments.
[0124] FIGS. 76-79 shows a custom fit ACH employing a scanning
method for determining an EPS mold pattern for TSF.
[0125] FIG. 80 illustrates an ACH, which contains a cooling system
1141, where a nominal load is .about.1.6 A @13.0 VDC.
[0126] FIGS. 80A-80C depicts equivalent electrical circuits without
fan speed control in the off mode, ventilate mode, and cooling mode
respectively.
[0127] FIGS. 80D-80F depicts equivalent electrical circuits with
fan speed control in ventilate mode.
[0128] FIGS. 81 through 84 illustrate the basic application of
audio speakers with optional Active Noise Cancellation, (ANC), to
an air convectively cooled, heated, and/or ventilated helmet.
[0129] FIG. 85 is a side view of approximately 2-3 mm thick
3Mesh.RTM. or other TSF interior trim.
[0130] FIG. 86 illustrates a helmet shell, having a helmet impact
absorbing foam, (EPS), or other impact absorbing structure.
[0131] FIG. 87 shows a channel for TSF or other air flow structure
1304 in EPS or other impact absorbing structure, a helmet shell
1305, an EPS, or other impact absorbing structure.
[0132] FIG. 88 is a side view of a helmet showing TSF or other air
flow structure 1302 and insulation or impact layer 1306.
[0133] FIG. 89 is a side view of a helmet having optional elastic
suspension elements to provide compliance between the user's head
shell and the outer shell to reduce rotational trauma to the neck
and/or brain.
[0134] FIG. 90 shows a side view of the helmet with a convective
headgear internal air flow, an elastomeric bulb air pump to actuate
retractable air dam, an air dam air release valve, an air flow
through headgear venting through face area, and a retractable air
dam at lower leading edge of full face type air convective helmet
to promote good venting of headgear air from face area.
[0135] FIG. 91 illustrates an air flow through front air curtain
vent.
[0136] FIG. 92 is a skin temperature chart that measures moderate
ambient air temperature, which shows the thermoelectric convective
headgear cooling function versus ambient temperature.
[0137] FIG. 93 is a chart of skin temperature as a function of
ambient temperature which depicts the skin temperature on different
parts of a nude person measure at different ambient
temperatures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0138] Teachings relating to the air conditioned helmets disclosed
in U.S. patent application Ser. No. 11/252,089 filed Oct. 17, 2005
entitled "AIR CONDITIONED HELMET APPARATUS" which issued as U.S.
Pat. No. 7,827,620 on Nov. 9, 2010, and U.S. patent application
Ser. No. 10/601,964 filed Jun. 23, 2003 entitled "AIR CONDITIONED
HELMET APPARATUS" which issued as U.S. Pat. No. 6,954,944 on Oct.
18, 2005, may be employed herein and the disclosures of which are
incorporated herein by reference in their entirety.
[0139] As used herein and as is commonly known in the art, as
depicted in FIGS. 1 and 1B, a helmet 101 has a helmet shell 110
having a first opening 30 of such dimensions as to permit receipt
onto the head of a wearer. The helmet shell 110 has a front portion
31 shaped to protect the front face of the wearer, and a rear
portion 32 shaped to protect the back of the head of the wearer.
The helmet shell 110 has a top portion 33 covering the upper, scalp
of the wearer, and a lower portion 36 near the base of the head of
the wearer. A vertical axis 34, which is generally parallel with
the neck and spin of the wearer, defines upper 33 and lower
portions 36 of the helmet 101 and helmet 110. A horizontal axis 35
is generally perpendicular to the vertical axis 34. The term "heat
pump" refers to a device which transfers thermal energy from a
source to a destination which includes thermoelectric devices
(e.g., Peltier devices). The brand name "Velcro.RTM." refers to
hook and loop fasteners, usually comprising two components which
are removably fastened when the two components are pressed
together.
[0140] The following disclosure pertains to improvements in the
thermoelectric air conditioned, or convective, helmet/headgear that
was originally disclosed in U.S. Pat. No. 6,954,944 B2, and
subsequently, in U.S. Pat. No. 7,827,620 B2. The improvements are
in several areas:
[0141] 1--How to protect the thermoelectric apparatus from damage
during the course of everyday use and even under moderate impact
forces, while establishing a form that is aerodynamically and
thermally efficient as well as aesthetically pleasing. The design
must also ensure that the thermoelectric heat pump apparatus does
not intrude into the interior of the helmet under severe impact
forces, especially considering that the optimum design
aerodynamically is not going to be knocked off readily in an impact
because it is integrated into the shape of the helmet smoothly. A
solution to packaging the cooling system into the helmet with the
above considerations will be disclosed in this spec.
[0142] Another critical function of the new extended helmet shell
design with indented or countersunk space for the thermoelectric
air temperature modifying apparatus is to smooth the back of the
helmet shell, eliminating any protrusions that could cause, as a
result of a tangential impact, a rotation of the helmet, which
would then cause a rotation of the user's neck, possibly causing
neck injury. An additional solution has been added in the form of a
standard helmet, with or without a slightly flattened rear surface,
with a suitable cover over the convective cooling, heating, or
ventilating system, to protect it in an impact and prevent any of
the convective system from catching on something and inducing a
rotation about the neck of the user in an impact. A number of
variations of the convective system cover are also disclosed. The
extended shell improvement is especially important because it
enables the Air Conditioned Helmet ("ACH") to be certified by the
appropriate approval agencies for use in transportation
applications.
[0143] 2--During the air cooling process, especially in humid
weather, moisture may be condensed out of the air that is blown
into the helmet interior air flow structure. The resulting
condensation will drip from it's source, the thermoelectric air to
air heat pump built into the helmet, and may cause discomfort
and/or a distraction for the user. A solution to this concern is
disclosed in the following specification in the form of a
condensation management system that evaporates condensation away as
it's formed, in cooling mode.
[0144] 3--The concept and solution of using a resistive heating
element to re-heat air sub-cooled below the dew point by a
thermoelectric air to air heat pump, including a two stage Peltier
device, in order to adjust the relative humidity of the air
delivered to a cushion that is sat on or laid on was introduced in
patent, U.S. Pat. No. 7,272,936 B2. This disclosure will show how
that concept can be applied to a thermoelectric air conditioned
helmet, in a compact, lightweight form.
[0145] 4--An air convection heated helmet for use in freezing and
sub-freezing temperatures to prevent helmet visor fogging and icing
and to provide comfortable air for breathing, which will also
significantly reduce body core heat loss in cold weather by
providing air at a higher and much more comfortable temperature,
i.e. .about.60.degree. F. vs. 20.degree. F. or colder.
[0146] 5--A high efficiency ventilated helmet/cap/hat for head
cooling in ambient weather conditions in which ambient air
temperature is sufficiently low enough to accomplish a meaningful
degree of body cooling via the head and scalp without the need for
sub-ambient cooling. This new ventilated version is particularly
suited for bicycling and running applications in moderate to cool
weather as it reduces cost and weight of both the headgear and the
battery required to run it.
[0147] 6--High efficiency air convection cooled, heated, or
ventilated helmets for industrial applications such as welding and
grinding, including specialized equipment known as a Powered Air
Purified Respirator, or PAPR, for welding and grinding materials
that involve toxic fumes.
[0148] 7--Numerous additional improvements, including
manufacturability, improved air filtration, certification, safety,
repair, and maintenance considerations.
[0149] FIG. 1 is a rear view of an air conditioned helmet ("ACH")
101 showing several components in an embodiment. The helmet 101
comprises an extended rear of helmet shell 110 having a
space/channel 112 formed by extended rear sides of shell to form an
air inlet 114. The helmet 101 has an air inlet 118 through shell
110 into helmet impact absorbing layer. Slots or grooves 116 for
flanges on cover and a platformed edge with slots 122 for clips on
cover to countersink cover flush with shell outer surface are
formed in the helmet 101. An optional boss with Rivnut 120 to
secure top of TE cover with screws may be formed in the helmet
101
[0150] A multiple blower type TE heat pump 130 and a single blower
type TE heat pump 132 are shown. The rear cover 124 may have an
optional NACA inlet duct 134 if cover completely covers channel.
Other openings can also be used. The rear cover 124 has a rejecter
air opening 136 with or without the grill. The rear cover 124 has a
rejector heat exchanger, (hot side in cooling mode), air outlet,
removably or permanently attached. This is shown with a hooked
extension type top fastener.
[0151] FIG. 2 is a side view of an air conditioned helmet showing a
removed cover in an embodiment. The helmet 101 has a shell
extension 111. Air enters the air inlet 114 and passes through
optional air filters type 1 140 and air filter type 2 142 to a fan
or blower 144. The helmet 101 has a convective system 146
countersunk into rear space/channel of shell extension, and an air
duct 148 from heat pump to helmet air flow structure/liner. It
passes through aperture in helmet shell and impact absorbing layer
160. This is where the optional new relative humidity control
resistive heater is optimally located. The helmet 101 has a lower
rear air flow layer edge seal 150, an air and thermal barrier layer
152, preferably Voltek Volara.RTM., .about.1-2 mm thick, and
knitted spacer fabric 154, such as 3Mesh.RTM., and an air flow
structure cover trim. The helmet 101 has an optional Tubular Spacer
Fabric ("TSF") TSF Air Vent Trim Grille Material 156, a TSF air
flow liner 158, and optional impact absorbing layer 160, as well as
a countersink 162 for TSF or other air flow structure fastener,
Velcro.RTM. disc, for example.
[0152] FIGS. 1 and 2 show views of the new air conditioned helmet
101 design with an extended rear section 110 that creates an
indented area that countersinks a thermoelectric air to air heat
pump, or resistive heating system, or ambient ventilating system,
inside the countersunk area in order to integrate the heat pump
into a helmet 101 with a smooth outer shell. A rear cover 124 is
shown which covers the heat pump assembly for good appearance,
protection of the convective apparatus, and smooth aerodynamics.
Also shown are two configurations of convective apparatus, one with
a single blower 132, and the other with two or more blowers 130.
The multi blower 130 configuration enables a less exaggerated rear
extension of the helmet shell because the diameter of the dual
fans/blowers is considerably smaller. It is possible to reduce the
rear extension 110 further by using a larger number of smaller fans
or blowers, and segmented Peltier devices, or resistive heaters, or
a simple adaptor for ventilation only.
[0153] FIG. 1 also shows an optional NACA ambient air inlet duct
134 in an air convection assembly cover that is closed except for
the NACA inlet 134 and a thermoelectric secondary, or hot air
rejector outlet, for sub-ambient cooling.
[0154] FIG. 2 shows a view of the optional air flow structure air
outlet vent trim 156 as disclosed earlier elsewhere in this
disclosure, from a different view in order to show that it is
possible for the grille trim 156 to be fastened to the optional
helmet impact absorbing layer 160 with the air flow structure
inserted behind it, instead of bonding the grille to the TSF. Very
importantly, it is also possible to fold the interior air flow
structure cover trim material 156 over the edge of the TSF, or
other air flow structure, air outlet to conceal the air outlet edge
of the air flow structure, however the ACH air flow structure
interior surface trim cover is best accomplished with Muller Textil
3Mesh.RTM. knitted spacer fabric, or an identical equivalent. An
example of a Muller 3Mesh.RTM. material that is very good from a
thermal standpoint and a cushioning standpoint in a relatively thin
sheet, (3 mm), is Muller 3Mesh.RTM. 5683-0300-2300-0015, which is
also suitable for wrapping around the air outlet edge of the air
flow structure because of an extremely low transverse pressure drop
through the material. Another version of the same type of knitted
spacer fabric is made by Macro International in a 2 mm thickness,
which also produces an excellent result with good thermal transfer
to and from the air in the TSF layer, while providing a good level
of cushioning to help compensate for small variations in head
shapes for any given size of helmet. Knitted spacer fabric, such as
the Muller Textil material disclosed above, performs better than
open cell foam in terms of thermal transfer, air, and vapor
permeability, as well as cushioning performance than open cell
foam. This is because the fibers that cross from one side to the
other side of the plane of the 3Mesh.RTM. type material bend like
leaf springs when the material is compressed. The bending of the
fibers is highly directional so that the permeability of the
material is not affected by compression nearly as much as open cell
foam. Closed cell foam is, of course, a good insulator, so it is
not appropriate as an ACH air flow structure interior trim
finisher, unless it is used specifically to insulate a particular
part of the helmet interior, and in that case, Voltek Volara.RTM.
is an excellent material, being a radiation cross-linked closed
cell foam with very small cells, enabling a very thin sheet,
approximately. 1-2 mm thick, with small closed cells and high
insulation, (R), values. FIG. 2 discloses the use of Volara.RTM. as
an insulation layer 152 for the air flow structure air inlet area
opposite the air inlet 114 into the air flow structure to prevent
cold spots on the user's head/neck with cooling or hot spots with
heating, and to seal the bottom rear edge of the TSF, or other air
flow structure. FIG. 1 illustrates two solutions to the attachment
of the cooling system cover to the helmet shell. One method is a
slot in the shell that receives a flat flange with a hook on it.
Pushing the cover 124 from top towards the bottom will cause the
cover 124 to bend slightly, releasing the hooked extension from the
slot and allowing the cover 124 to swing out, where it can then be
pulled up so that the flange(s) on the bottom edge will pull out of
corresponding slots or grooves 116 in the bottom edge of the
indentation in the shell.
[0155] The other approach is to add a small boss 120 to the lower
inside edge of the countersunk channel as shown to provide a space
for a Rivnut, which is a female fitting that is installed like a
Pop Rivet, with threads on the inside diameter. A screw can then be
used to secure the cooling system cover in place at the top, with
the lower flange and groove, or flange and slot, retaining the
cover at the bottom. The cover is molded into the same shape as the
corresponding surface at the rear of the helmet so that any impact
to the cover will transmit to the helmet shell via the attachment
points and the platformed edge of the indented channel that the
cover matches up to. FIG. 2 includes a view of the TE cover with a
hooked extension at the top instead of an opening for a screw
fastener, and optionally, a short extended edge at the bottom
engages into the slots or grooves at the bottom of the shell rear
as shown in FIG. 1.
[0156] FIG. 2 illustrates an optional air filter type 1, which is
an air filter positioned in the air channel formed by the extended
shell type ACH. The position is as shown in order to provide the
maximum amount of filter cross-section area for minimum air
pressure drop into the fans, which are very small and therefore
more susceptible to excessive inlet suction head pressure drop.
[0157] FIGS. 1A and 2A illustrate an alternative method of ducting
conditioned air into the ACH air flow structure liner underneath
the helmet lower back edge. FIG. 1A is a rear view of the helmet
showing an alternative method of ducting air into the air flow
structure liner. A notch 126 in the shell is preferred for the edge
input to the air flow structure, as shown in FIG. 1A because it
allows the helmet to rest normally on a flat surface when not being
used. Without a notch, the air duct projects below the shell edge
and causes the helmet to wobble in an unstable manner on a flat
surface, and the weight of the helmet puts stress on the air duct
itself.
[0158] FIG. 1B is a side view of an air conditioned helmet showing
a Volara.RTM. insulator and lower air flow structure edge air seal
of FIG. 2, replaced with the neck roll 191, (pad), and/or interior
trim, to seal the TSF lower edge and also prevent a cold spot,
which is a preferred embodiment. This is also shown in FIG. 48.
FIG. 1B also depicts an optional snap fastener 190 for neck roll,
pad, or interior trim to cover lower rear surface and bottom edge
of air flow structure.
[0159] FIG. 1B is very similar to FIG. 2, however FIG. 1B discloses
an important new additional optional solution to the problem of
sealing the lower edge of the air flow layer and simultaneously
insulating to prevent a cold spot on the back of the user's head
and/or neck opposite the air input in the cooling type ACH with air
entering at approximately 90 degrees to the direction of flow from
the back to the front of the helmet, as opposed to the type of ACH
where the air flow is directed into the air flow structure/layer
along the edge of the TSF at approximately 0.0 degrees to the
direction of air flow through the TSF, as disclosed in FIG. 2A. The
preferred solution is to use an air tight neck roll, pad, or
interior trim piece, configured as shown in FIG. 1B, and FIG. 48,
to both seal the bottom edge of the TSF, or other air flow
structure, to prevent air leakage, and cover and partially insulate
the lower .about.1-3'' of forward facing inside surface of the TSF
or other air flow structure to reduce thermal transfer and prevent
a cold spot on the user's neck and/or lower head in cooling mode,
or a warm/hot spot in heating mode, and prevent the leakage of
cooled, heated, or ventilating ambient air entering the air flow
structure from leaking out on the lower rear edge of, or region
near, the air inlet of the air flow structure. This is a preferred
embodiment, as it eliminates the Volara.RTM. insulation layer and
adhesive, and a separate bottom edge seal with adhesive for a
cleaner, simpler, and more efficient assembly process.
[0160] FIG. 10 shows the optional type 3 air filter 2 behind air
inlet openings and the rejector air opening 3, with or without
grill. FIGS. 10 and 2C, illustrate a full face motorcycle type
ACH/AVH with the air inlet vent and filter installed in the cover
for the convective apparatus. In this design, the cover covers the
entire space that contains the convective cooling, heating, or
ventilating apparatus, and has an air inlet with filter, preferably
of the electrostatic mesh type, mounted on the inside behind the
air inlet vent openings on the cover, called optional air filter
type 3, and an opening to accommodate the auxiliary air outlet for
a thermoelectric heat pump, if necessary. FIG. 10 is a variation of
FIGS. 1 and 2, which discloses air filters type 1 and 2.
[0161] FIG. 2A has a convective system 146 mounted in space at rear
surface of helmet formed by the extended shell, an air duct 147
from the heat pump to helmet air flow structure liner, wraps around
rear helmet shell and impact layer bottom edge, and an air flow
layer bottom edge seal except where air enters the layer on the
edge 149.
[0162] FIG. 2B shows the main impact absorbing structure 192 and
the separate extended shell impact absorbing structure 193. FIG. 2B
discloses another solution to the extension of a helmet shell to
accommodate an air convective cooling and heating, heating, or
ventilating system. In this solution, the extended parts of the
outer shell are fitted with separate molded impact absorbing
elements, instead of a single piece impact layer, made of a
suitable material, such as expanded polystyrene foam, (EPS), for
example. The purpose of the separate extended elements is to make
it easier, if necessary, to insert the extended impact absorbing
structure into the extended outer shell. The ease with which a one
piece impact absorbing structure can be inserted into an extended
outer shell will be determined to some extent by the overall shape
and design of the extended outer shell, and in some instances, the
multi-piece impact absorbing structure will facilitate the assembly
of an ACH with extended shell and impact absorbing layer(s).
[0163] FIG. 2C is a side view of a helmet having an optional air
filter 4 type 3, mounted behind vent openings in cover, and a rear
cover with rejector heat exchanger, 5 (hot side in cooling mode),
air outlet, which is removably or permanently attached. Here it is
shown with hooked extension type top fastener. The cover is removed
by pushing down at top to disengage the hook fastener. 6. The cover
6 has a hook or flange on lower edge 7 to retain bottom of cover.
This rear cover 8 covers the entire space containing the TE,
ventilator, or heating system.
[0164] FIG. 3 illustrates a helmet 101 showing an approximate
standard helmet rear surface 162, the shell surface at the rear of
the helmet 110 extended beyond the standard surface 164, and
convective assembly 166 shown without fan or blower(s), protected
by indentation into helmet shell, or extended shell, depending on
how you look at it. Shell is smooth, without protrusion that could
cause rotational neck injury from tangential impact. Rear cover is
not shown for clarity. FIG. 4 illustrates a helmet 101 having an
air inlet 114 and a TE assembly shown with multiple blower
configuration 130 where the rear cover is not shown for clarity.
FIG. 4 is an elevation view of the helmet 101 showing the
convective system air Inlet 114 shown with rear cover installed,
forming the top surface of the air inlet 114. FIG. 5A illustrates
alternative air channels or slots 10, in foam 11, with an optional
air permeable inner cushion layer 9. This may not be the preferred
embodiment.
[0165] FIGS. 3A and 4A are a top view and a side view of a helmet
having an extended shell that is smooth, without protrusions that
could cause rotational neck injury from tangential impact. The
helmet has an extended shell surface 194 at the rear of helmet, a
TE heat pump, ventilation system, or heating system assembly 195
shown without air mover(s), protected extended shell, where the
shell is smooth, without protrusions that could cause rotational
neck injury from tangential impact. The helmet also has an air
filter 196, and air duct 197, and one or more air inlets 198 in EPS
or other structure.
[0166] Specifically, FIGS. 3, 4, and 5 show two plan views and one
front elevation view of the new ACH. FIG. 3 shows the mounting of
an air convection assembly 166 without blowers and how it is
countersunk into the extended rear section of the helmet. FIG. 4
shows the same with a two fan setup 130. FIG. 5 shows the air inlet
114 for the thermoelectric heat pump, defined by the countersunk
area for the heat pump that tapers up toward the top front of the
helmet and the rear cover that constitutes the outer wall of the
air channel from the top front of the helmet to the rear of the
helmet in which the convective cooling, heating, or ventilating
system is located with helmet air entering the back of the helmet
in order to duct air into the helmet interior air flow structure,
which can be any structure capable of conveying air past the users'
head, including, for example, grooves or channels in the impact
absorbing EPS, (Expanded Polystyrene), or another impact absorbing
system or layer, as depicted in FIG. 5A but is preferably made of
Tubular Spacer Fabric, TSF, without the need for air channels and
their associated pressure drop and reduced exposure of the user's
head to temperature modified air, and disadvantages as described
elsewhere in this disclosure. Impact certification is necessary for
motor vehicle helmets and a secondary impact from channels
collapsing after an initial impact force spike in the EPS would
almost assuredly prevent certification due to additional potential
trauma from a secondary impact force spike.
[0167] To summarize, the advantages of the extended shell design
are:
[0168] 1--Eliminates air convection system external projections
that could catch on objects during a crash and induce a rotation of
the helmet about the neck in an impact.
[0169] 2--Eliminates external air switches and air scoops, and
multiple openings, in the helmet shell that reduce the overall
strength of the helmet shell. The extended shell ACH is stronger,
and potentially lighter, as a result. In addition to a strength
increase, the noise of the helmet will be reduced because of
reduced air turbulence due to the reduction or elimination of
projections from the surface of the shell.
[0170] 3--Because the shell is extended rear-wards, it is possible
to introduce more aerodynamic stability by placing the aerodynamic
center of pressure behind the center of gravity, which produces a
self-stabilizing effect, whereas placing the aerodynamic center of
pressure in front, or nearer the front of the center of gravity
will tend to induce oscillations and reduce aerodynamic
stability.
[0171] FIG. 6 illustrates a basic pattern for the convective helmet
interior air flow structure, showing the air inlet 114 (air in duct
profile example shown as a dashed line for clarity), the lower rear
edge air seal 172 if neck roll is not used instead, and an
insulation layer 150, preferably Voltek Volara.RTM.,
0.031''-0.062'' thick and 2-4 lb./ft.sup.3 to prevent cold spot
formation where air enters the helmet. Dotted line shows the
approximate air entrance duct on opposite side of insulation. This
may be preferably replaced with a modified neck roll, or pad, to
cover and insulate same area, as shown in FIG. 1B and FIG. 42. FIG.
6 also shows the airflow 171 when fitted into the helmet interior
through the TSF or other air flow layer cutting pattern 170 cut
with a computer controlled laser. The basic approximate pattern for
ACH TSF air flow liner with maximum internal area coverage in one
piece before folding and inserting into a helmet. Note orientation
of tubes for proper air flow when folded and formed into the
interior of the helmet. This may also be used in a cap or hat for
running, jogging, medical purposes, etc., when inserted into a
suitable shell, which may be rigid or flexible. Different types and
shapes of helmets may entail variations in this basic pattern for
optimal fit and air flow. When formed into the interior of a
helmet, the pattern shown lines up edges A with edges B,
facilitating a smooth interior surface and continuous air flow from
the entrance at the rear across the top and also along the full
length of the sides for complete air flow coverage of the user's
head. FIG. 6 shows the air out front 173, into face area in full
face type ACH 101.
[0172] FIG. 6 shows the basic pattern for the convective helmet
interior air flow structure, whether Tubular Spacer Fabric, (TSF),
or another air flow lining 170 that is fitted inside a helmet 101
or a suitable shell for other applications, such as a bicycle
helmet, runner's cap, etc.
[0173] The pattern shown in FIG. 6 guides some of the air
convection system air from the inlet behind the user's head up,
over, and around the head and vents down into the space in front of
the user's face. Note the two somewhat triangular sectors removed
so that the material edges fit together smoothly when the whole
piece is inserted into the helmet head space, and edges A and B
will line up with one another when the TSF sheet, or other air flow
structure, is fully inserted into the helmet head space, enabling
efficient internal airflow from back to front over the entire area
surrounding the user's head, including the back, top, and sides of
the head, venting out above the forehead and, optionally, at the
sides near the user's temples. An insulation foam layer 150,
preferably Voltek Volara.RTM., approximately 1-2 mm thick, with
closed cells, is also shown in the area proximate the entrance of
temperature modified air, but on the opposite side facing the
user's head, to prevent a cold spot from forming at the back of the
user's head and neck in cooling mode. The dashed line across the
bottom of the figure represents the edge air seal 172 as disclosed
in FIGS. 23c and 23d, which is a soft molded piece, made of
urethane, silicone, or other appropriate material, configured to
reliably block air flow out from the TSF or other air flow layer in
that region. Elsewhere in this disclosure, another edge seal
solution is disclosed in which a neck pad, or neck roll, is
modified to envelope the bottom edge of the air flow structure and
cover the area inside the air flow structure opposite the air inlet
to the air flow structure, to prevent temperature modified air from
leaking out of the lower edge of the air flow structure and, taking
the place of the Volara.RTM. or other insulation, to prevent the
formation of a cold spot at the back of the user's head/neck where
temperature modified air enters the air flow structure.
[0174] If the helmet is of the full-face type, with a visor, which
is preferred for motorcycle and snowmobile ACHs, because high
speeds develop more air pressure on the front of the ACH, and a
full face visor prevents that pressure from interfering with good
internal air flow from back to front, venting over the face. The
vented cool air cools the face and provides relatively cool air for
the user to breathe, which adds to the overall body cooling effect
of the air convection cooled helmet in warm weather. An important
feature of the subject embodiments when applied to bicycle helmets,
in addition to an approximate 51% improvement in endurance in warm
weather from head cooling, is that a full face type bicycle ACH
provides cooled air for breathing, which increases the overall body
cooling effect for a potentially even greater improvement in
endurance beyond the 51% found in laboratory tests with head
cooling only. Also, because the bicycle ACH does not need large
vent holes like the average ambient air ventilated bicycle helmets
so popular these days, the BACH offers better protection because it
covers the head completely, whereas most standard bicycle helmets
actually only offer approximately 50% head coverage in order to
provide minimum heat retention, which only allows ambient air to
impinge on approximately 50% of the user's head area, resulting in
a relatively low level of body cooling, if any, especially in warm
weather when ambient air is near, at, or above skin temperature.
The lab tests that showed a 51% improvement in exercise endurance
in warm weather used intermittent water spray evaporative cooling
on the subjects' head for cooling, which was not as efficient as
the sub-ambient cooled embodiments disclosed herein, especially in
warm humid conditions.
[0175] Another application of the subject embodiments is bicycle
helmets, which are generally much lighter than motorcycle and
automobile helmets because of the much lower speeds encountered
with bicycles and because a heavy helmet would place more of a load
on the bicycle rider. Bicycle helmets may have a foam impact
absorbing layer similar to motorcycle and automobile helmets, or
may not have a foam layer at all. The basic pattern of FIG. 6
allows the TSF, or other air flow structure, to fit smoothly inside
a helmet or skullcap shell. The orientation of the virtual tubes in
the TSF is important and indicated in the drawing for good air flow
and air distribution within the air flow liner.
[0176] FIG. 7 shows a side elevation view of a thermoelectric air
to air helmet thermoelectric heat pump with a new feature. The TE
helmet cooling, heating, and ventilating system 174 with condensate
management comprises optional filter 175, blower or fans 176,
blower(s) adapter 177, and a Thermoelectric device 178, resistive
heater, or smaller open space for ambient ventilation. FIG. 7 shows
the hot side in cooling mode 179, the warm/hot air to ambient 180,
along with vaporized condensation, the condensate wick 181, an air
barrier 182, cooled air to helmet 183, and cold side in cooling
mode 184.
[0177] The new feature is a condensate management system that
consists of a wick 181 that traverses both the cold side 184 and
the hot side 179 at the bottom of the assembly where cold air
enters the helmet and warm air from the hot side vents to ambient.
The purpose of the wick 181 is to collect condensate that drips
down from the cold side heat exchanger in humid weather and
transport it under a tightly fitting air barrier, that separates
the two air streams, over to the hot side where it is evaporated
away by the hot rejector air venting to ambient. This system 174
prevents condensation produced during cooling in humid weather from
dripping out of the helmet cooling system onto the user's neck or
back, eliminating the distraction of the water and making for a
better, more comfortable, product from the user's point of view.
The wick should be secured in place with adhesive.
[0178] FIG. 8 is a side elevation view air helmet convective system
201 in a preferred embodiment, where the system 201 inputs the air
into the air flow structure at approximately 90 degrees to the
longitudinal plane of the material. This is the preferred
embodiment because air flowing into the TSF at 90 degrees to the
normal orientation of the woven tubes produces a much more evenly
distributed air flow and cooling effect over and around the user's
head inside the helmet, whereas the embodiment of FIG. 8A inputs
air directly into the woven tubes, resulting In much more isolated
flow, resulting in much more isolated cooling, across the top of
the user's head with greatly reduced cooling on the sides of the
head, but more intense cooling of the face area in a full face type
helmet because of higher air flow velocity in that area.
[0179] The air helmet convective system 201 comprises an optional
filter 175, blower or fans 176, blower(s) adapter 177, a
thermoelectric device 202, single stage shown, two stage device
optional for extra dT, a condensate wick 18, an afterheater heat
exchanging surfaces 206 contacting resistive heater in air stream
to helmet, a resistive relative humidity control after-heater 210,
preferably of the PTC type, fins shown dashed line, and a power
input 209. FIG. 8 shows the warm/hot air to ambient 180, the air
barrier 182, the cooled air with reduced relative humidity to
helmet 207, and the cold side fins 208 in cooling mode
[0180] Specifically, FIG. 8 shows another side elevation view of a
thermoelectric air to air helmet convective system 201 of the
subject embodiments in which another new feature is added. The
additional new feature is a relative humidity control system in
which a resistive heater 210 with a heat exchanger is installed
downstream of the cold air source for the purpose of heating the
air up a few degrees in order to reduce the relative humidity of
the air. This requires that the helmet air be cooled below the dew
point, or the point at which condensation takes place, so that
moisture is precipitated. Once moisture has been precipitated,
there is less total moisture content in the same volume of air so
that when the air is heated moderately the relative humidity
reduces noticeably, but the air stream into the helmet is still at
a relatively low enough temperature to accomplish cooling in warm
weather. The advantage of relative humidity control is that is
enables a broader range of comfort for a given cooling temperature
because the air not only cools, but also has a greater capacity to
absorb perspiration, resulting in enhanced comfort because the air
is not only cool, but drier as well, without being too dry.
[0181] As can be seen in FIG. 8, a resistive heater 210 is located
at the outlet of the cool side 207, within the extension of the
heat pump housing that couples with the air duct opening in the
shell of the helmet that is optimally located on the back of the
helmet. This enables the apparatus to be added without increasing
the bulk of the cooling system assembly. Heat exchanging surface
extensions such as fins, attached to the heater, are shown as
dashed lines and are spaced approximately 1-2 mm apart across the
air outlet into the helmet in the air stream.
[0182] The basic sensors and controls for the relative humidity
control reheater may be located anywhere appropriate on or in the
helmet and consist of a cooling air relative humidity and
temperature sensor, micro-controller on a chip, with power stage,
and the reheater resistor itself. The micro-controller is
programmed to energize the reheater to the extent necessary to
reduce relative humidity while remaining below a predetermined
cooling temperature. The sensors and controls may also be located
in the remote control in line with the ACH power cord 209.
[0183] FIG. 8A discloses essentially the same apparatus; however,
FIG. 8A shows an optional added air duct 211 to allow air to be
ducted into the helmet air flow structure at .about.90 degrees from
that of FIG. 8. The air duct 211 comprises urethane,
Santoprene.RTM., or similar pliable material for optional radiused
air duct extension to TSF.
[0184] A two stage Peltier device 210 is also disclosed in FIG. 8A,
in order to achieve a higher air cooling dT to enable greater
sub-cooling to remove even more excess moisture before re-heating
up to the desired cooling temperature for a more idealized
temperature/humidity, or "effective temperature".
[0185] FIG. 8B discloses a variation of the afterheater 212 of the
relative humidity control for an ACH, in which the heating element,
with fins 213 attached, is located within the air outlet air
barrier between the cold and hot sides of a thermoelectric air to
air heat pump to cool or heat air for the ACH. Locating the heating
element within the air barrier creates a more compact assembly and
reduces the projection of parts outside the bottom of the
convective assembly to enhance safety in the event of a severe
impact.
[0186] FIG. 8A, which shows a detail of solutions for the
alternative thermoelectric air ducting means disclosed in the
original ACH patent. The new solution is to use a somewhat pliable
or flexible urethane extension on the outlet of the thermoelectric
air to air heat pump or convective heating or ventilating system
ducting ambient or cooled or heated air to the TSF or other air
flow structure that is located within or adjacent the impact
absorbing foam layer. An extension 211 is necessary because the
impact absorbing layer is usually between approximately one inch to
one and a half inches thick. The extension 211 should be made of a
material such as urethane, or Santoprene.RTM., for example, with a
Durometer of approximately 65-95 on the Shore A scale. Thus it will
hold its shape under normal circumstances, but will deform readily
under impact, so as to prevent any transmission of force to the
neck of the helmet user. The extension must be long enough to reach
past the impact absorbing layer and make a 90 degree bend to duct
temperature modified air directly into the edge of the air flow
structure, instead of at an angle more or less perpendicular to the
air flow structure. The preferred embodiment of the humidity
control system is disclosed in FIGS. 8 and 8A with a one or two
stage Peltier device. The two stage Peltier device will provide a
higher cooling delta T (hereafter "dT" which refers to the
difference in temperature between the hot and cold sides of the
device) which will perform better over a wider range of temperature
and humidity combinations than a single stage device.
[0187] FIG. 8B is an alternative configuration for the afterheater
with fins installed in, or as, part of the middle air barrier. This
revision places the heating element so as to not project into the
helmet impact layer air duct in an impact, although the entire
convective system is protected by a robust cover for vehicle
applications.
[0188] FIGS. 9 and 10 show further views of safety and aerodynamic
improvements to the air conditioned helmet, or air convection
helmet, also shown in FIGS. 1 and 2.
[0189] FIG. 9 is a plan view of a helmet 101 having tapered;
aerodynamically smooth convective system fairings 214. Tapered
aerodynamically smooth convective system fairings 214, one on each
side, radiused as smoothly as possible for minimum induced rotation
from tangential impact. Bonded to the outside of the helmet shell,
with cover over the channel and convective system. Cover is shown,
(dashed line and transparent for clarity), covering up to the top
of the channel with a NACA duct air inlet.
[0190] FIG. 10 shows a helmet 101 with an extended shell 111. The
extended shell 111 with channel for thermoelectric cooling system.
A cover is also shown. Multiple fan type cooling, ventilating, or
heating system are shown. Other views shown in FIGS. 1 and 2.
Dashed line is upper edge of cover, (transparent for clarity),
leaving enough opening near the top for air to enter into the
channel space.
[0191] The external thermoelectric heat pump, ventilating air
mover, or heating module housing is a design alternative to the
configuration of the previous disclosure in which the convective
assembly is countersunk into an extended helmet shell in order to
arrive at a smooth uninterrupted external helmet surface. The
object of the new external type housing of FIGS. 9 and 10 is to
produce aerodynamically efficient fairings 214 or a fairing fitted
to the exterior of a conventional helmet shell.
[0192] The new improved external convective assembly cover,
housing, or fairing 214, may be tapered from front to back to
produce the smoothest possible air separation from the back surface
of the helmet, to reduce noise, turbulence, and drag, while giving
the helmet a smoother external surface overall, as opposed to a
more or less rectilinear or rectangular box attached to the back of
the elongated, somewhat spherical shape of most helmets, especially
full-face type helmets. A tapered shape is more efficient than a
more spherical shape because it reduces air flow separation
turbulence at the rear surface of the helmet.
[0193] Air vent holes may be located anywhere on the surface of the
external cover, however if they are located on vertical sides of
the cover there will be good air access through the air vent
apertures to the blower inside the cover and it is not necessary to
put air inlet holes or gaps on or around the top or sides of the
fairing cover, reducing the incidence of rain intrusion into the
housing/cover. If too much rain gets into the convective assembly
housing, some of it might be blown into the interior of the helmet,
which is not desirable, although very small amounts of rainwater
are not harmful to the air mover(s) or the thermoelectric device,
or the resistance heating module.
[0194] For thermoelectric air cooled and heated helmets, or
resistance air heated, or ambient air ventilated helmets that have
the type of air duct to the interior of the helmet which does not
introduce air into the helmet air flow structure through an
aperture in the back surface of the helmet, but instead introduces
air into the air flow structure edgewise, an integral cover for
that air duct may be molded into the heat pump housing as shown in
FIGS. 16 and 17.
[0195] FIG. 11 illustrates a side elevation view of the extended
rear cover, or fairing 214, which is applied to the outside surface
of a conventional helmet shell. Side elevation view of extended
shell fairing 214, bonded to the outside of a standard shell. The
extended ACH shell is similar, but without the overlapping joint
line at the front of the fairing 214. The helmet 101 has a front of
the shell 102 and a visor 103. Full face helmet is shown. ACH may
be made in open face, modular, and half helmet styles for
motorcycle and other uses, however full face offers more face
cooling and cooled air for breathing, (with thermoelectric
sub-ambient cooling), which enhances the overall body cooling
effect. The helmet 101 has an extended fairing or cover 214, a
filter with a compact adaptor 142, air movers (fans or blowers)
144, and a convective apparatus.
[0196] Another new solution of these air convective helmet
embodiments disclosures are shown in FIGS. 12-15. FIG. 12 is a
heating apparatus 301 in which a blower is coupled to an optional
resistive heating element. The heating apparatus 301 comprises air
mover(s) 302, a heating module adaptor 303, resistive heating
elements 304, with finned heat exchangers, an external helmet air
duct adaptor 306, adjustable power to blower for variable speed
308, and an optional control for non-PTC heating elements 307 and a
temperature sensor for heater control 309. Heating or ventilating
air to helmet 310 is shown exiting the apparatus 301.
[0197] FIG. 12 shows a new and less expensive approach to helmet
heating in which a blower 302 is connected to an optional resistive
heating element module 304 consisting of a resistive heating
element, such as a PTC type element for example, or any other type
of resistive heating element, in contact with an extended surface,
such as fins or pins or the like to transfer heat from the resistor
to the air flowing to the helmet. When only ventilation is desired,
the resistive heating element(s) 304 can be turned off and the
blower 302 can be used alone to force ambient air into and through
the helmet air flow structure in the interior of the helmet.
Although any functional air flow structure may be used with the
apparatus FIGS. 12-15, the preferred embodiment uses Tubular Spacer
Fabric, (TSF), as the helmet internal air flow structure. FIG. 12A
is a cooling apparatus in which a blower 302 is coupled to an
optional resistive heating element with widely spaced, overrated
fins 304a.
[0198] FIG. 13 is a side elevation view of resistive heating
elements 311, fins 312 having normal efficient heat exchanger fin
density, and power terminals 313. It is important to note that the
resistive heating element can be omitted for a simple forced
ventilated helmet, and a speed control can also be added to the
blower or fan, with or without the heating element, to vary the
amount of air forced through the helmet. The preferred embodiment
for the heating element is a PTC type resistive element, since it
doesn't require a control circuit and will never exceed the
predetermined maximum temperature, (Curie Point), under any
circumstances, making it the safest, most compact, cost effective,
and most reliable lightweight embodiment. It is possible to make a
PTC resistive device with a switching temperature, TS, or Curie
point, of less than 40 C, which would be ideal for high efficiency
heat exchangers as shown, however the material required is
generally not readily available. In that case, the solution of
FIGS. 12A, 13A, 14A, and 15A would be the preferred embodiment
until production and sales justify the tooling to produce a PTC
device with an extra low Ts.
[0199] FIG. 13A is an elevation view depicting the resistance
heating elements 311 with low efficiency, low fin density heat
exchanger 312A. It is important to note that the difference between
this novel arrangement and the novel arrangement of FIGS. 12-15 is
that the heat exchanger(s) of FIGS. 12A-15A are overrated in that
they have fewer fins for less area. The reason for this is to
create a unique, simple, inexpensive way to use a PTC heating
device with a Ts, or switching temperature that is above the
desired maximum air temperature. The minimum typical Curie Point,
or switching temperature, for a PTC resistor is approximately
40.degree. C., or 104.degree. F. 40.degree. C. is too high for use
in the helmet to warm the users head, provide comfortable air for
breathing, and demist/defrost the helmet visor in low temperature
ambient environments, so overrated heat exchangers will simulate a
lower Ts because the device will not exceed its Ts, however the air
temperature will not exceed the desired level either when balanced
to the higher Ts with overrated heat exchangers. The higher Ts, of
40.degree. C. is still too low to cause problems should an air
mover fail. When production justifies the tooling, this solution
may be replaced with a lower Ts device and higher efficiency heat
exchangers
[0200] FIGS. 14 through 15A show the heating apparatus only. FIG.
14 is an end elevation view of a heating module 320 in an
embodiment. The heating module 320 comprises baseplates 321, and a
gasket 322. Air flow is indicated by the arrows. FIG. 14A is an end
elevation view of a heating module 320' in an embodiment, having
optional baseplates 321'. The heating module 320' comprises
optional baseplates 321', which may also use folded without
baseplates, and a gasket 322.
[0201] FIG. 15 is a plan view of a heating module 324 in an
embodiment. The heating module 323 comprises heat exchangers 1 324a
and 2 324b, power terminals 325 and resistive heating elements 326.
FIG. 15A is a plan view of a heating module 323' having a lower
density fin design in an embodiment. The heating module 323'
comprises heat exchangers 1 324a' and 2 324b' having low fin
density having relatively widely spaced and/or short fins for
smaller than optimal surface area.
[0202] FIG. 15B shows the conflux conductive elastomer or polymer
PTC heater 353 (the thickness exaggerated for clarity), a
box/housing 350, and a first heat exchanger 351 and a second heat
exchanger 352. The housing clamping folded fin heat exchangers to
rubber, or polymeric PTC heating material that cannot be
soldered.
[0203] A resistive heating module is shown with two separate heat
exchangers 320 and 322 in FIGS. 14 and 15 respectively. A single
sided assembly can also be used, but at reduced efficiency for a
given volume. For the double heat exchanger type of module, a
gasket (i.e. FIGS. 14 and 14A), is required between the two heat
exchangers in order to prevent air from leaking through between the
two heat exchangers, which would reduce overall heating efficiency
because some of the process air would not be exposed to the
extended surfaces of the heat exchangers.
[0204] A positive temperature coefficient of resistance, (PTC),
type resistive heating element is the preferred embodiment because
it is impossible for it to overheat if an air mover should fail and
simplifies overall control system design, however a conventional
resistive heating element can also be used with the apparatus FIGS.
12-15.
[0205] The solution of FIGS. 12 through 15 includes the use of high
efficiency heat exchangers 324a/b with relatively high fin density
because either the PTC heating element is formulated for exactly
the desired switching point, or Ts, at which the temperature of the
PTC device stops rising, or a plain resistive heater is controlled
precisely to not exceed a given temperature. For PTC devices with
higher than optimal Ts, the solution is given in FIGS. 12A through
15A, incorporating special low fin density heat exchangers so that
the PTC device operates at a higher Ts, but with an output air
temperature below Ts temperature.
[0206] Alternatively, the disclosures of FIGS. 12-15A can be used
for snowmobiling and other helmets used in very cold environments,
especially with high speed wind chill factors, to produce the
simplest and most cost effective and reliable heated helmets with
the preferred embodiment of a PTC type resistive heating element,
(or any resistive heating element with suitable controls), that
will never exceed a temperature limit of approximately
60-70.degree. F., for example, without complex, bulky, and
relatively expensive controls, thereby preventing overheating of
the user's head, while providing a much more comfortable helmet
interior and frost free visor, with much more comfortable air for
breathing in very cold environments.
[0207] FIGS. 12A-15A present a novel solution for PTC devices with
higher than optimal Ts, or switching temperature, to arrive at a
usable solution until production volume justifies a PTC device made
to order with an optimal Ts.
[0208] This solution is intended to enable production of a
convectively heated helmet with a PTC device that has a higher than
desired Ts, which are the most commonly available PTC resistive
devices, until requirements justify a special PTC heater made to
order with a relatively low Ts.
[0209] FIGS. 14B and 15B illustrate a novel solution for the use of
a relatively new PTC resistor material that is a conductive rubber
or polymer made by Conflux AB of Sweden, for the snowmobile version
of the convective headgear. Because the polymer or rubber cannot be
soldered, in order to use it for the snowmobile convective headgear
for warming air to defrost the visor and provide more comfortable
and efficient breathing air for the user, the air convection
heating system is designed to compress folded fins, with or without
baseplates, onto the PTC polymer or rubber material for high
thermal transfer efficiency without adhesives or solder. An
adhesive may function to attach the folded fins to the PTC
polymer/rubber, but will not exert enough positive pressure to
produce a thermally efficient interface between the materials. The
housing is designed to compress the PTC air heating element sheet
and folded fin assembly when the components are inserted into the
housing.
[0210] FIG. 16 illustrates a helmet with air vent holes 450 in rear
surface of cover instead of on sides of cover. FIG. 17 illustrates
a covering 452 for air duct for air entering the air flow structure
on the edge of the structure instead of the rear surface of the air
flow structure.
[0211] FIGS. 16 and 17 show a variation in the subject ACH in which
the air vent holes for the thermoelectric cooling and heating
system air mover cover, or resistive heating system, or ventilation
system air mover cover, are located on the rear housing surface
instead of on the housing sides. The location of the air inlet
vents is a functional and aesthetic consideration because the air
pressures at the surfaces of the helmet or headgear will vary in
different locations. The sides of the housing will have moderately
low pressure because the air flow tends to be relatively laminar
along the side surfaces. The presence of holes, slots, scoops,
etc., will alter the laminarity of flow.
[0212] FIG. 18A is a top view of a removable lining 401 in an
embodiment. The lining 401 comprises an air flow structure 405
under lining cover, a lining cover 402, Velcro.RTM. or other
attachment 404, and an air inlet insulation layer 406. Removable
cover lining 402 for TSF or other air flow structure without the
insulation layer of FIG. 19A, but shown with a Volara.RTM. or other
thermal insulation layer bonded or sewn in position opposite the
cooling air Input Into the helmet TSF liner, between the lining
cover 402 and air flow structure 405.
[0213] FIG. 18A shows the other basic liner configuration in which
there is no thermal barrier so that thermal transfer is uninhibited
over the head of the user, resulting in longer vectors over the
head and a shorter vector in the visor area, as shown in FIG. 18B.
A thermal barrier is shown in FIG. 18A in the area opposite the
inlet of cold air into the helmet, under the interior trim cover
layer, to prevent a cold or warm spot on the user's neck and head.
The thermal insulation layer is preferably made of thin
Volara.RTM., a radiation cross-linked closed cell foam, made by
Voltek Corp., although any other suitable flexible and efficient
thin insulation may be used.
[0214] The above describes a new and unique way of configuring the
ACH without having to increase the thermoelectric cooling and
heating system power requirement in order to accomplish more visor
heating or face cooling. The trade-off with this approach is that
less cooling is applied to the head in order to provide more
cooling to the face and lungs of the user.
[0215] FIG. 18B is a representation of the air flow within the
helmet 101a. This configuration exhibits more cooling/heating all
over head with less visor, face, and breathing air dT. Vector
lengths indicate more cooling of the head space and less cooling in
the front space of the helmet without center insulation layer.
[0216] FIG. 18C is a perspective view of the air flow structure 405
as fitted into a helmet 101a. The lining 401 comprises an air flow
structure 405, Velcro.RTM. or other attachment 404, and an air
inlet insulation layer 406. TSF or other air flow layer may be
glued in place however Velcro.RTM. 404 or other semi-permanent
fastener allows for removal. The assembled TSF or other air flow
structure 405a as fitted into the helmet is displayed, as well as
the assembled interior trim cover structure 405a shown with an
extended trim edge 412 to fold over air flow layer edge for
retention. Air flow layer interior trim cover, such as 3Mesh.RTM.
for example, as fitted into the air flow structure, with extra
flange material wrapped around edge perimeter of material.
[0217] FIG. 18C shows how the air flow structure interior cover
material, whether 3Mesh.RTM. or another material, although knitted
3Mesh.RTM., as made by Muller Textil, for example, is the preferred
embodiment for that component, may be cut and sewn into a more or
less hemispherical shape similarly to the way baseball caps are
constructed in order to form fit into the air flow structure as
installed in the helmet. The inner trim thus fashioned, can then be
allowed to drape into the head space of the convective helmet or
cap, or be held in place with snaps, semi or permanent adhesive,
Velcro.RTM., zippers, thin plastic sheet edges that insert on the
perimeter between the EPS impact foam or other impact layer, and
the helmet shell, as shown in FIG. 23B. An air flow structure air
outlet grill may also be designed to help hold the trim material in
place, by attaching the grill to the trim as shown in FIG. 23A as
can the rear lower air seal of FIG. 23C. The helmet interior trim
material can also be oversized, as shown in the far right figure in
FIG. 18C where the perimeter is extended, to wrap around the
perimeter of the air flow layer and the overlapping edges can be
glued into place with the whole assembly being held in the helmet
via adhesive, Velcro.RTM., snaps, etc.
[0218] Whatever means are used, one half of a fastener can be
countersunk into the impact absorbing layer so that the fastening
system doesn't cause a bulge on the inside surface. A countersink
for a Velcro.RTM., or adhesive, fastener is shown in FIG. 2.
[0219] The function of the optional insulation layer of FIG. 19C is
not affected by the structure of the air flow structure interior
finishing trim construction.
[0220] Many of the new solutions embodied in this disclosure are
applicable to the forced ventilated version, ("FVH"), of the ACH
and to the resistively heated cold weather air conditioned ACH.
[0221] FIG. 19A is a top view of a removable lining having an
optional insulation layer in an embodiment. The lining 420
comprises an air flow structure under lining cover 405, an air
inlet insulation layer 406, a removable cover lining for TSF or
other air flow structure 402, and an optional insulation layer
422.
[0222] FIG. 19D illustrates a novel solution for the cold weather
version of the convective helmet in which the inner liner is either
an insulation layer or a layer with reduced thermal conductivity or
thermal transfer for using heated air for defrosting the visor and
for breathing, without altering the temperature of the users head
or scalp.
[0223] FIG. 19C is a top view of a removable lining having an
optional insulation layer 422 in an embodiment. FIG. 19D is a top
view of a removable lining having an insulation layer or a partial
insulation layer 425 in an embodiment.
[0224] The apparatus described above can also be used for helmet
ventilation in warm weather and for demisting and defrosting of the
visor in freezing weather, such as for snowmobiling, for example,
which is normally done at .about.20.degree. F. ambient, or colder.
The TSF insulation layers of FIG. 19A and FIG. 19C can be used with
the TSF air inlet ducting for primarily visor defogging in very
cold weather, since most of the air is directed up and over the
head to the visor area and the heating effect can be reduced or
enhanced by using or omitting the insulation layer strip 422 along
the middle of the helmet TSF layer. It is unnecessary to use an
insulation layer 422 for a heated helmet if the temperature of the
heated air never exceeds approximately. 70.degree. F., max.
[0225] Effective demisting and defrosting of a visor in freezing
conditions can be accomplished with air at a high enough
temperature above freezing to melt ice or prevent the formation of
ice. An air temperature of 60-70.degree. F. is high enough to melt
or prevent ice, while being relatively much more comfortable to
breathe than sub-freezing ambient air, and significantly reduces
body core heat loss via the lungs, while snowmobiling, for example.
A lower heating temperature also requires less power.
[0226] It is very important to note that the resistive heating
element can be omitted, resulting in a forced ventilated helmet
that, while not as effective at body cooling as the sub-ambient
thermoelectric air system in warm or hot environments, is
nevertheless superior to passive ventilation, which is unable to
flow sufficient amounts of air through a helmet at sufficient
velocity over a large enough area for effective head and body
cooling, even in moderate to cool weather. It is also possible to
add an air mover speed control to the forced ventilated design to
enable the user to adjust the air flow to a desired level of
cooling. Forced ventilation is also applicable in ambient
conditions where ambient temperature is sufficiently low to provide
adequate cooling without cooling the air below ambient temperature
with a thermoelectric or other heat pumping device. Forced
ventilation is an excellent option for bicycle helmets when cycling
in ambient weather that allows for good head and body cooling with
ambient air because, in addition to reducing the cost of the
helmet, it reduces the weight of the helmet and the battery
required to run it. Cyclists who ride in cool and warm weather
should be able to use each type of convective helmet to advantage
under the appropriate conditions.
[0227] FIG. 19D has been added to illustrate a novel solution to
the concept of head or scalp warming for the cold weather
application of the subject convective helmet, in which the
insulation layer 422 of FIG. 19C is enlarged to cover more of the
inside of the helmet to limit head or scalp heating when using
heated air to defrost the visor and provide more comfortable air to
breathe in freezing temperatures. If air at a temperature of
approximately. 60-70.degree. F. is used to defrost the visor and
for comfortable breathing, the larger insulation layer covering the
inside of the helmet air flow structure of FIG. 19D will not be
necessary.
[0228] An improvement in the Air Convection Helmet is a removable
inner liner cover that can be configured to adjust the mode of
thermal transfer by using thermal barriers or not using thermal
barriers.
[0229] By making the lining relatively easily removable, the user
can more readily configure the helmet to suit their preferences.
For example, if the user prefers to have more cooling air on their
face than on their head, the air flow structure inside the helmet
that carries the air from one point to another inside the helmet
can be fitted with an extra barrier layer 422 (FIG. 19A) that
inhibits thermal transfer from the user's head to the air flowing
inside the air flow structure. The air barrier may be selected from
extra liner covers either offered for sale by the helmet
manufacturer, or included as standard equipment with the helmet. By
inhibiting thermal transfer, the air that flows from the rear of
the helmet forward toward the visor area at a lower temperature in
cooling mode or a higher temperature in heating mode, produces a
more pronounced cooling or heating effect in the visor area of the
helmet, and a reduced cooling or heating effect on the user's
head.
[0230] This is illustrated by FIG. 19B in which the length of the
vectors, or arrows, indicates relative convective cooling or
heating power. FIG. 19B is a representation of the air flow within
the helmet 101b. FIG. 19D illustrates the helmet offers less
cooling/heating all over head with more visor, face, and breathing
air dT. Vector lengths indicate less head space cooling or warming,
and greater cooling or warming in the front air space with center
insulation layer. Removable cover lining for TSF or other air flow
structure with additional insulation layer in the middle, back to
front for applications where the air is ducted directly into the
TSF along the edge, instead of at 90 degrees to the plane of the
material. 90.degree. to the plane is preferred because it causes
the air to spread out around the user's head more evenly and
completely. Direct ducting results in a narrow band of cooling
across the middle of the user's head with much less cooling effect
outside that area.
[0231] FIGS. 18A and 19A both show Velcro.RTM. patches 404, which
are one method of securing the liner cover into the helmet. The
corresponding Velcro.RTM. patches can be secured to the air flow
liner itself or to certain places within the helmet foam impact
absorbing layer. Other methods may also be used to secure the liner
cover, including Zippers, adhesive, snaps, etc. The air flow
structure liner cover can also be sewn in a form similar to a
baseball cap without a brim, as disclosed in FIG. 18C, and secured
only on its perimeter, fitting freely up against the air flow
structure inside the air flow structure head space when pushed
fully into the head space.
[0232] FIGS. 20 and 21 illustrate new concepts that reduce the
apparent volume of the ACH thermoelectric cooling and heating and
resistive heating system, and reduce the extension of the rear of
the helmet to accommodate the apparatus by configuring the heat
pump with a radius that more closely matches a conventional helmet
rear contour where the convective apparatus is mounted on the
helmet.
[0233] FIG. 20 illustrates a cooling and heating system 501 in an
embodiment, showing the conventional outside rear of helmet 502,
and an optional curved ceramic plates 503. Minimum ACH
thermoelectric or other convective system volume design with
radiused fin baseplates to match helmet shell curvature. Baseplate
volume and weight are non-optimal. Baseplate r-theta thermal mass
are also relatively high. FIG. 20 illustrates a novel approach to
making the thermoelectric cooling system more compact and
conformable to the shape of a helmet by molding the ceramic plates
of the thermoelectric device, shown larger than scale for clarity,
with a radius. A folded fin heat exchanging surface can then be
bonded to the radiused ceramic plates for a curved assembly as
shown.
[0234] FIG. 21 illustrates a cooling and heating system 505,
showing the conventional outside rear of helmet 502 and a
thermoelectric stack (TES) 506. Also indicated are the divided
convection system with twice the air movers, but smaller diameter
507 and the current single convective system (solid lines) with two
air movers 508
[0235] Another radiused concept, but using a modified TES,
(Thermoelectric Stack, Feher U.S. Pat. No. 6,855,880), which allows
for the thermoelectric device and heat exchanger fins to be formed
in a radius to match helmet shell curvature, but with even less
mass than a conventional flat type thermoelectric air to air
assembly. This also offers higher thermal efficiency due to reduced
r-theta over conventional thermoelectric air to air assemblies and
faster time-to-dT because of significantly reduced thermal mass.
This design also reduces the strength of the TE assembly, enabling
it to crush more readily in an impact if necessary or desired. The
TES assembly is also lighter than a conventional TE device with
bonded copper or aluminum fins, and is more efficient
thermodynamically. The radiused TE assembly can be made wider,
flatter, and thinner for the same air pressure drop, with smaller
diameter air movers to enhance compactness. Another way of
producing the radiused thermoelectric module is to use any suitable
flexible dielectric substrate in place of the usual rigid ceramic
plates found in conventional thermoelectric modules, however, TES
is the most efficient and cost effective embodiment.
[0236] The solution of FIG. 21 is to use a Thermoelectric Stack,
(TES), as described in U.S. Pat. No. 6,855,880, because the TES may
be configured with a radius to conform to the shape of the helmet
shell where it is attached to the helmet shell. Not only does the
TES offer the space savings of a radiused design, but it also
offers numerous other advantages including:
[0237] 1--Less thermoelectric heat pump assembly weight and thermal
mass due to the elimination of heat exchanger baseplates and
ceramic dielectric plates on both sides.
[0238] 2--Much faster cool-down and warm-up because of reduced
thermal mass.
[0239] 3--Higher thermal efficiency due to reduced r-theta, or
thermal impedances across the system.
[0240] 4--Reduced cost because ceramic plates and heat exchanger
baseplates are eliminated.
[0241] FIG. 20A shows thermoelectric Pellets 16, flexible
insulator/support planes 18, inner fins 17, tapered outward, before
bending and installing in housing, and outer fins 19, tapered
inward, before bending.
[0242] FIG. 20B shows a conventional non-flattened helmet shell
rear surface 25 and optional curved ceramic plates 26. Ceramic
plates molded with radius to fit helmet shell to provide a wider
flatter thermoelectric assembly for minimum projection out from the
helmet shell.
[0243] FIG. 21A shows the conventional outside rear of helmet 20.
Assembly above after bending, fins are straight, originating from
the same instant center. The advantages of low weight, high thermal
efficiency, and fast response of the TES may be applied to an ACH
with a flattened rear surface as well as with a conventional
rounded rear surface.
[0244] FIG. 21B shows stamped copper or aluminum fins 21 in a
square U shape, straight, flat, rigid non-conductive fin and pellet
assembly support plates 22, and TES as patented in U.S. Pat. No.
6,885,880 B2 for use instead of a conventional Peltier
thermoelectric air to air cooling system for convective
headgear.
[0245] FIGS. 20B and 21B show another novel solution to making a
convective helmet with minimum projections out from the helmet
shell for maximum safety by not inducing rotation about the user's
neck if subjected to a tangential or lateral impact. FIG. 20B shows
a thermoelectric air to air assembly in which the thermoelectric
device(s) have ceramic plates with an important difference. In the
subject embodiments the plates of FIG. 22B are molded, using
beta-alumina ceramic, or any other suitable ceramic or dielectric
material with good thermal conductivity, with a radius or curve,
that matches the curvature of the helmet shell where the
thermoelectric assembly is mounted to the outside of the
helmet.
[0246] FIG. 21B shows another new way to achieve a relatively
flatter thermoelectric assembly for the same reasons, by using two
or more smaller and thinner flat modules, articulated into the
curvature of the helmet shell for minimum projection out from the
shell. Smaller diameter fans or thinner blowers are used with this
arrangement. The ultra-flat assemblies are wider because the
cooling surface area must be the same and the air flow
cross-section must be the same, as the previously disclosed compact
thermoelectric assembly using a narrower and deeper form. For
example, four Sunon.RTM. GM0501PFV1-8 GN fans, or similar, may be
used for the ultra-compact design with 2 TE modules that are
smaller than the single module assembly with 2 larger Sunon.RTM.
fans. It is more compact and desirable to mount the fans or
blower(s) close to the modules without bulky manifolds or adaptors,
although a space of at least on half diameter of the fan between
the fan outlet and the fin inlet is recommended. The multiple
cooling or heating modules with smaller fans approach can also be
used to advantage with a helmet that has a flattened rear
surface.
[0247] FIGS. 20A-21B depicts an update includes the use of a
Thermoelectric Stack, (TES), without a radius. Since it is possible
to flatten the back of a helmet if necessary to accommodate an
adequately compact convective system. FIG. 9B is added to
illustrate the difference between the TES with and without radius.
FIGS. 20A, 21A, and 21B show another novel solution required to
optimize the solution of FIGS. 20 and 21, the TES TE module
assembly of U.S. Pat. No. 6,855,880 B2, with fins that can be
radiused to fit the curvature of a helmet shell more compactly, in
addition to offering advantages in terms of weight, volume, thermal
response time, efficiency, and cost, because of the elimination of
the ceramic insulator plates and heat exchanger baseplates.
[0248] In order to arrive at the proper fin alignment, the fins
must be pre-bent so that the inner fins, facing the helmet shell,
will reduce in angle, resulting in a straight fin, and the outer
fins, facing away from the helmet, are pre-bent to increase in
angle, resulting in straight fins. The inner fins are initially
tapered outward, and the outer fins are initially tapered inward,
so that when the assembly is formed into a curved shape with a
radius, the fins all have the same instantaneous center of origin.
If this important step is not done, the inner fins will taper
inward, reducing the air flow cross section and increasing the air
flow pressure drop, and the outer fins will bend outward, reducing
the air flow pressure drop. The coefficient of thermal transfer can
be diminished on the outer fins because of reduced turbulence and
velocity, in addition to the flow characteristics on both side
being thrown out of balance by the increased cross section on one
side and the reduced flow cross section on the other.
[0249] The solution of FIGS. 20A and 21A may be achieved with the
use of a suitably thermally conductive flexible element on which
electrical traces are placed to form circuits with pellets to make
a flexible thermoelectric module. Folded metal fins may be attached
to the flexible module, pre-bent as shown in the figures, so that
the entire assembly may be radiused as shown without the fins
interfering with one another. The flexible element may be a
polymer, or a combination of graphene and polymers or other
flexible materials, for flexibility and improved thermal
conductivity, with good dielectric properties, over conventional
thermoelectric module heat acceptor and rejector surfaces. Kapton
has also been used to make conventional flat insulated
thermoelectric module heat exchanging surfaces for fins, pins, and
the like.
[0250] It should be added that the technology disclosed in U.S.
Pat. No. 6,855,880 B2 may be used to advantage for cooling with ACH
shells that are flattened to some extent at the rear and don't
require a radius in the Peltier device assembly to offer the other
advantages of less weight, lower cost, higher thermal efficiency,
and faster thermal response.
[0251] FIG. 22 illustrates the location of the helmet air outlet
vents that vent into the face area of a helmet equipped with the
ACH apparatus. FIG. 22 is a schematic view of a helmet 550,
illustrating an air flow layer seal 552, a convective system 554,
an outer shell 556, an insulation or impact layer 557, TSF or other
air flow layer top face air vent trim location 560, and side face
air vent location, near temples.
[0252] FIG. 22B shows double articulated TE modules with radii,
designed for small air movers, such as the above Sunon.RTM. GM0501
PFV1-8, for maximum compactness and a low and high cooling mode.
FIG. 22B illustrates another novel solution to make the ACH even
more compact and flexible. A double articulated and radiused
thermoelectric module assembly includes either a flexible substrate
that enables a radius, or a molded rigid plate with radius to make
the double articulated and radiused module assembly more compact
than the double articulated modules with straight substrates or
plates.
[0253] FIG. 22C shows a side view of the helmet with a TSF or other
air flow layer 162, insulation or impact layer 160, outer shell 28,
convective system 29, and a rear air inlet TSF lower edge air seal.
30
[0254] FIG. 22AB shows a plastic strip 820 stitched to 3Mesh.RTM.
or other air flow structure interior trim cover, with or without a
hem, shown without a hem for clarity with approximately 2-3 mm
thick 3Mesh.RTM. or other TSF interior trim. 821
[0255] FIGS. 22AB and 23AB show a detail of an additional solution
for trimming the helmet interior air flow structure in the most
simple and inexpensive way with a pleasing aesthetic and practical
effect. A thin flexible plastic strip or sheet, approximately
0.50'' to 1.0''x.about.8-10''x.about.0.020'' thick, is sewn to an
edge of the air flow layer trim material, a preferred material
being Mueller 3Mesh.RTM., approximately 2-3 mm in thickness, or an
equivalent knitted material. The plastic strip can then be inserted
between either the air flow structure and the helmet impact foam,
covering the inside and edge of the air flow structure, but
allowing air flow with a very low pressure drop so as to not effect
helmet cooling performance. Alternatively, the plastic strip may be
sewn onto a larger piece of interior air flow structure trim
material and inserted between the helmet shell and the helmet
impact foam. In either case, the purpose of the plastic strip is to
anchor the interior air flow structure trim material to the helmet
securely and to do so without interfering with outward venting air
at the front of the helmet above the forehead of the user. Means
for preventing air loss from the lower back edge of the interior
air flow structure, where the air enters the back of the helmet are
described elsewhere in this disclosure. Also disclosed in FIG. 23AB
is a special thin, (.about.2 mm), optional air tight layer, used at
the bottom of the TSF or other air flow structure material, to seal
the lower edge and prevent air leakage from that edge, as an option
to other air flow structure lower edge sealing means disclosed
elsewhere in this disclosure.
[0256] FIG. 23 is a perspective view of the trim molding 564. FIG.
23A shows a thin flexible plastic strip 800 stitched to finisher
and trim, soft flexible air outlet vent grill finisher 802, and
3Mesh.RTM. or other air flow structure interior trim cover 801.
FIG. 23A has been to illustrate a way of trimming the inside of the
ACH. The production ACH will need the following:
[0257] 1--Aesthetic finishing so that the interior of the helmet
looks good.
[0258] 2--Some degree of cushioning on the interior air flow
structure to make the helmet as comfortable as possible, because of
variations in head shape within the range of a given size, and to
soften the surface of the air flow structure, if necessary.
[0259] 3--Removability for cleaning.
[0260] 4--Very good air and vapor permeability for good thermal
transfer efficiency.
[0261] 5--Durability.
[0262] 3Mesh.RTM. is a knitted textile made under different by
numerous weaving and knitting mills, including Muller Textil, that
has worked best so far as an interior trim material for air
convective helmets. 3Mesh.RTM. type fabrics have excellent
permeability and durability and offer excellent cushioning with
thicknesses as small as 2-3 mm, which is even better for thermal
transfer efficiency than thicker padding materials. The cushioning
characteristics of 3Mesh.RTM. type textiles also reduce, but don't
eliminate, the need to size the helmet shell up to compensate for
the additional space taken by the air flow structure and the
internal trim.
[0263] One of the ways to use 3Mesh.RTM. knitted or other types of
interior trim materials in an ACH is shown in FIG. 23A, where a
thin flexible plastic sheet, on the order of approximately 0.020''
thick, is sewn to the edge of the 3Mesh.RTM., or other air flow
structure interior trim cover, and also to one side of the flexible
molded air flow structure air vent trim finisher so that the trim
finisher can be positioned over the end of the air flow structure,
securing the interior surface finisher.
[0264] Even if the air flow structure were to be molded into the
impact absorbing foam layer, the same arrangement would work best
with a small modification, shown in FIG. 23B, where the top flat
side of the finisher is rotated 90 degrees so that it can be
inserted into a groove or channel in the foam, or the gap between
the foam helmet liner and the helmet shell, to secure it.
[0265] Tubular Spacer Fabric, (TSF), is the best approach to making
a helmet air flow structure for a number of reasons:
[0266] 1--TSF provides maximum thermal efficiency because
temperature modified air is supplied to essentially the entire
surface to be cooled or heated, increasing thermal transfer
efficiency according to Newton's Law of Thermal Transfer:
Q=h.times.A.times..DELTA.T. A is area and, all else being equal,
the total amount of heat transferred will be directly proportional
to the area. Slots or channels or grooves in EPS foam will
generally result in an area that is not more than approximately
half the size of a TSF structure area, resulting in approximately
half the potential total heat transferred for the same total helmet
interior area, coefficient of thermal transfer, h, and .DELTA.T, or
temperature difference.
[0267] 2--In the case of a safety product like a helmet, impact
loading is critical. TSF spreads an impact load out over the entire
interior area of the helmet resulting in much lower specific impact
loading per square inch on the user's head in the event of an
impact. This is why all of the best helmets have smooth continuous
interiors and keep the size of the air channels that are currently
used for passive ventilation to a minimum, which, unfortunately
also results in very little actual thermal transfer and resulting
body cooling, especially since the relatively very small amounts of
air that are circulated through the minimal channels in the foam
are filled with small amounts of ambient air, which can be near,
at, or even above body temperature on a warm or hot day.
[0268] Impact absorbing foam, EPS, with channels or grooves that
are large enough to be of any significance from a thermal transfer
point of view, (even at 50% foam/50% space, which is still very
inefficient), will crush relatively easily at the same density,
resulting in a spike when the user's head reaches the flat part of
the foam, resulting in a secondary impact spike, or bottoming out,
which is highly unlikely to pass certification requirements because
of the potential trauma. Increasing the density of the foam to
compensate for the channels or grooves is possible, however then
the specific impact load per square inch of contact area to the
user's head is increased also.
[0269] 3--TSF, made with polyethylene and poly propylene fibers,
will probably outlast the EPS in the helmet. DOT, Snell, and helmet
manufacturers recommend replacing helmets every 5 years, but it's
unlikely that most people do that. TSF has been tested in an air
conditioned mattress pad for eight years and remained almost as
new, so TSF could enhance the long-term real world performance of
air conditioned helmets that are used past their optimum
replacement date, by eliminating, or at least significantly
reducing, the level of perspiration in the helmet, which is one of
the major contributors to the deterioration of EPS in helmets over
time.
[0270] 4--TSF is very cost effective and lightweight, contributing
to a convective helmet that is priced competitively and is also low
in weight.
[0271] FIG. 23B shows a soft flexible air outlet vent grill
finisher 802 and 3Mesh.RTM. or other air flow structure interior
trim cover 801. FIG. 23C shows extruded or molded seal outer face
810. FIG. 23D shows a closed plug 811, a side wall 812, plugs are
shown spaced farther apart than normal for clarity 817.
[0272] FIGS. 22C, 23E, and 23D discloses a molded or extruded
urethane seal strip for the lower back edge of TSF, or other air
flow structure, in addition to the Volara.RTM. insulator and edge
seal of FIG. 2. FIGS. 23C and 23D show an ACH TSF rear lower edge
seal. Flexible silicone, urethane, rubber, PVC, etc., with a Shore
Durometer of approximately 30-35A is used to neatly cover and seal
the lower rear edge of TSF type air flow structure. Located
approximately. where shown in FIG. 22C, at the lower rear edge of
the TSF layer to prevent air that enters the TSF layer from leaking
or venting out the bottom edge instead of flowing up and around and
through the remaining length of the TSF layer and venting above the
forehead. An optional plug molded into the seal is shown with a
dotted line. The plugs locate in the virtual tubes of the TSF to
provide a more secure mounting of the seal, especially with very
thin side walls to minimize any perception of an edge by the user
of the helmet. One of the advantages of the disclosed seal is that
it enables rapid assembly with a good seal at reduced cost. The
molded seal outperforms the Volara.RTM. seal and insulation barrier
of FIG. 2, with a better seal. Volara.RTM. should be used as the
insulation layer with the molded seal because Volara.RTM. provides
a superior thermal barrier for a given weight and thickness than
the materials that are good candidates for the molded seal. FIG.
23e shows a variation of the TSF air outlet vent trim of FIG. 23.
The variation is that there are plugs, like the seal of FIGS. 22C,
23C, and 23D, which serve to locate and secure the trim, but
they're open to air flow, as is the front face, to allow air to
flow freely out of the TSF. The front face of the air seal of FIGS.
22C, 23C, and 23D are closed to block air flow. The air seal of
FIGS. 22C, 23C, and 23D is preferably made with hollow closed plugs
as shown, in which case the main face need not be closed in order
to block air. The weight of the air seal is reduced by molding the
front face as part of the closed hollow plugs, eliminating a second
wall.
[0273] The rear lower edge seal may also be made without closed
plugs and with closed plugs where the openings in the TSF are
perpendicular to the edge and with a plain U channel where the
openings may be angled forward, such as on the sides, near the
ears. An edge seal may also be made by molding silicone, urethane,
etc., into a simple channel for use with TSF or any other air flow
layer material. The seal may secured with any suitable compatible
rapid cure adhesive/sealant, or the plugs can be designed to engage
the tubes deeply enough to firmly attach the seal strip to the TSF
edge.
[0274] FIG. 23E shows a front face 813, air outlets 814, side wall
815, plug with opening for air outlet 816, and plugs 817 are shown
spaced farther apart than normal for clarity.
[0275] FIG. 23E shows a variation of the TSF air outlet trim, FIG.
23, in which the air outlet vent trim of FIG. 23E, has plugs that
register into the tubes of the TSF as in the TSF edge air seal of
FIGS. 22C, 23D, and 23E, FIGS. 22C, 23C, and 23D. The variation in
the novel edge seal is in that the air outlet vent trim has
openings in the plugs to allow air to vent freely from the TSF air
flow structure. Textiles and other meshes may also by used as vent
trim, including 3Mesh.RTM. and 3Mesh.RTM. type knitted materials
with extremely low air pressure drops, however clear openings are a
design alternative with a low pressure drop for good air
circulation into the face area of full face type helmets in
particular. The plugs of the edge seal of FIGS. 22C, 23C, and 23D
can be configured to engage the tubes of the TSF deeply enough to
firmly attach the seal strip to the TSF edge, with a small amount
of adhesive to secure it. An advantage of using 3Mesh.RTM. to cover
the air flow structure air outlet is reduced cost and weight.
[0276] FIG. 23AB shows the helmet air flow layer interior
trim/padding layer 825, an optional air tight layer 824 to seal
bottom edge of TSF or other air flow structure, a plastic strip
sewn to interior trim 822 to anchor trim by inserting between EPS
and shell. A trim anchoring strip 823 inserted between either the
helmet shell and foam or air flow layer and foam, shown inserted
between shell and foam, so as to cover both the air flow layer and
the helmet impact foam.
[0277] There are two primary vent areas:
[0278] 1--Top face. This is above and across the forehead, venting
down into the face area.
[0279] 2--Side face. These vents are on both sides of the face,
venting into the face area at approximately the temple level.
[0280] In order to ensure maximum performance, it is necessary for
the helmet cooling or heating air to be able to vent out of the
helmet air flow structure with minimum pressure drop. It is also
desirable to cover the venting edge of the TSF layer, or other air
flow structure, with something that gives it a quality finished
look.
[0281] 3Mesh.RTM., or an equivalent knitted material, functions
well when wrapped over the edge of TSF, as a simpler less expensive
alternative, so the molded air outlet vent trim of FIG. 23 should
be considered an alternative solution.
[0282] The object of the grille molding of FIG. 23 is to
resiliently cover the air flow structure vent edge enough so that
it looks well finished, while maintaining minimal air pressure
drop.
[0283] It is also possible to sew a strip of extremely open mesh to
the liner cover material so that the open mesh wraps around the
venting edge of the TSF or other air flow structure. The drawback
of this approach is the greater visibility of the edge of the TSF
or other air flow structure, compared with 3Mesh.RTM. type knitted
material or a molded grille.
[0284] FIGS. 24 and 25 are side views of a resilient mounting
system 570 in one or more embodiment. The resilient mounting system
570 supports a thermoelectric cooling system, resistive heating, or
ventilating system 571, to which ball-pins 572 are attached. FIG.
25 show the ball-pin 572 coupled to a grommet 573 to support the
system 571.
[0285] FIG. 26 is a plan and side elevation view of an empty
grommet 573 and a separate ball-pin 572. FIG. 27 is a plan and side
elevation view of a grommet 573 coupled to a separate ball-pin 572.
The side elevation view of the grommet with optional rivet to
helmet and ball-pin inserted.
[0286] FIGS. 24 through 27 illustrate a resilient mounting system
570 for the cooling, heating, and ambient air ventilation systems
571 of the ACH using rubber or urethane or other appropriately
durable and resilient material for grommets 573 with a groove and
hole that are sized to secure a ball and pin fastener 572
resiliently while allowing the assembly to be disassembled with
sufficient peeling or pulling force to prevent the mounting from
coming apart during normal use, but allowing the assembly to be
removed for repairs or to be knocked free of the helmet shell if
impacted tangentially to the surface of the helmet shell. A further
object of the resilient mounting system is to allow for simple
quick assembly during production and to isolate the helmet to some
extent from vibration and noise generated by the air moving devices
used to move air through the convective system and helmet air flow
structure.
[0287] A convective system cover can also be mounted to the
convective system itself in numerous ways, including adhesive,
screws, snap-fit, etc.
[0288] The convective system air input into the helmet air flow
structure may be configured to insert into an air duct in the rear
of the helmet shell and impact layer to the air flow structure, or
ducted under the rear edge of the helmet head opening as described
in the first patent, U.S. Pat. No. 6,954,944. The resilient heat
pump mount 34 of the referenced patent, U.S. Pat. No. 6,954,944,
has been used; however it may not be reliable enough over time. The
resilient mounting system of FIGS. 24 through 27 is designed to
achieve the same goals and benefits of resilient mount 34 of U.S.
Pat. No. 6,954,944, but with greater reliability and durability and
ease of assembly. The opening in the helmet, or cap, shell should
always be a bit larger than the air duct in to the interior of the
helmet, or cap, so that vibration from the convective system air
duct doesn't transmit directly into the helmet, or cap, shell, in
order to minimize noise.
[0289] FIGS. 28 through 31 show a new housing, or cover, for the
ACH air convection assembly. A significant feature of the new cover
is that it has air inlets on the sides of the cover instead of on
the back or top surface.
[0290] FIGS. 28 and 30 are plan and side elevation views
respectively of a helmet cover 601 having a convective system cover
602 extended from the shell. This may not be the preferred
embodiment.
[0291] As shown in FIGS. 29 and 30, in one or more embodiments an
ACH helmet 601 or helmet apparatus 611 comprises a helmet shell 610
having a first opening 30 of such dimensions as to permit receipt
onto the head of a wearer. The helmet shell 610 has a front portion
31 shaped to protect the front face of the wearer, and a rear
portion 32 shaped to protect the back of the head of the wearer.
The helmet apparatus 611 further comprises a device housing 660
positioned on the outer rear portion 32 of the helmet shell 610.
The device housing 660 has a generally curved section 661 that
emerges from the upper part 671 of the device housing 660 in
contact with and emerging away helmet shell 610 that extends
downward toward the first opening 30 of the helmet shell 660 where
the generally curved section 661 terminates 672. The device housing
660 has two generally vertical side-walls 662a and 662b nearly
perpendicular from the curved surface 661. The device housing 660
forming a cavity 37 between the helmet shell 610 and an outer
surface of the device housing 660 in which the at least one air
inlet 603 is formed in the device housing 660. The helmet apparatus
611 further comprises an air conducting layer 676 (e.g., air flow
lining 170 as depicted in FIG. 6) distributed about substantially
the entire interior of the helmet shell 610. The helmet apparatus
611 further comprises a device 675 (e.g., the Thermoelectric helmet
cooling, heating, and ventilating system 174 as shown in FIG. 7, or
the heating apparatus 301 shown in FIG. 12) for producing a
pressurized stream of air, the device 675 receiving intake air from
the at least one air inlet 603 of the device housing 660 and
producing a pressurized stream of air in fluid communication with
the air conditioning layer 170 in one or more embodiments.
[0292] In an embodiment, at least one air inlet 603 is formed in
both 662a and 662b of the two generally vertical side-walls of the
device housing 660. In an embodiment, the at least one air inlet is
formed in one of the two generally vertical side-walls 662a or 662b
of the device housing 660. In a preferred embodiment, the device
housing 660 is configured to reduce rotational moment upon
tangential impact to the helmet apparatus 661. The device housing
660 is configured for detachment from helmet 610 upon impact on the
helmet apparatus 611. The device 675 is configured for detachment
from helmet 610 upon impact on the helmet apparatus 611. In
embodiment, the device 675 is detachably coupled to the helmet 610
with a hook and loop fastener (e.g., 621 as shown in FIGS. 32-34).
In a preferred embodiment, the device housing 660 further comprises
a rejector air outlet 614 for exiting heated air, in which the
rejector air outlet 614 is positioned to prevent the exiting heated
air from entering the at least one air inlet. The rejector air
outlet 614 is formed in the generally curved surface 661 of the
device housing 660. The air moving past the "hot" place 204 of the
heat pump 202, as shown in FIG. 8 for example) is exited to the
rejector air outlet 614 of the device housing 660. The device 675
is a Positive Coefficient Temperature ("PTC") type resistive
heating element (e.g., 301 shown in FIG. 12).
[0293] In an embodiment, the helmet apparatus 611 comprises a
helmet shell 610 having a first opening 30 of such dimensions as to
permit receipt onto the head of a wearer. The helmet shell 610 has
a front portion 31 shaped to protect the front face of the wearer,
and a rear portion 32 shaped to protect the back of the head of the
wearer.
[0294] The helmet apparatus 611 further comprises a device housing
660 positioned on the outer rear portion 32 of the helmet shell
610. The upper part of the device housing 660 in contact with and
emerging away helmet shell 610 extending downward toward the first
opening 30 of the helmet shell 610. The device housing 660 forms a
cavity 37 between the helmet shell 610 and an outer surface of the
device housing 660, the device housing has at least one air outlet
614. The helmet apparatus 611 further comprises an air conducting
layer 676 distributed about substantially the entire interior of
the helmet shell 610, and a device 675 for producing a pressurized
stream of air. The device 675 receives intake air from the at least
one air inlet 603 of the device housing 660 and producing a
pressurized stream of air in fluid communication with the air
conditioning layer 676.
[0295] In an embodiment, the helmet apparatus 611 comprises a
device 675 for cooling the scalp of the wearer, the device 675
receiving air from the at least one air inlet 603. In a preferred
embodiment, the device 675 and the device housing 660 are
configured for detachment from helmet 610 to enable air filter
cleaning.
[0296] FIGS. 29 and 31 are plan and side elevation views
respectively of a helmet cover 610 having a having a side air inlet
603 and a rejecter air outlet 614 for thermoelectric cooling system
only. The radii reduce rotational moment from tangential impact
although the entire assembly can be designed for easy removal upon
impact, or removal to service or clean components 660 may be
severed with screws or other removable means.
[0297] This is significant because it makes it easier to minimize
two important issues:
[0298] 1--Hot air from the rejector side of the thermoelectric
cooling system in cooling mode floats up at the rear of the heat
pump when standing still or moving slowly, whether riding a
motorcycle, horse, bicycle, or running and standing, and can be
recirculated back into the ambient air inlet, reducing heat pump
performance significantly. By putting the air inlets on the side,
warm or hot rejector air will not be available for recirculation
because of the positioning of the air inlets on the side walls of
the cover, which improves thermal efficiency in cooling mode.
[0299] 2--Rain. Although a little rain won't hurt the convective
system, it is something that should be limited as much as possible
without adversely affecting other aspects of convective system
operation. Since the air inlets are on the side of an essentially
vertical surface that is at approximately 90 degrees to the smooth
curve of the helmet shell, it is much more difficult for water that
lands on the helmet shell to roll into the air inlet, either from
air pressure or gravity. The cover shown in FIGS. 28-31 is an arc
shape in side elevation. It is possible to make the radius of the
cover the same as or greater than the helmet radius in order to
produce an air scoop. The problem with the air scoop is that it
will scoop rain almost as well as air when moving forward on the
road in the rain. Rain can also roll down the surface of the
helmet, inside the scoop, down into the convective system, which is
not desired.
[0300] The ACH convective system cover of FIGS. 28-31 is a simple
design aesthetically that also serves an important function in
minimizing both hot air recirculation in active cooling mode and
ingestion of rain by providing an air inlet on two sides that is
placed on a flat or slightly radiused side wall that is at
approximately 90 degrees to the curved surface of the helmet shell.
By mounting the inlets on the sides, the hot air that vents out of
the rear bottom rejector vent, will be less inclined to impinge on
the sides when the motorcycle is at rest or moving slowly and there
is no wind blowing, thereby maintaining higher ACH cooling mode
performance when the user is stationary, as in waiting at a stop
signal, for example.
[0301] The motorcycle ACH with the above removable cover 660 has
been certified for both the DOT (Department of Transportation) and
the ECE (Economic Commission for Europe).
[0302] The production ACH (e.g., helmet apparatus 611) for vehicle
use is lighter in weight than some ordinary helmets, which is
desirable because it puts less strain on the user's neck muscles.
The production ACH has also been carefully designed and engineered
with numerous unique features, including impact absorbing
structures.
[0303] The convective ventilating, cooling, and/or warming system
itself is an energy absorbing structure because:
[0304] 1--The first energy absorbing structure is the convective
ventilating, cooling, and/or heating system cover (e.g., device
housing 660), which is firmly attached in place at the rear 32 of
the ACH. It is removable for vacuuming of the air filter and any
other servicing of the convective system, but is firmly secured to
the shell 610 of the ACH and absorbs the initial force of an impact
at the rear 32 of the ACH 601.
[0305] 2--Any additional impact energy is then absorbed by the
pliable convective ventilating, cooling, and/or heating, system
housing (e.g., device 675), which is molded out of Santoprene, or
any similar elastomer or polymer, that is strong, but pliable and
will not shatter or splinter upon impact, but deforms, allowing any
further energy to be absorbed by the folded fins of the heat
exchangers bonded to the convective system Peltier thermoelectric
cooling device or PTC heating device, which are oriented such that
an impact will be absorbed by the crushing and folding of the fins
in the direction of a direct impact at the rear of the helmet.
[0306] 3--The next impact absorbing element is the outer shell of
the ACH that is under the convective system and overlays the
standard EPS inner impact absorbing layer (e.g., impact absorbing
layer 160 as shown in FIGS. 2 and 2A) of the ACH 601.
[0307] The result is a very efficient impact absorbing structure
that has the ability to absorb and dissipate impact energy in
addition to providing ventilation, cooling and/or heating air to
cool the user's head and body and provide temperature modified,
filtered air for breathing, with no weight penalty when compared
with the average conventional plain helmet.
[0308] FIG. 32 illustrates a new improved way of attaching the
thermoelectric air to air heat pump or other convective system of
the subject embodiments to the helmet in a way that is safe,
inexpensive, lightweight, durable, and which enables an exposed
convective system to be knocked free of the helmet shell in a
lateral impact while securing the assembly during normal use.
[0309] FIGS. 32 through 34 illustrate that an air heat pump or
other convective system 620 maybe attached using Velcro.RTM. with
adhesive 621 to the helmet having an outer shell 623 and impact
absorbing foam 624. The radii 622 may be determined by the size and
shape of the helmet.
[0310] The solution shown in FIG. 32 is a hook or loop fastener,
such as Velcro.RTM., with adhesive on each of the two sides. The
way it functions is that the hook or loop patch is adhered to the
helmet shell during assembly and then the convective system
housing, which has a corresponding Velcro.RTM. hook or loop strip
adhered to it, is then positioned so that the hook and loop
surfaces interlock and secure the thermoelectric assembly to the
helmet shell.
[0311] Because the hook and loop are not permanent attachments, it
is possible for the convective assembly to be detached from the
helmet shell with a carefully predetermined degree of force, as a
function of the hook and loop fastener area, preventing cervical
injury due to rotation of the helmet caused by a tangential impact
to the thermoelectric assembly attached to the helmet shell. The
removable nature of the hook and loop attachment also facilitates
removal of the convective system so it can be easily repaired or
replaced. Assembly is also streamlined so manufacturing cost is
reduced.
[0312] Another advantage of the new solution of FIGS. 32-34 is that
the adhesive hook and loop fastener also acts as a subtle vibration
isolation system to reduce noise and vibration transmitted into the
helmet shell from the fans or blowers of the convective cooling,
heating, or ventilating system.
[0313] FIG. 33 illustrates how the Velcro.RTM. strip or spot
secures the thermoelectric heat pump assembly to the helmet shell
resiliently, spacing the assembly from the shell and partially
isolating it from the shell by means of its resilient interlocking
fibers. As shown, a hook or loop Velcro.RTM. strip is bonded to the
convective assembly and a hook and loop strip, or patch, is shown
bonded to the helmet shell, however the arrangement can be
reversed, or a stack of two strips of adhesive Velcro.RTM. can be
used for even more vibration and noise isolation.
[0314] Another extremely important advantage of the Velcro.RTM.
fastener is that it will not penetrate the helmet shell in a direct
impact, unlike a pin or screw protruding outward radially from the
shell, which can be pushed inward toward the wearer's head in a
direct radial impact. The only element holding the convective
system to the helmet shell is the Velcro.RTM.-to-Velcro.RTM. bond,
which does not require the tearing free of a screw or rivet, etc.,
from a positive attachment to the helmet shell.
[0315] The cooling, heating, and ventilating system of FIGS. 32-34,
illustrates and discloses a new variation for introducing helmet
air into the air flow structure edge by ducting under the bottom
edge of the helmet shell and impact structure.
[0316] In one or more embodiments, a radius has been molded into
the thermoelectric housing as shown to allow for the use of
Velcro.RTM. hook and loop fastening tape on a helmet with a
radiused surface. By adding the radii, the Velcro.RTM. tape can
make better contact across its entire surface for a carefully
designed level of grip to allow for detachment of the TE assembly
when subjected to tangential impact of a predetermined minimum
magnitude on a helmet without a flattened rear surface for the
convective system to interface with, although a slightly flattened
rear helmet shell surface is preferable because it results in a
more compact ACH with reduced rear extension.
[0317] FIG. 35 is a cross-sectional view of an air system. FIG. 36
shows a TSF, or other air flow layer 836, where these optional
radii 831 depend on the size of the helmet, the heat pump can also
be tilted toward the helmet shell instead of vertical although air
flow into the helmet is more efficient as shown. There is also a
pliable TE assembly coupling/adaptor 833, a Voltek Volara.RTM. or
other insulation and air barrier layer .about.1 mm thick. 834, and
an air duct molded into EPS layer 835. FIG. 36A shows an expanded
view of an example of the removable coupling/adaptor. 832
[0318] FIG. 37 shows a comparison of TES type TE assembly with
conventional TE based assembly. These optional radii 831 depend on
the size of the helmet, the heat pump can also be tilted toward the
helmet shell instead of vertical although air flow into the helmet
is more efficient as shown.
[0319] Embodiments presented in FIGS. 35, 36, 37, and 36A show
another convective system mounting and ducting option. In these
figures, radii are molded into the components at the appropriate
points to allow for good hook and loop tape fastener performance
with the air duct from the thermoelectric assembly being routed
through a port in the back wall of the helmet shell instead of
under the back edge of the helmet shell, as in FIGS. 32-34. In this
configuration, the majority of the air duct to the air flow
structure is molded into the impact absorbing layer inside the
helmet.
[0320] FIG. 38A is a front view image of the helmet with a smoothly
integrated cover 653A eliminates increased rotational moment from
tangential impacts. The cover can be made to be removable for
repairs, maintenance, etc. Cover shown with air inlet slots at
leading edge of cover for air movers and filter media mounted
behind slots.
[0321] FIG. 39A illustrates a power cord with grommet/seal in cover
653 having a power lead exiting the cover through a seal or grommet
670. FIG. 40A illustrates an alternative system air inlet with
filter media.
[0322] FIGS. 38 through 40AA, disclose an ACH thermoelectric
assembly cover 651 that is designed to integrate smoothly into the
shape of the back of the helmet 650 in order to prevent induced
helmet rotation as a result of a tangential impact on the rear of a
convective helmet housing the ACH convective apparatus. The helmet
650 has a cover 651 that has several air inlet openings with filter
media on the inside 652, a fairing cover 653, a thermoelectric
cooling and heating, resistive heating, or ventilating system 654,
a thermoelectric rejecter air outlet vent 655, openings with filter
for air and to let rain drain out 656, as well as a thermoelectric
hot air vent rejector vent 850 when in a cooling mode. The smoothly
integrated cover eliminates increased rotational moment from
tangential impacts. The cover can be made to be removable for
repairs, maintenance, etc. Cover shown with air inlet slots for air
movers and filler media mounted behind slots.
[0323] Air inlet holes 652 are shown to allow air flow into the
convective system. Air flow from the auxiliary, or rejector, heat
exchanger of the thermoelectric convective cooling and heating type
system may be vented from a slot or orifice as shown in FIGS. 40
and 40A. Another approach to an air inlet vent with filter is to
put openings, which can be any shape, but are shown as slots, in
the rear cover. Air filter media, such as woven plastic
electrostatic mesh, foam, carbon, etc., may be mounted on the
inside surface of the rear cover. The lower inlet style shown in
FIG. 40A positions the inlets 657 at the bottom of the rear
fairing, or cover, so that any rain water that enters through the
air inlet openings cannot drip or be drawn into the air mover
inlets. Optional air Inlet openings 657 located low and to the side
of the fans to prevent rain from dripping into the fans, with
filter media on the inside.
[0324] The upper air inlet opening type of FIGS. 38, 39, and 40 may
allow some rain to drip into the air movers, but offers a different
look and may offer an advantage in aerodynamic air pressure and
flow, from the air mover(s) point of view. The filters of FIG. 40A
are mounted low enough so that air can enter and any rain that
enters will be able to drain from the bottom edge of the cover.
FIG. 40 shows additional air filter inlets that allow rain that may
enter through the upper mounted air inlet and filter to drain from
the bottom of the cover also, in addition to filtering air drawn
into the cover.
[0325] It should be noted at this point that it is also possible to
configure the ACH air cooling and heating system interface with the
helmet in another way.
[0326] The normal foam impact absorbing layer in a helmet is
approximately 1.25'' thick. In some cases it might be more or less,
but on average it's approximately 1.25'' thick. The shell may be
notched so that the air duct from the TE assembly to the TSF goes
under the back edge of the helmet shell, as shown in FIGS. 1A, 2A,
32, 33, and 34, and then curves upward to feed cooled air into the
edge of the air flow structure.
[0327] This approach can be modified so that the helmet shell is
notched, but the foam impact absorbing layer is not. The impact
foam layer has an air duct molded into it that leads from the
thermoelectric output to either the side surface or lower edge of
the air flow layer, as shown in FIGS. 41 through 42A. A plastic
cover can be bonded to the exposed foam edge surrounding the air
duct in the notch to protect and finish it aesthetically, as shown
in FIG. 41.
[0328] FIGS. 38A, 39A, and 40AA, illustrate another unique solution
for convective helmets in which an extended rear cover/fairing is
designed to cover the convective apparatus and is provided with air
inlets on its leading edges at the lower sides of the rear of the
cover. This arrangement has several advantages.
[0329] 1--The air inlets are low, at or below the level of the air
mover intake, and to the sides, so that any rain water entering
will not be drawn into the air movers.
[0330] 2--The air inlets are on the sides of the helmet, which,
with the extended rear shell cover, has a larger radius than the
curvature of the helmet from front to back over the top, which
results in an air flow that remains attached to the surface of the
helmet further back, enabling more efficient intake of air into the
air inlet openings than with air inlets and filters behind.
[0331] 3--When used with a thermoelectric heat pump, the hot air
exiting the vent at the bottom of the helmet rear cover is free to
convect upwards when standing still with no wind without being
drawn into a center mounted air inlet opening.
[0332] 4--The presence of the air inlets, where they're located, on
the lower rear sides of the helmet, visually reduces the apparent
length of the helmet from a side elevation view, making the helmet
appear more compact.
[0333] 5--The bottom filtered air inlets allow rainwater to drain
and filter air drawn into the cover by the convective system.
[0334] FIG. 39A also discloses a grommet/seal on the power cord
located in a lower surface of the cover to prevent air leakage
without filtration. The extended rear cover of FIGS. 38A through
40AA can also be used without filter in the air inlets when used
with an air filter adapted to the convective system as in FIG. 61A,
for example.
[0335] FIG. 41 is a view of a helmet shell 701 having a foam impact
layer 702 formed in a notch 703 in lower back edge of helmet shell
701 with a cover/trim for exposed foam surface 704.
[0336] FIG. 42 is a cross-sectional view of the cooling, heating,
or ventilation system 705 (e.g. cooling/heating system) coupling
with the helmet shell 701 through the notch or opening in lower
back wall of helmet shell 713. FIG. 42 also illustrates the air
duct to side of air flow structure molded into foam layer 706, the
air barrier in lower edge 707, the trim 708.
[0337] FIG. 42A is a cross-sectional view of the air/heating system
705 coupling with the helmet shell 701 through the notch or opening
in lower back wall of helmet shell 713 to the air duct to edge of
air flow structure 712 molded into foam layer overlapping air flow
structure edge. FIG. 42A also illustrates the trim 708, the air
flow structure 709, the edge of air flow structure 710, and the
insulator/air barrier 711.
[0338] FIGS. 42 and 42A show a revision to the art disclosed
previously in the subject embodiments. Instead of relying on a hook
and loop or tape attachment for the thermoelectric assembly of the
subject embodiments, another approach is shown in the revised
drawings. The radiused elements are still shown as an option,
however the entire attachment of the thermoelectric assembly to the
helmet can be accomplished with a pliable coupling incorporated
into an air duct adaptor of suitable Durometer installed into the
air duct leading from outside the helmet into the inner air flow
structure.
[0339] The lower air outlet of the TE assembly is shown with a
flange that engages a groove in a flange at the inlet of a
relatively pliable adaptor fixed to the helmet. By carefully
specifying the size and shape of both flange and groove, either an
external or internal flange and groove, and the softness, or
Durometer, of the two pieces, a good balance between every day
usable stability and the ability to release the TE assembly under
tangential or lateral impact, or by peeling and pulling, will offer
an optional means of attachment of the TE assembly to the helmet.
The relatively low Durometer of the adaptor also serves to decouple
vibration, to some extent, from the TE assembly to the helmet for
reduced noise and improved comfort.
[0340] The hook and loop fastener should be considered the
preferred embodiment, however, when combined with a convective
system air output to the helmet with small grip flanges, such as
disclosed in FIG. 39B and FIG. 42A, since the hook and loop plus
flanged inserted duct will be most resistant to vibration and
G-forces and still be relatively easy to assemble, remove, and
replace.
[0341] FIG. 43 shows a side elevation view of a convective system
housing for thermoelectric cooling and heating, resistive heating,
or ventilation system of FIGS. 41 and 42, with a radiused surface
for a Velcro.RTM. hook and loop type fastener for helmets with
radiused rear shell surfaces. Alternatively, the rear of the shell
may be flattened to some extent to eliminate the need for a radius
for the best fastener performance. Also in FIG. 43 is disclosed
another refinement of the disclosed embodiments in which a larger
number of smaller diameter air movers are used to achieve a shorter
extension of the rear of a convective helmet. Using smaller air
movers requires that a shorter, wider thermoelectric module, or
resistive heating module be used or more than one shorter wider
module to interface smoothly with the smaller diameter air movers,
also depicted in FIG. 21B. FIG. 21 shows a further refinement along
the same lines, in which four smaller air movers are used, shown
superimposed upon the current basic module housing to show the
difference in the extension at the rear of an air convective helmet
as a result of using a larger number of smaller diameter air
movers.
[0342] The thermoelectric stack of U.S. Pat. No. 6,855,880, shown
in FIG. 21 enables a flexible convective cooling system that can
conform readily to the standard curvature at the rear of a helmet
to contribute to reducing the necessary extension at the rear of a
conventional helmet shell with radiused rear surface, for
convective thermoelectric cooling and heating, resistive heating
and forced ventilation.
[0343] In the case of a convective helmet built as disclosed in
FIGS. 3, 4, 5, 16, 17, 29, 30, 31 and so forth of the subject
embodiments, any of the above disclosed attachment methods may be
used since it is then not necessary for the TE assembly to be
released, or to break away, under tangential or lateral impact.
[0344] Sunon.RTM. GM1202PHV1-8 fans are the preferred device and
the proprietary fan frame without standard mounting holes for those
fans, as disclosed in FIG. 49A. Also noted in FIG. 49A, is the fact
that the fan rotors are separate in separate frames with no bonding
points between the separate fan frames. This is to prevent
undesirable resultant waveforms and vibrations that can be
generated by the different vibrating waveforms of each rotor, since
each rotor may not be perfectly balanced, when mounted in a common
frame. The resulting waveform generated by the combined waveforms
can be an undesirable droning, pulsing, or beating that is
conducted through the convective system to the structure of the
convective headgear, especially headgear that covers the user's
ears, as is the case with a full face motorcycle type convective
helmet, for example. Resilient adhesive, such as silicone, for
example, to secure the fans to a preferably resilient housing, is
acceptable for areas other than adjoining fan frames.
[0345] FIGS. 43 and 43A are side views of a cooling/heating system
705 having an insert slot 720 for coupling with a "radius insert"
721 shown larger than scale for clarity. FIG. 43A shows the
cooling/heating system 705 coupled to an optional extended air duct
722 to headgear inlet with optional resilient isolator made of
Sorbothane.RTM., or similar, to reduce vibration to headgear. The
optional barbed end 723 and the extended duct 724 are also
illustrated.
[0346] FIGS. 44 and 44A illustrate and radius insert 721, as well
as an optional isolator 725, an optional EPS or other foam inner
element 726, and an extended duct.
[0347] FIG. 44B illustrates an air system having an
isolation/decoupling material 850 between air mover and adaptor, a
fan/blower 851, an adaptor 852, a snap fit 854, a soft isolator
855, an air duct extension 856, and a second air mover isolator 853
between air mover adaptor and convective housing.
[0348] FIG. 44C has a snap fit 854, a soft isolator 855, an
optional EPS liner 857, and an air duct extension 856.
[0349] FIG. 44D shows an isolation/decoupling material 850 between
fan and adaptor, a fan/blower 851, an adaptor 852, a pliable
convective system air duct 860 with coupling/adaptor and vibration
isolator, a shell 623, an impact absorbing layer 624, if used. In
addition, it has a TSF, or other air flow layer 836, an inner trim
layer, a shell opening clearance from air duct 861, an isolator
862, a counter-bore for isolator in EPS 863, and an air duct molded
into EPS layer 864, if EPS is used.
[0350] FIG. 44B discloses a separate air duct extension for
headgear convective system with snap fit to convective system to
allow a soft isolator, preferably Sorbothane, and preferably of
approximately Shore 20, 00 scale, to be bonded to the headgear
while enabling the convective system to be removed and replaced if
necessary. FIG. 44C illustrates the same solution, however with an
optional rigid foam liner between the air duct extension with snap
fit to the convective system, and the soft isolator that is bonded
to the headgear. FIG. 44D illustrates the installation details of
the detachable air duct adaptor with isolator installed in headgear
with a shell and EPS impact absorbing layer.
[0351] FIGS. 44B through 44D illustrate a preferred alternative to
the air duct extension with isolator also disclosed in those
figures. Alternatively, and preferably, a thinner, lighter, less
expensive Sorbothane or similar material of a Durometer of
approximately 30 Shore 00 Scale surrounding the fans within the fan
adaptor has shown superior vibration isolation over the isolator
material on the convective system air outlet, eliminating the need
for an isolator on the air outlet, and the need for a removable
fitting for the air duct and attendant concerns about attachment
and removal of the convective system. An additional isolator is now
disclosed in FIGS. 44B through 44D between the air mover adaptor
and the thermoelectric or resistive heater housing to further
isolate air mover vibration from the convective system and, further
on, the convective headgear.
[0352] FIGS. 43, 43A, and 44 show a solution to the problem of
mounting the same convective assembly 705 to different sized and
different shaped convective helmets. A solution is the radius
insert 721 shown in the figures. Slots molded into the convective
housing allow a molded radius insert 721 with a given radius in
either or both of the x or y axis to be fitted to the mating
surface of the TE housing so that Velcro.RTM. or any other
attachment means may be used more effectively by matching the
contour of the TE housing to the shape and size of the helmet being
used. Also shown larger than scale for clarity are resilient
couplings for the air inlet into the helmet that help to isolate
the thermoelectric assembly from the helmet foam impact absorbing
layer for reduced noise, while enabling the convective assembly to
be knocked free of the helmet, given a tangential impact on the
convective assembly of sufficient magnitude, to prevent trauma to
the user's neck via torsion about the axis of the neck, or to be
easily removed for repair or replacement. An adhesive Velcro.RTM.
upper fastener should be sized in order to sufficiently stabilize
the convective assembly in place without causing the magnitude of
the tangential force required to dislodge the convective assembly
from its mounting to exceed the desired level for neck safety. The
assembly described above is primarily for convective helmets that
have the convective assembly mounted openly on the outside of the
helmet, instead of faired into a modified helmet shell, or covered
with a rounded cover to prevent any protrusions from catching on
anything in an impact. A resilient mounting system is of value in
the faired-in type of helmet in order to reduce noise and vibration
transmission from the convective assembly to the foam impact
absorbing layer.
[0353] For any convective system, including ventilation, air
cooling and/or heating, FIG. 43B illustrates an optional extended
air duct to the headgear. This is particularly useful for headgear
with substantial impact absorbing layer thickness. The extended air
duct is shown with an optional vibration isolator made of an
elastic or resilient material such as Sorbothane, for example, of
approximately Shore 70 on the 00 scale, or similar, to limit
vibrations from the convective system air mover(s) to the headgear
structure. An optional barbed end is shown to provide additional
retention strength for the convective system if desired.
[0354] FIG. 44A illustrates another new option. Since the pliable,
elastic isolator material, especially Sorbothane.RTM., is somewhat
soft, it has a relatively high surface friction. In order to
optimize convective headgear production assembly, an optional EPS
or other smooth molded foam inner element may be positioned within
the isolator to facilitate insertion, and removal if necessary, of
the convective system air duct extension.
[0355] The isolator with inner foam element may be glued in place
and then the convective system may be inserted into the EPS or
other foam inner element more easily and consistently than with
only the relatively high surface friction isolator installed in the
EPS or shell adaptor of the convective headgear assembly.
[0356] FIGS. 44B-44D illustrate and disclose an optimized isolator
to reduce noise and vibration transmission from a convective air
system into the shell of a convective headgear structure.
[0357] FIG. 44B shows an air duct extension on the convective
system equipped with a soft isolator, preferably made of
Sorbothane, visco-elastic polymer made by Sorbothane Inc., of Kent,
Ohio. The preferred Durometer is approximately Shore 20 on the 00
scale, although other Durometers may be used to fine tune a given
application.
[0358] FIG. 44C discloses a compound isolator consisting of an EPS
foam liner surrounded by the Sorbothane isolator material. The
unique purpose of this arrangement is to allow the convective
assembly to be removed more readily because the friction between
the air duct and the EPS is much lower than between the air duct
and the Sorbothane.
[0359] FIG. 44D discloses a variation of the above isolators, in
which the EPS liner is eliminated by using a two piece air duct
with a snap fit that allows the convective system to be detached
from the air duct portion with the isolator without the difficulty
of having to deal with the high friction between the air duct and
the Sorbothane, or other soft polymer isolator material, which may
have a somewhat gummy consistency in the most effective Durometer
ranges.
[0360] FIGS. 44B through 44D illustrate a preferred alternative to
the air duct extension with isolator also disclosed in those
figures. Alternatively, and preferably, a thinner, lighter, less
expensive Sorbothane or similar material of a Durometer of
approximately 30 Shore 00 Scale surrounding the fans within the fan
adaptor has shown superior vibration isolation over the isolator
material on the convective system air outlet, eliminating the need
for an isolator on the air outlet, and the need for a removable
fitting for the air duct and attendant concerns about attachment
and removal of the convective system.
[0361] An additional isolator is now disclosed in FIGS. 44B though
44D between the air mover adaptor and the thermoelectric or
resistive heater housing to further isolate air mover vibration
from the convective system and, further on, the convective
headgear.
[0362] FIG. 45 is a side view of a cooling/heating system 705
having fan(s) or blower(s) 729 configured for coupling to a helmet.
FIG. 45 illustrates a Velcro.RTM. hook or loop patch 730 glued to
helmet shell, a Velcro.RTM. loop or loop patch 731 glued to a
helmet shell, and an optional Velcro.RTM. loop or hook piece 738,
folded to secure TE assembly in a second place while allowing a
small amount of compliance for reduced noise and vibration
transmission into the helmet shell and enabling the assembly to be
knocked free in a tangential or lateral impact. I lieu of the
folded Velcro.RTM. element, the simple hook and loop halves can be
used to removably secure the upper part of the convective assembly
to the helmet.
[0363] FIG. 45A shows the details of the coupling including a
connecting flange 735, a cooling, heating, and ventilating system
housing 736, and a pliable adapter 737. FIG. 45B depicts a simple 2
piece Velcro.RTM. hook and loop fastener w/ air duct flange seal
grip 733 which may be a preferred embodiment. FIG. 46 depicts a
Velcro.RTM. and loop fastener bonded to convective housing (TE
cooling) resistive heating or ventilating and the helmet shell
[0364] FIGS. 45-46 disclose a variation of the solutions disclosed
in previous drawings of the subject disclosure involving the use of
Velcro.RTM. as a semi-permanent fastener securing the convective
assembly to the helmet shell while allowing the assembly to be
readily separated from the helmet or cap in a direct tangential or
lateral impact, or for repairs or replacement.
[0365] FIG. 45 shows an option in which a Velcro.RTM. strip 738 is
folded and placed in between two hook or loop patches in order to
provide more compliance, and hence more decoupling, of vibrations
from the convective assembly air movers into the helmet shell
and/or foam impact absorbing layer, where, because of the general
shape of the helmet, noise can be easily amplified by the shape of
the helmet and close proximity of the shell to the head and ears of
the user.
[0366] The Velcro.RTM. attachment shown in FIGS. 45 and 46 can also
be used as shown in the FIGS. 32-34. FIG. 45B also illustrates a
hook and loop fastener without a folded hook or loop element and
another solution for attaching the convective assembly, which may
be the thermoelectric cooling/heating system, a resistive heating
system for heating, or a ventilating unit that adapts a fan or
blower to a helmet air inlet, using a push-fit air duct with a
flange, as shown in FIG. 45B, to seal and grip the interior of the
helmet EPS impact absorbing structure, in conjunction with the hook
and loop Velcro.RTM. type fastener shown in the preferred
embodiment of FIG. 45B. FIG. 45B and FIG. 48A are essentially the
same preferred embodiment, especially for convective helmets with
impact absorbing structures. For caps and hats with only thin
thermal insulation layers, the convective system couplings of FIGS.
36 and 36A FIGS. 42 and 42A, FIG. 45A, FIG. 48 can be used with an
appropriately short air output extension, and with a hook and loop
upper support fastener.
[0367] FIG. 48 also shows a dashed line for the interior trim layer
behind the neck roll 763 and insulation and edge air seal. This
indicates that the interior trim layer may be sewn to the top edge
of the special neck roll, which eliminates the thickness of the
trim layer behind the neck roll for a more compact assembly, if
desired or necessary.
[0368] FIG. 47 depicts a thermoelectric device 754 with a fan
housing in an embodiment, and shows a multi-Durometer Heat Pump
Housing 753, an upper fan housing 751 softest, Shore .about.60-80A
Santoprene.RTM., for example, and a bottom Housing 752 moderately
soft, .about.80-95A Santoprene.RTM., for example. The
multi-Durometer housing can be molded with different Durometers in
different areas or made up of multiple sections of different
Durometers bonded together. FIG. 47 should be changed to
approximately Shore 40-60A Durometer for the upper fan or blower
adaptor instead of Shore 60-80A Durometer.
[0369] FIG. 48 depicts a thermoelectric device 754 with a fan
housing in an embodiment, which includes an extended helmet air
duct from the lower convective system housing. FIG. 48 shows a TE
device 754 coupled to a helmet 759, showing a shell 760, an impact
absorbing layer or structure 767 TSF 761, or other air flow
structure, a neck pad 763, (neck roll), covering lower edge and
inside surface opposite air inlet. Interior trim may be sewn to
neck roll, and optional bonding point 769, and a Shore
.about.80-95A Durometer adaptor w/ housing cold air outlet glued
into impact absorbing layer air duct or snap-fit in two pieces.
There is also depicted is an opening in shell 764 is larger than
air duct to avoid touching the air flow 766.
[0370] FIG. 48A illustrates a preferred embodiment for coupling the
TE device to the helmet. FIG. 48A illustrates a Hook & loop
fastener 781, Grip Flange grips 782 and/or glues into impact
absorbing layer, and a. Condensate trap/wick evaporator 784.
[0371] FIG. 49 is a top view of the dual Durometer fans 792 and
794, where the point of an optional attachment point 790. FIG. 49A
illustrates a preferred embodiment, employing fan frames designed
to eliminate standard screw mounting holes and resulting need for
sealing said holes. Also, no bonding between fan frame contact
surfaces, to prevent undesirable waveforms and noise resulting from
multiple rotor vibration waveform interactions. Resilient adhesive
ok on other surfaces.
[0372] Normally, fans are made in single units, with a mounting
hole for a screw, rivet, or other fastener in each corner. The
single frame double fan is designed to solve two major issues. One,
is air leakage through conventional mounting holes, which are not
used because the helmet fans are bonded in place without any
fasteners. This is done to simplify assembly and to reduce noise
transmitted into the helmet shell by using a resilient fan adaptor
with a pliable fit. The fan adaptor is made of a compliant material
so that vibration is partially absorbed by the adaptor. Prototypes
using conventional fans required sealing of the mounting holes,
which is an added step that requires time and materials and
increases cost. Two, the assembly is easier and faster to assemble,
which reduces cost, because two separate fans don't have to be
aligned and sealed during assembly. Another noteworthy feature of
the disclosed improvement is the rounding off of the outside
corners of the fan assembly. This makes for a more compact assembly
that is easier to package when installed in an ACH.
[0373] An alternative double fan frame, for initial lower volume
production, is disclosed in dashed lines in FIG. 49 because the
molds for the larger radiused frame adaptor, that adapts the frame
to the rectangular cooling, heating, or ventilating assembly, are
much more expensive than for the rectangular frame with small
radii, and are more feasible when high volume production is
established.
[0374] FIG. 49A and other figures in this disclosure illustrate two
or more headgear air movers mounted next to each other in a
relatively compact configuration. The separate fans, with separate
frames should not be rigidly bonded together. If any bond is deemed
desirable, it should be a soft resilient bond, such as a very thin
bond line of flexible silicone adhesive sealant, for example.
[0375] When two or more fans are mounted next to each other in
close proximity, any noise/vibration waveforms produced by those
fans will interact and may produce additional waveforms of varying
amplitude and character, some of which may be perceived as
unpleasant by the user, when not obscured by a dominant background
noise.
[0376] The full face motorcycle helmet covers the head and ears of
the user, surrounding the user's head in close proximity to the
user's head and ears. Any noise/vibration produced by a source,
such as an air mover, which may be a fan or blower, mounted in
and/or on the helmet will be transmitted relatively efficiently in
the form of "surround sound" by a helmet or headgear shell and
impact layer or thermal insulation layer. Under these conditions,
the user may be able to hear fine details of noises/vibrations
produced by the air movers quite clearly, in both air and solid
conduction modes, i.e. through the air and through the structure of
the helmet and contact points with the user's head. Therefore, it's
very important that:
[0377] 1--The air movers be mounted resiliently to minimize
conductance of noise and/or vibration.
[0378] 2--The air mover rotors, or impellers, and motors, are not
mounted to a rigid common frame.
[0379] 3--The separate air mover frames are not mounted or bonded
rigidly together.
[0380] 4--Very importantly, the rotors or impellers and motors for
each air mover are balanced to a higher than average standard.
[0381] The average standard for fans is G 6.3, as shown in the
Balance Table below. From experience, for use with convective
headgear in which the user's ears are to be covered by the
headgear, the minimum standard for convective headgear multiple air
mover balancing is to be raised to G 2.5 or better, in order to
reduce noise overall and minimize the amplitude, or intensity, of
any potentially unpleasant resultant vibrations which may be
transmitted clearly to the user.
[0382] It should be noted that when a properly designed convective
headgear, such as a full face motorcycle helmet, is worn while
riding a motorcycle, noises and vibrations of the convective system
will generally by inaudible because of all of the various
background sounds that will take precedence. However, for the sake
of product refinement and maximum user satisfaction under all
possible circumstances, a higher standard of balancing of the air
movers than has generally been accepted for prior existing consumer
applications of air movers is needed for the convective
headgear.
[0383] A side benefit of a higher balancing standard is improved
air mover longevity.
TABLE-US-00001 Balance Table Balance quality grades are
standardized in ISO 1940. Balance Vibration quality velocity in-mm
grade-G per second Rotor types-General examples Crankshaft drives
of large Diesel G 100 100 engines-Complete engines for trucks and
locomotives G 40 40 Crankshaft drives for engines of trucks and
locomotives G 16 16 Parts of crushing machinery-Parts of
agricultural machinery G 6.3 6.3 Fly-wheels-Fans-Aircraft gas
turbine rotors-Electrical armatures-Process plant machinery-Pump
impellers Machine-tool drives-Turbo G 2.5 2.5 compressors-Small
electric armatures-Turbine-driven pumps G 1 1 Grinding machine
drives-Textile Bobbins-Automotive turbochargers G 0.4 0.4
Gyroscopes-Disk-drives-Spindles for high- precision applications
The smaller the number, the smoother the operation
[0384] FIGS. 47, 48, and 49 illustrate further refinements to the
Air Conditioned Helmet consisting of a noise and vibration reducing
construction involving the use of multi-Durometer components.
Multi-Durometer means that a single component, which may be cast,
molded, or even printed, for example, consists of more than one
material hardness or Durometer. FIG. 47 shows an ACH thermoelectric
device and fan housing which can also be used for a resistive
heating system, and ventilating system with the upper section 751
that holds the fans molded in a relatively soft urethane or other
moldable material with a Durometer of approximately Shore A, 60-80.
Wall thickness has a bearing on Durometer selected for the required
level of strength and structural stability, however the primary
purpose of the soft material is to dampen noise and vibration at
the source, which is the fan or blower motor and impeller. FIG. 48A
illustrates another solution including an extended helmet air duct
from the lower convective system housing, incorporating optional
gripping elements 781 so that adhesive/sealer need not be used,
which facilitates a much cleaner and easier assembly and convective
system replacement if desired or required at some point. A strip of
hook and loop fastener is also shown on the side of the lower
housing facing the helmet shell to support the entire assembly
while allowing for removal if necessary. This is essentially the
same as the preferred embodiment disclosed in FIG. 45B.
[0385] The lower section that houses the thermoelectric module and
heat exchanger assembly, that connects with the coupling attached
to the helmet, or inserts into the air duct in the helmet, should
not be as soft, i.e., .about.Shore 80-95A, in order to support the
weight of the entire assembly adequately and not deform when
inserted into a foam impact layer. The adaptor that is attached to
the helmet and that allows the convective assembly to be detached
from the helmet in an impact, or for replacement, projects outward
into the air duct at the rear of the helmet from the impact
absorbing foam layer in the helmet, through an opening in the shell
of the helmet to isolate the convective system from the shell of
the helmet in order to minimize noise and vibration transmission
into the helmet.
[0386] If the helmet is made with an extended shell that forms a
protective housing for the convective system housing and a smooth
deflecting surface that eliminates or minimizes rotation of the
helmet about the axis of the user's neck from an impact, the
methods shown in this disclosure for allowing the thermoelectric
assembly to detach in a controlled manner will not be necessary,
although the hook and loop fastener and output air duct with grip
flange are preferred for any ACH because of relatively easy
assembly and removal, high reliability, and moderate noise and
vibration transmission. Very importantly, the pliable lower section
will not shatter or splinter in a severe impact at the rear of the
ACH, eliminating shards that might enter the air duct at the rear
of the ACH, although there is TSF and the interior trim material,
in the preferred embodiment, between the user's head and the air
inlet into the ACH.
[0387] FIGS. 50 through 52 disclose an aerodynamically efficient
housing for a bicycle convective ACH battery, particularly the
thermoelectric cooled version, because the forced ventilated
version uses an extremely small lightweight battery that can be
clipped to the user's shirt or shorts. The battery housing of FIGS.
50-52 is shaped to have low aerodynamic drag in plan view and is
ideally made of carbon fiber for very low weight, although it can
be made of other materials at lower cost, with a small increase in
weight. The version shown is designed to be strapped to the top
tube of the bicycle with Velcro.RTM. strips. The size of the
housing can be made according to the capacity of the battery, which
is currently preferably of the lithium ion type, depending on how
long the helmet is going to be used. The purpose of the housing is
to protect the battery and dc-dc converter, if one is used, in case
it rains or the bike falls over or the rider crashes, to prevent
damage to the battery and converter and to make for a neat, tidy,
low drag installation. Air vents are shown front and rear to allow
the battery and dc-dc converter to receive fresh air for
cooling.
[0388] It should be noted that the EPS foam or other impact
absorbing structures or systems shown in this disclosure are
normally found in helmets intended for transportation use. Other
applications of the above disclosed technology may not include a
foam impact absorbing layer, in which case the disclosed features
of the embodiments will be applied without the foam impact layer.
It should also be noted that the inside of any helmet in which the
disclosed embodiments is employed is best made with a smooth
continuous surface, however it is possible to secure the TSF, or
other air flow structures, to a suspended inner liner, such as that
found in helmets used in welding, grinding, and in the construction
industry, by using a thin wall, lightweight supporting cap or hat
to support the air flow structure. The cap or hat may be made by
vacuum forming, blow molding, injection molding, hand layup,
etc.
[0389] The solutions of the embodiments disclosed herein can be
applied equally well to the lightweight bicycle helmets that are
well known today. Bicycle helmets are molded mostly or entirely in
foam, sometimes with a thin plastic veneer over the foam. They also
usually have lots of openings to reduce heat retention on
essentially the top and upper sides of the head.
[0390] FIG. 53 illustrates a front quarter view of the helmet that
has a power cord with connector 821, a mini air mover 822, an
optional windshield/visor 823 to contain cooled air venting from
above the forehead into the user's breathing space for additional
cooling via the face and lungs, and a cooled air nose piece 824 or
cannula 870, concentrates cooled air to nose for breathing. This
may be used with or without a windshield/visor.
[0391] Unlike conventional bicycle helmets that have a maximum open
area to expose as much of the user's head to ambient air, the BACH
is designed to cover as much of the user's head as possible for
maximum active head cooling, since cooling Q equals air
dT.times.Area.times.h, which is the coefficient of thermal
transfer. The helmet shown is based on a ski helmet and encloses a
large part of the user's head without any ventilation openings, and
is relatively compact and lightweight.
[0392] This type or air conditioned or ventilated helmet design may
be used for other applications in addition to cycling, such as
welding, grinding, military, jogging/running, etc. Versions for
nonvehicle use may have a thinner shell to save weight since impact
absorbing requirements are less demanding for most non-vehicle
applications.
[0393] For running and jogging applications, the helmet cap doesn't
need an impact absorbing layer. A thin lightweight shell with a
thin efficient insulation layer, (.about.0.62''-0.125'' thick),
between the shell and the air flow layer, as shown in FIG. 69, pg.
28, with an interior trim layer are all that is necessary to
minimize the size, weight, and cost of the jogging/running type
ACH, cap, or hat.
[0394] The nose piece may be replaced with a cannula to supply
clean, cooled air directly into the user's nose for enhanced body
cooling via the lungs. The cannula may be supplied with cooled air
from the thermoelectric heat pump air outlet into the helmet via a
flexible tube with its own mini pump or blower if necessary. The
cannula tube is shown here outside the helmet for clarity however
it can be installed inside the helmet. The cannula can also be
designed to allow bypass air in the event of excess inhalation.
[0395] FIG. 53A shows a battery cord with connector to helmet,
where the battery 825, preferably lithium ion, to power the bicycle
ACH. May be strapped or otherwise attached to bicycle frame or
rider's belt. May also include a voltage converter if necessary to
convert battery voltage to a compatible voltage for the
thermoelectric device(s) and air movers.
[0396] FIG. 53B shows a side view of the helmet with the bicycle
version shown with openings that are eliminated as in FIG. 47 92,
an inner air flow layer(s), preferably TSF 903, a cover w/ filter
904, a thermoelectric air cooler, heating system or forced
ventilation air mover 905, and a brim re-shaped to function as an
air dam in front of headgear interior air flow outlet vent.
[0397] FIG. 53B illustrates a helmet very similar to the helmet of
FIG. 53. The air vent openings shown in FIG. 53B are eliminated for
the ACH/AVH, however. The jogging/running version is very similar,
but with a thinner shell for reduced weight.
[0398] FIG. 53 shows an example of another type of helmet used for
cycling and for skiing. The ski helmet has no openings because it's
used in cold weather and the bicycle, or BMX, version has some
opening to vent air. In an embodiment of the subject embodiments in
which the lightweight compact ski helmet has been converted to a
bicycle ACH, an optional windshield is shown in FIG. 53 that can be
fitted to the front of the lightweight helmet in order to retain
some of the cooled air that vents from above the forehead of the
user into the breathing space created to provide cooled air for
breathing, which enhances the overall cooling performance of the
ACH. Also shown are a small nose piece and a cannula, that
concentrate helmet cooling air to the nose for more efficient
cooling via the lungs because less ambient air is mixed with
cooling air. The nose piece or cannula may be powered with a mini
air mover as shown in FIG. 53, which draws cooled air from the
thermoelectric convective system and pumps it to the user's nose.
The power cord used to connect the helmet to a battery is also
shown and FIG. 53A a shows a battery, preferably of the lithium ion
type, with cord and connector that connect to the helmet cord and
connector.
[0399] Further reference to a variation of the molded foam type
bicycle helmet, modified to function as a convective helmet, is
made later in this disclosure referencing FIGS. 75 and 75A and FIG.
75.
[0400] The nose piece mentioned above can be replaced with a
cannula to supply cooled air directly into the user's nose for
further enhanced body cooling via the lungs. A cannula is more
efficient because it doesn't allow for as much mixing of ambient
air with cooled air before entering the user's nose, as is the case
with the small nose piece or the larger front visor. The cannula
may be used with or without a front visor, but preferably with a
visor for maximum efficiency. A flexible tube of approximately one
quarter of an inch in diameter, with or without a booster pump or
blower, takes sub-ambient temperature air from the thermoelectric
heat pump air outlet where it enters into the helmet, and blows it
through the flexible tubing to the cannula and into the nose of the
user for enhanced body cooling via the surface area of the lungs.
The features disclosed in FIG. 53 may be used in other air
convective helmets and caps in addition to cycling helmets, such as
jogging and running caps, welding, grinding, motorcycle,
snowmobile, industrial hardhats, military, etc.
[0401] FIG. 53B is a side elevation of a bicycle/BMX version of the
helmet style of FIG. 47, showing typical BMX air vent openings, to
clearly show the thermoelectric air cooling system, heating system,
or forced ventilation air mover, with cover and air filter. The air
vent opening is omitted for ACH use.
[0402] FIGS. 53 and 53B can be made with extra thin shells and no
impact layer for extra low weight, with or without a brim to shade
the eyes and face from the sun, in both the forced ventilated form
or active thermoelectrically sub-ambient air cooled form, for
joggers and runners, who will benefit from significantly enhanced
endurance, (up to 51%), when jogging or running in warm or hot
weather. When cooling the head, the more of the head that is
covered and exposed to cooling air, the more effective the body
cooling process will be.
[0403] FIG. 53B now illustrates an air dam in the form of an
extended and lowered brim in front of the headgear interior air
flow outlet vent to prevent pressure building-up that interferes
with efficient venting of air from the air flow structure by
blocking ambient air flow in and around the interior air flow
outlet vent.
[0404] FIG. 54 discloses a unique wiring schematic for the ACH that
includes switches that provide for off, ventilate, low cool and
high cool. Two separate thermoelectric modules 912 and 914 are
shown, however it is possible to make a single thermoelectric
module with two sections that can be switched in series or parallel
to accomplish low and high cooling. Two separate modules are
preferred because there is less thermal stress on two small modules
than on one large module with 2 or more sections, resulting in
higher reliability for the two separate modules. A provision is
also made to power a noise cancellation system 916 as shown,
including switch S4 926 to optionally enable selectively activating
an active noise cancellation system powered by the helmet air
cooling system power supply cord and circuit. FIGS. 54A through 54C
show a unique option which is to use a single three position double
pole double throw switch for all three basic functions, without low
cool and high cool, or low heat and high heat. The switch mid
position is the off position and the other two positions are
ventilate, with only the fan(s) energized, and a single cooling
position, with both fan(s) and thermoelectric device(s) energized.
FIG. 55 shows a plug that can be configured to plug into an
existing accessory socket such as Powerlet.RTM. DIN type plugs and
sockets, made by Coliant Corp. of Warren Mich., for example, and/or
battery charging plugs used in electric scooters and electrically
assisted bicycles. The same plug can be used to power the ACH by
connecting to the vehicle battery.
[0405] FIG. 54 shows a control circuit for Air Conditioned Helmet
with provision in circuit for additional features such as active
noise cancellation, WiFi, radio, etc. Circuit includes a main
on-off switch, S1 922, and a double pole single throw switch, S2
923, for ventilation mode in the open position, and active cooling
mode in the closed position. The thermoelectric device(s) are
equipped with thermal breakers 998 to prevent permanent damage if
an air mover should fail.
[0406] Circuit also accommodates an optional third switch, S3 924,
to put more than one thermoelectric device 912 and 914 in series
and parallel electrically as a method of providing an adjustable
low and high active cooling power in addition to a forced
ventilation mode without the need for the bulk, cost, and weight of
a variable output dc-dc converter or other electronic voltage
adjusting controller. Series/parallel switching is also more
efficient energy wise. An adjustable voltage controller may be
provided, however it adds weight and bulk to the helmet if mounted
on the helmet. An additional component mounted on the helmet also
has to be configured to meet safety agency approval. A novel
solution to this problem is to mount the variable voltage converter
in the plug that plugs the helmet into the motorcycle or other
vehicle, as shown in FIG. 55 below. This converter can either
control voltage to the thermoelectric device(s) to vary cooling
power or to both the TE device(s) 912 and 914 and the fans or
blowers 918 to control cooling power and air flow levels. The
control switches can be mounted either on the control or on the
ACH. If mounted on the ACH, wires between the switches and the
control can be included in the power cord, and the control box can
be molded to, or otherwise connected and attached to the power
cord. Another novel, simple and inexpensive approach is to use a
double pole three position double throw switch for
off--ventilate--active cooling. This can be accomplished with a
single thermoelectric module or with more than one module, as shown
in FIGS. 54A through 54C. Another novel solution if disclosed in
FIGS. 54A through 54C. A potentiometer is added as shown in the
switch to provide a blower speed control only in ventilation mode.
Single blower type thermoelectric systems require a predetermined
air flow on the hot rejector side in cooling mode to ensure
adequate cooling on the hot side. The solution disclosed below is
simple, compact, lightweight, and inexpensive and ensures that the
single blower type thermoelectric system has adequate hot side air
flow when in cooling mode, and allows for a variation in air flow
to the user's head and face in ventilation mode only.
[0407] Another novel feature of FIGS. 54A through 54C is the
adjustable potentiometer that is connected to two of the switch
poles as shown. The purpose of this new and unique concept is to
enable the air mover speed, and resulting air flow, to be adjusted
in ventilating mode only and not in the cooling mode setting with
the thermoelectric convective cooling system. The reason for this
is that the thermoelectric cooling system will not tolerate large
variations in air flow unless an input power control is used, which
increases size, weight, and cost of the thermoelectric type
convective helmet. If ambient temperature is favorable for the use
of ventilation only, a much lighter, cheaper and more compact
control solution is a potentiometer that is wired as disclosed to
only function in ventilation mode to adjust the ambient ventilation
cooling power of the helmet to ambient conditions.
[0408] A novel inexpensive, compact, and lightweight solution added
to the novel switch control of FIGS. 54 A, 54B, and 54 C disclose a
potentiometer added to the 3 position double pole switch in the
drawings in such a way as to provide a simple speed control for the
thermoelectric air to air convective system of the convective
helmet. Although it is possible and is disclosed elsewhere in this
overall disclosure, to use more than one blower or fan, a single
blower or fan type convective system may be desired for some
reason. The circuit of FIGS. 54A, 54B, and 54C will provide an
adjustable ventilation mode while ensuring normal air flow when in
cooling mode, which is when the thermoelectric device(s) for the
cooled convective helmet must have a predetermined level of air to
ensure adequate cooling of the hot side in cooling mode. Whenever
the system is switched from cooling to ventilation or vice versa,
it will automatically go from the predetermined air flow rating of
cooling mode to the adjustable air mover function to enable fine
tuning of the cooling power of ambient air in ventilation mode.
[0409] FIG. 55 discloses a power cord with an optional dc-dc
convertor in-line to enable the use of the helmet with different
battery types and voltages. Also the control switch for the
convective helmet is shown in the power cord.
[0410] FIG. 55 illustrates a dc-dc converter 920 if necessary for
different battery types or electric bike main batteries or variable
voltage control for warming mode, a plug for vehicle socket or
battery connector, or battery charger socket for electric bikes
922, a power cord 924, a connector to helmet 928, and a switchbox
on ACH power cord. 926
[0411] FIGS. 56 through 58 disclose a variation of the novel method
for controlling the cooling and heating power of a thermoelectric
convective, or resistive convective system as used in the subject
embodiments, in the simplest, most cost effective way. By switching
two or more thermoelectric modules, or resistive heating elements,
in different configurations of series and parallel connections, the
resistance of the modules can be varied, resulting in different
levels of current flow, producing different levels of cooling and
heating power without the need for electronic power controls, such
as switching mode controllers, for example. The human body has the
ability to adjust to varying levels of cooling and heating by
varying the amount of vasoconstriction beneath the skin surface,
especially in the scalp, to control, within a limited range, the
amount of heat rejected or absorbed. This ability, combined with a
distinct range of adjustment on the part of the cooling and heating
medium, results in a relatively wide range of total adjustability
without the necessity for more complex and expensive controls in
day to day use under normal day to day conditions. For certain
applications, such as helmets for snowmobiling, where a warming
mode is desirable, the double heating module approach is
advantageous because it allows the modules to be switched in series
in warming mode, reducing heating power to prevent overheating the
user's head in warming mode.
[0412] FIGS. 59, 60, and 61 show another alternative large area air
filter installed into the fan air inlet snorkel. FIGS. 59, 60, and
61 show a filter 942, which may be made of any suitable filter
material, including foam, paper, cotton, or other woven materials.
Preferably made of plastic, such as an electrostatic mesh for
example. The filter is located at a tangent, as opposed to
radially, for maximum air flow cross-section area for low pressure
drop with maximum compactness for minimum rear helmet
extension.
[0413] The housing itself 944 may be made of any material, however,
a moderately flexible urethane or similar material is recommended,
as can be made to self-grip the fan assembly and will collapse
easily if necessary in any impact.
[0414] FIG. 61A is updated to show the air filter media installed
in the compact air filter adaptor designed to enable a large filter
area within the curvature of the back side of the convective
headgear. The filter media is shown installed and is a polymer
fiber electrostatic filter sheet that is attached to the pliable
elastomeric adaptor with glue, staples, rivets, stitching, using a
separate frame to secure it in place. If the filter media is
co-molded with the adaptor a separate frame is not necessary, as
the co-molding process envelopes, or encapsulates, the filter media
around the perimeter of the filter adaptor flange.
[0415] Embodiments employ a snorkel, or filter adaptor to make the
entire assembly more compact incorporating the fan housing and TE
housing adaptor into the snorkel. An air inlet snorkel for the air
mover(s) is helpful at higher vehicle speeds because it prevents or
reduces the air mover inlet(s) behind the helmet from being
subjected to fluctuating air pressure at certain helmet angles at
certain vehicle speeds due to separation and turbulence at the
trailing surface of the helmet. The inlet to the snorkel should be
in front of the most forward air separation point so that
relatively laminar, undisturbed air is taken into the air mover(s).
This ensures that the performance of the convective ACH cooling,
heating, or ventilating, system performs linearly, or more nearly
linearly, at all vehicle speeds. The ram air effect available at
higher speeds may increase air flow through both sides of the
thermoelectric cooling system, providing more cooled air to the air
flow structure inside the helmet. An optional adjustable valve to
control the ram air effect is contemplated. The valve should have a
multiple detent ratcheting mechanism to allow for an adequate
number of securely set positions. The valve can also be installed
optionally in the air path into the thermoelectric assembly of the
ACH with shell contoured to contain the thermoelectric
assembly.
[0416] Embodiments include a version of the snorkel which is
separate from the helmet shell and is mounted on the convective
system housing. The snorkel will detach from the helmet along with
the convective system housing if the thermoelectric system housing
is designed to detach in a tangential, or lateral, impact. It
should be noted that the snorkel is only desirable if the
convective system, whether cooling, heating, or ventilating, is
located outside the helmet shell at the rear of the helmet shell.
Enclosed convective systems, with covers, as disclosed elsewhere in
this disclosure, will not need the snorkel. The snorkel is then
modified and used as a compact air filter adaptor.
[0417] By integrating the fan housing into the snorkel or air
filter adaptor, it is not necessary to make the snorkel, or air
filter adaptor, fit on the outside of an existing fan adaptor.
Assembly of the integrated fan housing and snorkel requires a
slightly longer lead length from the thermoelectric device to allow
the leads to be threaded through the appropriate opening in the fan
housing portion of the snorkel because the fan or blower leads will
have been threaded through beforehand.
[0418] Another new convective system air inlet snorkel designed for
use with the radiused TES type thermoelectric module assembly for
maximum compactness. A radiused resistive heating element may also
be used with this type of snorkel if the assembly is mounted out in
the open at the rear of a helmet.
[0419] The snorkel adaptor to the thermoelectric assembly is
radiused to match up with the radiused TES or resistive heating
type assembly. It should be noted here that the TES type assembly
offers the advantages of reduced weight, faster response, higher
efficiency, and reduced cost whether or not the ability to form a
radius is employed.
[0420] Embodiments may have an optional radius in the upper portion
and air inlet section of the snorkel and another option, which is
to use a flat upper section and straight inlet. If the radiused
inlet in used, the adjustable valve cannot be used because the
valve would have to also be radiused and would bind when rotated
out of symmetry with the radius of the inlet and upper section.
Embodiments provide a solution to high pressure build up, if
unwanted, with passive vent openings that are designed to vent air
adequately at high speeds. This solution can be made adjustable
with a sliding element that can slide up and down or side to side
to open more or less vent area as needed.
[0421] FIG. 61A shows the most recent design refinement 946 of the
concept of FIGS. 59 through 61. Intended for use with an enclosed
convective cooling, heating, or ventilating system. This may be a
preferred embodiment. When used with a removable cover on the rear
of the helmet, the filter may be vacuumed periodically. The
electrostatic air filter mesh media is secured to the adaptor with
adhesive, staples, stitching, or rivets. A separate matching frame
to secure the mesh to the adaptor is also shown in FIG. 61A
[0422] FIG. 61A is a 3D CAD rendering of a new filter design, based
on the filter assembly disclosed in FIGS. 59 through 61, designed
particularly for an electrostatic mesh air filter, combining the
filter and snorkel for minimum volume and maximum filter area, when
installed in a convective helmet that uses an extended shell,
and/or a rear cover instead of being out in the open as in the
prototype photo above, especially with air inlets mounted low and
on the sides FIGS. 32A, 33A, and 34AA, to prevent any possibility
of rainwater entering the filter and convective system. The
electrostatic mesh filter is not shown in FIG. 61A for clarity,
however the filter is either molded in place or clamped in place
with a frame with holes for rivets, etc., and positioned more or
less as shown in FIG. 61. The filter element is mounted tangent to
the arc of the snorkel for maximum filter area in the most compact
space.
[0423] A flange is shown on the modified snorkel in FIG. 61A with a
mounting frame with fasteners, such as rivets for example, however
the filter element, preferably an electrostatic plastic mesh type,
may be molded onto the flange of the adaptor with an over-mold
instead of using a clamping frame with fasteners. Using fasteners
with mesh only is not a good approach, as vibration and forces from
vacuuming to clean the filter might work the mesh loose where the
fasteners project through the mesh.
[0424] Embodiments include an example of an ACH configured for use
as a welding or grinding helmet. Welding helmets take different
forms, however the most common element is the faceplate, or mask
that protects the welders face from heat, light, sparks, etc. The
faceplate or mask also incorporates protection for the welders eyes
in the form of a tinted view port to reduce the glare of the arc in
the case of electric cutting and welding, and/or sparks and flames
if gas, electron, or plasma cutting or welding.
[0425] Since welding is in itself a hot process, welders are
usually exposed to lots of heat, in addition to sparks, flames,
fumes, and intense light during cutting and welding.
[0426] Welders usually wear protective garments in addition to a
helmet and/or mask to more completely protect themselves, which
only increases discomfort in warm weather, and even more so in hot
weather.
[0427] Since the scalp is the most efficient area to cool the body,
it makes sense to use head cooling to ameliorate the above effects
of protective gear when engaged in the hot activity of cutting,
welding, and grinding, especially in warm and hot conditions.
[0428] The welders ACH feature an optional movable faceplate to
allow the faceplate to be lifted up out of the way if necessary.
This will be necessary if the tinted lens or viewport is not of the
adjustable type that switches from tinted to un-tinted
automatically whenever the welding process begins and ends. The
viewport may also be hinged itself, of course, so that it can be
flipped up out of the way without moving the faceplate. A hinged
faceplate makes it easier to put the helmet on and take it off.
[0429] Essentially, the welding ACH consists of the head covering
part and the face covering part. The head covering part may be
separate from the face covering part or the two may be integrated
into one assembly with or without a flexible or movable connection
between the two. The objective is to cool the welders head as fully
as possible while providing a suitably tinted view port and
appropriate face protection.
[0430] A compact form-fitting air filter to the welding helmet of
FIG. 28 is contemplated. Although air filters are disclosed
elsewhere in this disclosure, this air filter is different because
it is designed for heavy duty use, while remaining compact. This is
accomplished by making the filter, which may be of the HEPA type,
or any other type, radiused and, ideally, rectilinear, in order to
offer the largest filtration capacity with minimum pressure drop in
the most compact form, which includes a radius so that the filter
conforms to the shape of the outer surface of the helmet.
Optionally, the filter can be countersunk into the indented channel
in the outer shell formed by either extending the basic shell or by
adding shell extension fairings to the outside surface of the
shell. The channel then forms a protective location for the
filter.
[0431] An optional booster fan or blower to the inlet of the filter
of on the ACH/PAPR, (Powered Air Purifying Respirator), type ACH,
to compensate for the pressure drop through the filter. A larger
fan or blower may be used, however a more compact packaging
solution is to use additional small fans or blowers at the filter
inlet because they can be configured much more easily to conform to
the shape of the helmet, allowing everything to be packaged on or
in the helmet for maximum overall system compactness.
[0432] The booster fan or blower may also be used if necessary with
transportation and others types of convective helmets, including
heated and ventilated helmets, if a filter type with a relatively
high pressure drop is desired.
[0433] FIG. 62 is an expanded view of the different layers inside
the welding, grinding, PAPR, and other types of convective helmets
and caps, such as jogging/running caps, that don't require an
impact absorbing layer and instead feature a thermal insulation
layer to maintain high thermal efficiency. The thermal insulation
layer may be made of conventional molded EPS, (Expanded
Polystyrene), Volara.RTM., or other closed cell foam or other high
R-factor insulation material, with a thickness of between
approximately 0.10'' to 0.25'' for minimum helmet size and weight
with good thermal performance.
[0434] FIG. 62 illustrates a lightweight addition, which is a
helmet/cap construction with an impact absorbing layer between the
shell and the air flow layer replaced with a thin lightweight
thermal insulation layer, which may be EPS, Voltek Volara.RTM., or
another suitable thermal impedance of approximately 2-5 mm in
thickness, to reduce helmet/cap size, weight, and cost in
non-vehicle related applications such as running and jogging, in
addition to welding and grinding, for example, while maintaining
high thermal efficiency by minimizing heat leak into the helmet
cooling air, or out of the helmet heating air.
[0435] FIG. 62 shows an outer shell 951, an air flow structure
layer 952, an optional non-slip surface 953 for adjustable head
strap secure grip, a support boss, or structure, for 954 convective
system, a thermal insulation layer 955, an interior trim layer 956,
and a lower edge seal 957.
[0436] Layer detail of FIG. 62 expanded for clarity. This structure
applies to air conditioned helmets that don't require an impact
absorbing layer, as those for transportation use do. A thermal
insulation layer is necessary for high thermal efficiency and
performance. The impact absorbing layer in transportation type ACHs
provides more than adequate thermal insulation for high thermal
efficiency. Support structure for convective system may be molded
into the thin shell or molded separately and bonded to the thin
shell to provide an adequate base to connect the convective system
with the thin shell headgear structure.
[0437] FIG. 62 has been modified to include an important
improvement, which is a support boss, either integrally molded into
the thin wall shell or separately molded and bonded to the outside
of the thin wall shell. The purpose of the support boss is to
provide a length of air duct to support a convective air system
mounted to the rear of the thin wall shell. A thin wall shell will
not provide enough depth to support a convective system air duct
that is integral with the convective system. An alternative
solution is disclosed in FIG. 75A.
[0438] A thermal sensor, such as, but not limited to, a
thermocouple or thermistor for example is shown in FIG. 62 with
electrical leads and is located downstream from the air input to
the helmet air flow structure, preferably close to the
thermoelectric cooling and heating system for accuracy. An optional
resistive heating element may be added downstream of the
thermoelectric air input to the helmet if the helmet is to be used
in extremely cold environments to boost heating. Otherwise, the
thermoelectric heat pump will provide enough heating to bring the
outside air up in temperature, without going above scalp
temperature, as it is not advisable to actively heat the scalp
above the natural normal skin temperature. A maximum air
temperature of 60-80.degree. F. makes for a simpler control
system.
[0439] The PAPR type ACH can be designed to have a heating mode, in
addition to the cooling and ventilating modes disclosed herein so
that the respirator function of the ACH/PAPR, which is also used to
ventilate or actively cool the user's scalp and body with cool
ambient or sub-ambient air with air for breathing and air that
develops a positive pressure in the helmet to exclude undesirable
gases, vapors, dust, etc., from the helmet, can be used to avoid
overcooling with respirator air if the ambient air temperature is
below the appropriate temperature, and raise the respirator and
head and body cooling air to the most comfortable and appropriate
temperature for good health and safety.
[0440] A material that may be usable as a commercially feasible
alternative to TSF for convective helmet air flow structures has
been developed by Livermore Labs. It is a printed material that is
essentially a stacked lattice, or mesh layers, of silicone strips,
bonded together at the cross-over points. The Durometer of the
silicone can be varied to produce a stacked lattice with varying
degrees of rigidity and conformability. The mesh or lattice can be
a 90.degree. mesh or otherwise, however the material does provide a
self-supporting open mesh stack layer of whatever desired
thickness, and the silicone strips, or filaments, can also be
varied in diameter or thickness. The latticework may be made
sufficiently permeable to air to offer a moderately low pressure
drop along the axis of flow, with fairly good permeability at the
surfaces contacting the user. The overall air flow efficiency and
thermal permeability of the material will be less than that of TSF
however, because most of the thickness of TSF is open tube
structure, with a single woven layer on each major facing surface,
so the Livermore material is a potentially lower performing
alternative to TSF for air convection headgear, since it has more
larger elements in the air stream than TSF. The new printed
material is also likely to be considerably heavier than TSF, since
the load bearing ability of the printed silicone is in beam-bending
mode and not arch compression mode as with TSF, and more material
is required to compensate for less efficient structural load
bearing.
[0441] Embodiments include a unique variation of the AC-PAPR or
powered respirator, with cooled and warmed air being supplied in
two channels. Channel 1 is the main channel that cools or warms the
user via the scalp and supplies the same air to the space in front
of the user's face via the vent above the user's forehead. Channel
2 is an additional channel that supplies air from the same cooled
and warmed, or ambient temperature, source, but only to the area in
front of the user's face.
[0442] The reason for this is that it may be desirable to have more
air and pressure in the breathing space than would be desirable
from a head and body cooling or warming standpoint. The air of
Channel 2 will not affect head and body temperature, so, although a
small amount of face cooling or heating may be accomplished, the
air of Channel 2 is used primarily to exclude unwanted gases,
vapors, dust, etc. from the face/breathing area, while the air in
Channel 1 is used for head and body cooling or warming, plus
breathing and gas and vapor exclusion.
[0443] An air duct, preferably insulated for improved thermal
efficiency, is shown connected to a remote thermoelectric air to
air heat pump with an air inlet filter. The remote unit may be
mounted in a backpack or on a belt. FIG. 71 shows a variation of
the helmet of FIG. 70 in which the extended shell of FIG. 70, which
contains an internal air channel for Channel 2 air, is changed to
the conventional type helmet shell with Channel 2 air managed with
an external air duct, either rigid or flexible, mounted to the
outside of the helmet shell and adapted to the face shield via the
respirator adaptor as shown.
[0444] Two methods, other than with AC line power, of powering the
ACH are shown. One is to attach a battery, preferably of the
lithium type, directly to the belt or backpack mounted
thermoelectric air cooling and heating system, and the other, which
is the preferred embodiment for off-line power, is a separate
battery pack mounted on the floor to relieve the user of the weight
of an adequate battery to run the helmet for extended periods of
time. Conventional PAPRs for welding and grinding have no cooling
or heating and, as a result, use a battery to run only a blower or
fan off-line, which requires much less energy than cooling and
heating that air. The controls for the cooling and heating system
may be mounted on the thermoelectric system or inline with the
power cord from the remote battery.
[0445] Normally, a bag like enclosure is fitted to the bottom of a
PAPR with a drawstring or elastic band to form a loose seal around
the user's neck. This allows for the establishment of a positive
pressure inside the PAPR to exclude noxious gases and fumes. A
minimum of 6 cubic feet per minute of air flow into the PAPR face
area is required to meet NIOSH respirator requirements. The two
channel approach disclosed above allows for variations in air flow
for cooling and warming and respiration. A valve to bias cooled or
warmed or ambient respirator and cooling or warming air is also
contemplated. It is advantageous to use a separate blower or fan
for Channel 1 and Channel 2, and is the preferred embodiment. By
using a separate filtered fan or blower for Channel 2, it isn't
necessary to cool or warm Channel 2 air, which reduces the size,
weight, cost, and energy consumption of the thermoelectric cooling
and heating system, while ensuring, if necessary, that there is
enough respirator air to exclude fumes and gases as necessary. The
advantage with a common air source for both channels is that the
cooling and warming capacity will be higher, enabling more cooling
and warming for more extreme conditions and larger, heavier
users.
[0446] FIG. 62 has an added note disclosing an improvement to the
ACH for welding, grinding, and other industrial applications. Since
welding helmets either have an extension of the face protector that
projects back over the users head to protect from sparks and heat,
or have no covering other than the usual one-size-fits-all
adjustable headband, the ACH type helmet can be made without impact
absorbing characteristics, which means that the shell that contains
the air flow structure, which is preferably TSF, but can also be
any other usable material or structure, can be somewhat flexible.
Such a flexible shell can be made in a number of ways, including
blow molding, and vacuum forming, which may be more cost effective
than injection molding, for example. The wall thickness of the
industrial helmet type shell should be thin for low weight, low
cost, and moderate flexibility so that it can more readily conform
to the shape of the users head and won't increase neck fatigue.
[0447] The TSF air flow structure is flexible in every plane except
to only a small degree across the air gap, so it will readily
conform with a flexible shell. The better the air convection helmet
fits the user, the higher its thermal transfer efficiency will be
because the TSF structure puts airflow closer to more of the user's
head at higher velocity and less air will leak out from around the
edges of the structure, so more air is available for head surface
cooling or warming.
[0448] The added flexibility will also enhance the comfort of the
helmet during a long period of welding because it will reduce or
eliminate pressure points.
[0449] A further embodiment of the embodiments for PAPRs wherein
the air cooling and heating system is mounted on the helmet for
maximum thermal efficiency is contemplated. The remotely mounted
thermoelectric air cooling and heating system has two disadvantages
compared with the on-board mount system.
[0450] 1--Pressure drop through the air duct hose from the belt
mount to the helmet.
[0451] 2--Heat leak into the air duct hose in cooling mode, and
heat leak out of the air duct hose in heating mode.
[0452] The on-board thermoelectric system mount substantially
reduces the above losses for better performance with a smaller,
lighter, less expensive system that uses less power, which results
in reduced battery size, weight, and cost for battery powered
applications.
[0453] Embodiment demonstrates an example of the on-board type
PAPR. The current standard ACH thermoelectric air cooling and
heating system produces .about.4 cubic feet per minute of
temperature modified air into the helmet interior surrounding the
user's head. The NIOSH minimum air flow for PAPRs is 6 CFM. A
second air channel, referred to as Channel 2, is the make-up air
channel, which supplies additional air to produce the minimum, or
greater than minimum, total respirator air when added to Channel 1
cooled or heated air.
[0454] Approximately 4 CFM of cool ambient or sub-ambient cooled
air is capable of substantial body cooling when applied closely to
the scalp of the user. Although the thermoelectric air cooling and
heating system can be designed for a larger air flow, it is
desirable to minimize the size, weight, energy consumption, and
cost of the thermoelectric apparatus and this can be accomplished
by supplying additional respirator air to the front of the helmet
with a simple, compact, lightweight, and relatively inexpensive
blower with a filter rated from 2 CFM minimum, up to any desired
additional respirator make-up air flow rate.
[0455] The ideal location for the battery, since cooling and
heating require a battery with larger capacity than that required
for simply blowing ambient air for respiration, is on the floor,
with an extension cord to the belt mount system. The respirator
make-up air blower and filter are not shown because they are
mounted on a belt, since heat leak and pressure drop are not
significant for ambient air, assuming that ambient air is cool
enough to cool or warm enough to warm, since there is no cooling or
heating and there is no heat exchanger pressure drop to account for
in the ambient respirator air Channel 2.
[0456] It is also possible to mount the Channel 2 air flow system
on-board the helmet, for example in the space above the Channel 1
system. Since the make-up air for the basic ACH cooling and warming
system is as little as only approximately 2 CFM to perhaps as much
as approximately 4 CFM, to meet the NIOSH minimum, a make-up air
system for Channel 2 can be relatively very lightweight and
compact, Channel 1 head cooling or warming air combines with
Channel 2 make-up air in the face area for respiratory needs, while
Channel 1 air cools the user's body via the scalp. In warm weather,
the cooled air from Channel 1 combines with ambient air from
Channel 2 to provide sub-ambient air to cool the face and for
cooler breathing, while in cold weather, warmed air from Channel 1
combines with ambient cold air from Channel 2 to provide warmed air
for the face and for breathing.
[0457] Embodiments include another configuration of the powered
respirator type ACH, or ACH-PAPR, in which both Channel 1 and
Channel 2 ventilating, cooling, or heating, are remote from the
helmet. Ideally, the cooling and heating system should be mounted
on the helmet for maximum thermal and air flow efficiency. This
does not preclude the remote mounting of the cooling and heating
apparatus, Channel 1, and the make-up air source, Channel 2 if
desired for some reason.
[0458] Another unique solution for the subject embodiments, which
is not a preferred embodiment, but is possible as an alternative.
An embodiment contemplates a combination of a thin wall ACH helmet
with an expanded adjustable headband type mounting system for a
conventional welding mask or grinding mask. Virtually all current
welding and grinding masks use an adjustable one-size-fits-all type
mounting system. Head and body cooling however require maximum
coverage of the head for maximum body cooling efficiency. Typical
adjustable headband type helmet and mask mounting systems are sized
to accommodate the average range of human head sizes, without the
additional volume of a helmet, so the typical adjustable headband
mounting system must be expanded to allow for the additional volume
of a thin wall ACH helmet.
[0459] When this is done, the welding or grinding mask can be
mounted onto the thin wall ACH helmet, however, the ACH helmets
must still be made in different sizes to accommodate different head
sizes. A good fit, with minimum internal padding, is required for
good convective helmet thermal performance.
[0460] An approach is not a preferred embodiment because the
adjustable headband type mount is relatively complex and is not as
secure as a thin wall convective helmet shell with face mask pivot
mounting bosses molded into the sides of the shell.
[0461] The adjustable headband mounting option also requires a
non-slip surface, or a ridgeline above and below the headband, to
prevent the headband from slipping off of the ACH helmet, which
would be unacceptable during welding. This is another reason that
the ACH helmet with pivot mounting bosses is a preferred
embodiment.
[0462] FIGS. 63-65 are disclosures of a switch control circuit for
multiple thermoelectric Peltier modules for the ACH convective
cooling or heating system. Multiple modules allow for low and high
cooling and heating power control without the use of electronic
controls, resulting in extra high reliability, lower cost, and less
weight and system volume. An electronic power control may be
provided, however the combination of the human body's
thermo-regulatory system with the efficiency of scalp cooling, plus
ambient ventilation, and a low and high setting in both cooling and
heating modes, provides a wide range of practical accommodation for
varying ambient temperature conditions with maximum reliability,
minimum cost, weight, and volume.
[0463] FIGS. 63-65 illustrate the three states 960A, 960B, and
960C. First is cooling mode 960A, with the no. 2 switch 992 in the
cooling mode position and the Peltier devices in parallel via the
no. 3 switch 993, which provides maximum cooling power. Second is
ventilation mode 960B, FIG. 64, with the no. 2 switch 992 in the
mid position so that only the blower 918 is actuated by the main
switch, providing ambient air to the helmet. In FIG. 64, the no. 3
switch 993 happens to be shown in the parallel position, however
whichever position the no. 3 switch 993 is in will not matter
because there is no power to the no. 3 switch.
[0464] Third is heating mode 960C, FIG. 65, with switch no. 2 992
in the heating mode position and the no. 3 switch in the series
position, which produces heating mode with the Peltier modules 14
in series, for the low power setting in heating mode. The no. 3
switch 993 may be switched to parallel for cooling mode also,
resulting in a low cooling mode setting. A thermal circuit breaker
998 is shown on each Peltier module in FIGS. 63 through 65 to
prevent damage to a module if an air mover(s) should fail. PTC
heating devices don't require over-temperature protection.
[0465] FIGS. 66-68 disclose a variation of the above circuit with a
single Peltier module shown. A series-parallel switch and polarity
reversal switch as disclosed in FIGS. 63-65 above may be applied to
the circuit depicted in FIGS. 66-68, however, for clarity, the
primary purpose of the circuit depicted in FIGS. 66-68 of is to
provide a blower speed control for ventilation mode only. When the
circuit of FIGS. 66 through 68 is switched into cooling, (or
heating mode in some variations), the variable resistor, or other
blower speed control, is switched out of circuit. The reason for
this is that, if there is only one air source for both sides of the
Peltier device, the Peltier device cannot be used at full power at
less than rated air flow without damage. The purpose of the circuit
depicted in FIGS. 66-68 of is to ensure that the air mover speed,
and hence the volume of air blown into the helmet, is only
adjustable when the Peltier device is not energized, as in
ventilation mode.
[0466] Embodiments disclose yet another variation, which is
probably the overall PAPR preferred embodiment for welding,
grinding, and PAPR applications. Embodiments differ in that it
discloses the thermoelectric air cooling and warming system mounted
on the helmet for maximum thermal efficiency, by eliminating heat
leak into an extended air duct hose in cooling mode, or heat loss
out of an extended air duct hose in heating mode, and either a
common blower or separate blowers mounted remotely, on the user's
belt, for example, along with any specialized air filters for toxic
gases or vapors, blowing filtered ambient air to the Channel 1
cooling and heating system and also the respirator make-up air at
the front of the helmet as shown in the figures. The head cooling
and heating system is on the helmet, and air movers are remote from
the helmet.
[0467] A battery can also be mounted on the user's belt, however,
cooling and heating the air results in a higher power and energy
consumption, so the ideal place to put a battery, if line power is
not available, is on the floor or the ground, with an extension
cord to the blower on the belt and the thermoelectric cooling and
heating system on the helmet. This configuration provides maximum
thermal efficiency with minimum helmet weight.
[0468] An optional valve is shown to enable the adjustment of the
air flow bias between the two air channels if desired.
[0469] Embodiments also disclose an optional convective cooling and
heating system mounted to cool or warm Channel 2 air for
respirator/visor make-up air, if desired. As in the Channel 1
circuit, ambient air from an air mover remote from the helmet is
ducted over both sides of a Peltier device with heat exchangers,
with the auxiliary air vented.
[0470] Embodiments having the PAPR configuration will also work
very well for painters in spray booths, who often wear protective
garments in addition to respirator head gear, which will tend to
get warm or hot, since all of their body is enclosed and the air
that is ducted to their head gear is provided to their face area
only. Paint cures much more rapidly as ambient air temperature
increases, so paint booth temperatures will generally be at a
minimum of 70.degree. F. to as high as 85.degree. F.+. At these
ambient temperatures, a fully enclosed human performing the
physical task of spray painting will need cooling for optimal
comfort, resulting in optimal work productivity, quality, and job
satisfaction.
[0471] By keeping the thermoelectric cooling system on the helmet,
the thermal efficiency of the cooling system is optimized. The
ambient air supply to the headgear via a flexible air duct hose is
cooled before flowing over the painter's head, providing body
cooling via the scalp and cooled air for breathing, in addition to
excluding unwanted paint spray from the headgear.
[0472] FIGS. 69, 70A, and 71 are further disclosures of the
ventilated version of the subject embodiments.
[0473] The ventilated helmet functions well when ambient
temperature is far enough below scalp temperature for a sufficient
dT, or temperature difference, to produce body cooling.
[0474] A control circuit is disclosed in FIG. 70A that includes a
simple, lightweight, compact, durable, and inexpensive resistive
blower or fan speed control, to keep the cost of the helmet or cap
low and attractive for those who want a less expensive alternative
to the Air Conditioned Helmet, or Air Convection Helmet, (ACH). A
variable resistance is included to enable ambient ventilation air
volume to be adjusted. FIG. 70A illustrates a fan/blower(s), a
fan/blower speed control potentiometer 976, a single pole, single
throw switch, or switch 980 can be incorporated into pot, and a
power Input. 982
[0475] The AVH, or Active Ventilated Helmet, may be made with an
extended shell as disclosed elsewhere in this disclosure, and may
also feature an air filter and/or a snorkel for vehicle use to
stabilize air pressure in the air mover at higher vehicle,
(motorcycle, snowmobile, etc.), speeds, maintaining a more
consistent cooling effect over a wider range of vehicle speeds. The
heating module of FIGS. 12 through 15a of this disclosure, may be
incorporated into the AVH of FIGS. 69 and 70 for heating in cold
weather, as in a snowmobile helmet, or a PAPR version, for example.
FIG. 69 shows an optional snorkel 980 for blower or fan, to limit
rain ingress and excessive air pressure in higher speed vehicle
applications, a blower(s) or fan(s), a blower adaptor to helmet air
inlet 982, preferably made of a medium Durometer urethane, an air
inlet for air mover assembly, and a thermoelectric hot air outlet
983 not necessary w/ ventilation only.
[0476] Important note: The air filter of FIG. 67A, may also be used
with the AVH, to reduce dust build-up on the air mover and inside
the helmet air flow structure.
[0477] FIG. 72 discloses another variation of the subject
embodiments. In this variation, either an inner shell is supported
by flexible suspension elements between the inner shell and the
outer shell, allowing for compliance between the two shells. The
purpose of the compliance is to mitigate rotational forces caused
by tangential impacts that can cause the helmet to rotate in such a
way as to cause trauma to the user's neck and/or brain. Another
method of achieving a similar mitigation is to make the inner
impact liner out of two or more movable, or sliding, layers of
impact absorbing material that can slide over one another to
provide a similar level of compliance between the user's head and
the outer shell of the helmet.
[0478] FIG. 72 shows an optional movable impact absorbing layer
1000 with variable densities or multiple movable layers, or elastic
suspension elements to provide compliance between the user's head
shell and the outer shell to reduce rotational trauma to the neck
and/or brain. In it, there is an air inlet, an optional snorkel
1003, with or without filter, such as a plastic mesh electrostatic
type, for example, as shown, a rear cover is short at the top 1004
to leave an opening for the air inlet in the extended rear shell, a
filter 1005, and a fan(s) or blower(s). In addition, there is an
air convective cooling or heating or ventilating system 1006 may be
countersunk into extended rear surface of helmet as shown, an air
inlet duct 1007 is molded plastic or rubber that is soft enough to
deflect with a compliant inner impact absorbing structure, a bottom
edge seal 1008 for air flow layer or lower part of neck roll, an
air flow layer 1002. May be Tubular Spacer Fabric, but may also
consist of air spaces or channels between impact absorbing
suspension elements and/or multiple impact absorbing layers or
structures, as noted above. There is also a compliant suspension
elements or multiple movable impact absorbing layers. 1001
[0479] Note: The TSF airflow structure may be replaced with an
inner shell or element that is perforated to allow temperature
modified air to circulate freely around the suspension elements to
cool or warm the user's head. Direct air flow into a TSF layer will
result in superior thermal performance, however.
[0480] Extra Note: The optional movable impact absorbing structures
shown in FIG. 72 and/or 89 above can also be used with the
thermoelectric cooled and heated helmets shown in other figures of
this overall disclosure.
[0481] In both of the above examples, it is possible to arrange for
openings in the inner shell to allow air that flows in the space
between the inner shell and the outer shell, around the suspension,
or impact absorbing, elements to accomplish some level of head
cooling.
[0482] The inner shell must maintain a certain level of rigidity in
order to support the suspension elements and the outer shell
adequately for good protection, so the amount of permeability of
the inner shell may be limited in order to ensure adequate inner
shell rigidity.
[0483] In the second example, also part of FIGS. 72 and 89, where
multiple layers are designed to slide over or within one another to
provide some degree of rotational compliance for the helmet
assembly, gaps may be provided to allow for some internal air flow
in order to provide some degree of head cooling for the user via an
air flow structure, preferably TSF, but not limited to TSF.
[0484] FIG. 72 shows how the air conditioned helmet of the present
disclosure can be configured to work with the above techniques,
incorporating the thermoelectric heat pump or an air mover for
forced ventilation, or an air mover with resistive heater for
heating, with an extended shell with rear cover for good
aerodynamics and to minimize rotation of the helmet under
tangential impact, as disclosed more fully herein. A more
conventional helmet shell with extended rear cover may also be used
with the solutions.
[0485] FIG. 73A is an electrical circuit of a fan/blower speed
control including a potentiometer 976 that controls the current
flow to the fan/blowers 918.
[0486] FIG. 74 illustrates a soft air deflector above forehead 1011
to direct more warm air to the visor, and an optional thermal
impedance layer 1012 to limit head warming with higher visor air
temperatures.
[0487] The best and preferred air flow structure is TSF, which is
located around the user's head for maximum thermal transfer, and
may be used in conjunction with either the inner shell and
suspension elements of that type of compliant helmet, or may be
affixed to the inner surface of the innermost layer of the multiple
sliding layer type of compliant helmet, to provide the benefits of
high performance head cooling for the user. Although TSF is the
best and the preferred air flow structure, it may be possible, as
mentioned above, to use openings in the inner shell or gaps in the
nesting layers, to allow for head cooling air flow, however, the
best overall thermal performance for a given size, weight, and cost
of the air conditioned helmet will be achieved with TSF as the air
flow structure.
[0488] FIGS. 73-74 of this disclosure illustrate more fully the
resistively heated helmet apparatus disclosed in FIGS. 12-15, and
12A-15A, FIGS. 12 through 15A, and mentioned above with reference
to FIGS. 69-71.
[0489] As mentioned elsewhere in this disclosure, another
application of the subject air convection cooled and heated, or
ventilated helmet is helmets for use while riding a snowmobile.
Snowmobiles are capable of speeds of approximately 150 mph, and
when traveling at high speeds in cold weather, extreme wind chill
develops on the front of the rider's helmet, including the visor,
cause icing and a resultant reduction in visibility through the
visor, as well as intense cooling inside the front space of the
helmet.
[0490] Snowmobile helmets often incorporate a heated visor, using a
transparent conductive film, to keep the visor clear of snow and
ice, and to reduce the extreme wind chill cooling effect on the
visor, which, in addition to potential icing, can get so cold as to
draw the heat out of the face space of the helmet, leading to
discomfort for the user. Air inside the front of the helmet can
reach very low temperatures, resulting in additional loss of body
core heat via breathing the low temperature air.
[0491] The convective helmet design of the subject embodiments
enables a unique and superior solution to the snowmobile helmet
problem. Because air is used to cool and heat or ventilate the ACH
disclosed herein, it is possible to simultaneously warm the user's
head and defrost the visor using air that is warmed outside the
helmet before being blown into and through the helmet. Ambient air
enters a resistive heating element at the rear of the helmet and is
raised in temperature up to a relatively warm and comfortable, but
not hot, temperature of approximately 60.degree. F., which is much
warmer than the visor, but still below skin temperature. As a
result of this, it may be necessary to place an optional thermal
impedance layer, as indicated in FIG. 94, much like that disclosed
in FIGS. 18C-19D FIGS. 19C and/or 19D, for very low temperature
use, over the TSF, or other air flow structure, to limit head
cooling via air at a temperature below skin temperature, and to
channel that air to the front of the helmet only to defrost and
demist the visor and provide above ambient temperature air for
breathing to reduce body core heat loss.
[0492] The warmed air improves comfort inside the helmet and keeps
the visor free of ice by raising the temperature of the visor above
the freezing point of water. The warmed air is available for
breathing and is much more comfortable than breathing ambient air
that can be at approximately 20.degree. F. or colder. Breathing air
at 60.degree. F. is more comfortable than breathing very cold air
and, very importantly, reduces the amount of core heat lost from
the user's body via the breathing of very cold ambient air,
reducing the need for additional body heating while riding a
snowmobile.
[0493] A soft air deflector at the top of the visor to direct
relatively warm air more forcefully onto the visor interior surface
is also disclosed in FIG. 74.
[0494] FIGS. 12A, 13A, 14A, and 15A disclose a novel solution to
the problem of obtaining PTC resistive heating elements with a
switching temperature, Ts, below 40.degree. C. 40.degree. C. is
higher than the ideal maximum air temperature for warming the
user's head, clearing the visor, and providing comfortable air for
breathing in ambient conditions below freezing, when the convective
helmet will be used for snowmobiling, for example. A more ideal
temperature would be approximately. 15.degree. C. instead. In order
to run the PTC device at or near it's switching temperature of
40.degree. C. to provide stable heating at the desired temperature,
and ensure that the temperature will never rise much higher than
that under any circumstance, the unique solution of FIGS. 12A-15A
is to overrate the heat exchangers with less than ideal surface
area to enable the PTC device to run at or near the higher Ts,
while providing heated air at the preferred lower temperature. The
objective is to heat ambient air from a lower ambient up to
.about.60.degree. F., or thereabouts. The lower efficiency of the
overrated heat exchanger, with less than ideal surface area,
results in a lower air temperature rise per watt of power in the
PTC device, necessitating a higher power consumption, however, when
production volume increases sufficiently, it then becomes practical
to have a special PTC resistive heating element manufactured with a
Ts of 15.degree. C., resulting in lower power consumption because
of the use of higher efficiency heat exchangers.
[0495] It should be noted that the heat exchanger for the
resistively heated helmet heating element may be extruded, however
a folded fin type heat exchanger will be much lower in weight in
order to make the snow helmet heating assembly as lightweight as
possible. Minimum weight is desirable to prevent neck fatigue for
the user.
[0496] FIG. 75 illustrates a more or less conventional molded foam
type bicycle helmet, which normally has numerous large openings to
prevent heat retention in the helmet. The active convection cooled,
or forced ventilated version of this helmet differs in that:
[0497] The foam shell needn't be as thick because the helmet vent
openings are eliminated, except for the one air inlet opening in
the rear of the shell to receive cooled air or force ventilated
ambient air into the interior air flow structure.
[0498] Ideally, the rear lower section of the above helmet should
be lowered as shown with a dashed line to enable the cooling system
to be mounted lower and to effectively cool or ventilate more of
the user's head for more effective overall body cooling, which is a
function of the total area of the head that is cooled and the
temperature difference between the air entering the helmet and skin
temperature.
[0499] The convective system is shown mounted to the helmet with a
cover and an air filter integrated into the cover. The filter can
be made of any appropriate air filter material, however a preferred
material is woven polypropylene fibers that function
electrostatically to attract and retain particulates, keeping the
interior of the helmet cleaner over time in addition to keeping the
heat exchanger fins in the convective system cleaner and more
efficient over time. The air filter may be vacuumed periodically
with a brush attachment.
[0500] A major difference between the conventional molded foam
bicycle helmet and the convective molded foam bicycle helmet is
that the convective helmet is molded in discrete sizes, instead of
being made in one or two basic sizes with an adjustable ratchet
type head strap to fit intermediate sizes. This is because the
better the air flow structure of the convective bicycle helmet fits
the user's head, the better job it will do of cooling the user's
body via cooling of the scalp.
[0501] FIG. 75A shows an outer shell 1120, an air flow structure
layer 1121, an optional pad 1122 for optional Velcro.RTM. fastener
for convective system, a convective system support connector with
short air duct 1124, a thermal insulation layer 1123, an interior
trim layer 1125, and a lower edge air seal 1126, with cold spot
insulator, preferably Voltek Volara.RTM., approximately 1-2 mm
thick.
[0502] FIG. 75A illustrates the preferred embodiment of convective
headgear for a running cap structurally, with a thin lightweight
shell, a thin thermal insulation layer, an air flow structure, and
an interior trim layer.
[0503] Referring back to FIG. 62, this is the basic preferred
embodiment for any ACH that doesn't require an impact absorbing
layer, such as running and jogging caps, and welding and grinding
headgear, for example. Foam type bicycle helmets can eliminate the
outer shell and thermal insulation and use an air flow structure,
preferably TSF, within the molded foam head space.
[0504] FIG. 75A has been modified to include and disclose a
connector on the lower rear of a thin wall shell to allow a
convective system with a snap fit adaptor to be attached to the
short air duct on the thin wall shell. An optional Velcro.RTM.
fastener pad is also disclosed to provide a second support point
for the convective air system.
[0505] A basic convective headgear basic cooling function chart is
also now added to illustrate how the sub-ambient air cooled
headgear maintains a useful air dT over a wide range of ambient air
temperatures, when properly designed, with a reduction in
efficiency, or Coefficient of Performance, for the thermoelectric
Peltier system, as ambient temperature drops, resulting in a
significant reduction of, or the elimination of, overcooling at low
ambient air temperatures while providing a meaningful dT at the
highest ambient air temperatures, and without the need for a
control system that increases headgear complexity, cost, weight,
and bulk.
[0506] FIGS. 75B-75F are perspective views of a bicycle air
conditioned helmet 1170 ("BACH") in one or more embodiments. The
"BACH" bicycle helmet 1170 has a front section 1175 which is placed
over the face of the wearer, and a rear section which protect the
back of the head of a wearer. The BACH helmet 1170 has a helmet
shell 1173 and a rear cover 1171 which attached to the helmet shell
1173 through the use of attachment means such as screws 1172 an
embodiment. The rear cover 1171 has a plurality of air inlet vents
1174. FIG. 75B illustrates the BACH helmet 1170 that is partially
disassembled showing the internal structure 1178 which supports the
heating/cooling/or ventilating device 1180 as shown in FIG. 75E
[0507] FIGS. 75G and 75H are cross-sectional views of a bicycle air
conditioned helmet 1170 ("BACH") in one or more embodiments. The
device 1180 has a filter 1181, and fans or blowers 1182 which has
an air duct 1183 for injecting temperature controlled air in to the
helmet 1170.
[0508] Relative humidity and heat index are not considered in the
basic convective headgear cooling function chart because those
variables are not controllable with the basic thermoelectric
convective system, although relative humidity control solutions are
disclosed in this disclosure elsewhere. Adding those controls
increases cost, weight, and volume of a thermoelectric convective
system for convective headgear.
[0509] Embodiments illustrate an optional perforated air inlet
cold/warm spot insulation layer. The perforations shown allow for a
moderated degree of cooling or warming to be experienced in the
specific area opposite the air inlet without forming a cold or hot
spot over time. The insulation layer without perforations prevents
virtually any cooling or heating sensation or effect in order to
prevent cold/hot spot formation. The results of allowing a limited
and distributed portion of the air inlet area to be exposed to the
incoming air stream are:
[0510] 1--Some cooling or warming of that area of the user's head
and neck is accomplished, instead of shutting thermal transfer off
to avoid a cold or hot spot, which contributes to more effective
overall body cooling or warming.
[0511] 2--The user's perception of cooling and warming is enhanced
by experiencing a cooling or warming over a larger portion of the
user's anatomy.
[0512] An additional component of this update is an air dam,
located at the front of the helmet just above the user's forehead,
in front of the air flow structure air outlet vent. the air dam
prevents direct impingement of moving air that is the result of
forward motion on a motorcycle, bicycle, or when running, into the
region of the air flow structure outlet vent. This prevents forward
motion external air flow from building up pressure on the air vent,
which can effect convective headgear internal air flow, reducing
convective headgear performance.
[0513] FIGS. 76 through 79, disclose the solution to a new
challenge that is the result of another innovation in helmets,
custom fitted helmets made by scanning the user's head to create a
mold for the EPS or other impact absorbing layer/structure so that
the helmet will fit the customer's head perfectly.
[0514] FIGS. 76, 77, 78, and 79 show a customer's head being
scanned 1130, a scanned image/map of user's head 1131, scanned
image scaled up 1132 to accommodate air flow structure thickness
plus some interior trim thickness and provide a suitable pattern
for the custom fit EPS that will accommodate the TSF or other air
flow layer material plus interior trim material for highest quality
of fit and performance, from both a thermal standpoint and from a
protective standpoint. The resulting flat pattern for TSF 1133, or
other air flow material, after removing excess folded material from
pattern when installed into helmet EPS or other impact absorbing
structure. When installed in helmet, sides A and B contact evenly
to allow for evenly distributed air flow throughout the material
around the user's head from the air inlet to the front of the
helmet and provides a smooth interior surface without
discontinuities.
[0515] The challenge is how to apply the convective technology of
the subject embodiments to the custom fitted helmet, which is the
subject of FIGS. 76 through 79.
[0516] The process of making and installing a convective air flow
structure such as TSF, for example, into a custom made-to-measure
helmet is:
[0517] FIGS. 76 and 77 depicts a customer's head is scanned,
generating a 3D map of the customer's head. The method for scanning
without including the subject's hair has apparently already been
established, perhaps with a thin tight fitting skullcap.
[0518] FIG. 78 depicts a map is scaled up a percentage based on the
thickness of the air flow structure, which, for TSF, is 8 or 9 mm,
plus half the thickness of the inner trim liner material, which is
between 2 to 3 mm, for an additional 1 to 1.5 mm. The scaled up map
is used to generate a mold for the impact absorbing layer that will
accommodate the air flow structure and approximately half the
thickness of the liner trim, resulting in a perfect comfortably
snug fit with a small amount of compression of the inner liner
material.
[0519] FIG. 79 depicts that, in the meantime, a TSF pattern is made
up using a piece of TSF by pushing a flat piece of TSF into the
finished molded helmet foam head space, with excess folded material
trimmed away, resulting in a pattern that looks more or less like
FIG. 99. Excess TSF material bunches up in folds on the inside of
the helmet space when the flat sheet is pushed down in and when the
excess material is carefully trimmed away, the result is a smooth
layer of TSF on the inside surface of the head space.
[0520] In series production of standard convective helmets, TSF, or
other air flow structure material, is cut with a computer
controlled laser cutting table for a precise edge and fit and to
melt the fiber ends so that they don't unravel at the edges during
handling and use.
[0521] It is possible to use the first TSF or other air flow
structure material layer described above under FIG. 79 to make a
second, more precise pattern by digitizing the first hand cut
pattern and then precisely cleaning it up in the computer digital
image file, and then use that to cut a final TSF or other air flow
structure material with a computer controlled laser cutting table.
The digitized pattern can then be filed with the original scan of
the customer's head for future reference if another custom helmet
is ordered by the same customer.
[0522] FIG. 80 discloses the power cord with the simplified 3
position DPDT switch to provide a simple off--ventilate--cool
control for a thermoelectric air convectively cooled helmet along
with the optional control circuit disclosed elsewhere in this
disclosure to provide fan speed adjustment when in ventilation mode
only to prevent damage to the thermoelectric device in power
cooling mode.
[0523] FIG. 80 illustrates an ACH, which contains a cooling system
1141, where a nominal load is .about.1.6A @13.0 VDC. There is an
.about.8''L lead from TE and fans with water resistant 3 pin
connector 1142, a zip-Ties both sid