U.S. patent number RE43,173 [Application Number 12/722,898] was granted by the patent office on 2012-02-14 for helmet with in-mold and post-applied hard shell.
This patent grant is currently assigned to K-2 Corporation. Invention is credited to Aaron Ambuske, Andrew Logan, Scott McManigal.
United States Patent |
RE43,173 |
Ambuske , et al. |
February 14, 2012 |
Helmet with in-mold and post-applied hard shell
Abstract
The invention is related to a helmet having an interior foam
liner with at least two shell portions. The helmet includes an
exterior in-mold shell portion covering a portion of the liner. The
helmet also includes an exterior post-applied shell portion
covering a portion of the liner that is not covered by the in-mold
shell portion. The helmet includes conduits located between the
liner and the post-applied shell portion for ventilation and air
flow useful for removing the heat generated by a user.
Inventors: |
Ambuske; Aaron (Seattle,
WA), Logan; Andrew (Newbury Park, CA), McManigal;
Scott (Pacific Palisades, CA) |
Assignee: |
K-2 Corporation (Seattle,
WA)
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Family
ID: |
34676745 |
Appl.
No.: |
12/722,898 |
Filed: |
March 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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60527452 |
Dec 5, 2003 |
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Reissue of: |
11003928 |
Dec 3, 2004 |
7475434 |
Jan 13, 2009 |
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Current U.S.
Class: |
2/425 |
Current CPC
Class: |
A42B
3/125 (20130101); A42B 3/06 (20130101); A42C
2/002 (20130101); A42B 3/28 (20130101) |
Current International
Class: |
A42B
3/00 (20060101) |
Field of
Search: |
;2/6.3,6.7,410-412,422,425 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Monolithic," Webster's New Twentieth Century Dictionary,
Unabridged 2d ed, p. 1163. cited by other .
Third-Party Communication from Edward W. Bulchis of Dorsey &
Whitney LLP regarding analysis of U.S. Pat. No. 7,475,434, dated
Jan. 23, 2009, 17 pages. cited by other.
|
Primary Examiner: Hurley; Shaun R
Attorney, Agent or Firm: Christensen O'Connor Johnson
Kindness PLLC
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of provisional U.S. Application
No. 60/527,452, filed on Dec. 5, 2003, incorporated herein
expressly by reference.
Claims
The invention claimed is:
1. A helmet, comprising: a .Iadd.foam .Iaddend.liner having a first
generally concave major side and a second generally convex major
side; an in-mold .Iadd.hard .Iaddend.shell having a first generally
concave major side and a second generally convex major side,
wherein the generally concave major side of the in-mold shell is
disposed on .Iadd.and bonded to .Iaddend.the surface at the
generally convex major side of the .Iadd.foam .Iaddend.liner
.Iadd.and partially covers the generally convex major side of the
foam liner.Iaddend.; and a post-applied .Iadd.hard .Iaddend.shell
.Iadd.defined by a single layer of material, the post-applied hard
shell having a first generally concave major side and a second
generally convex major side, wherein the generally concave major
side of the post-applied hard shell is .Iaddend.disposed on the
generally convex major side of the .Iadd.foam .Iaddend.liner
.Iadd.and a portion of the generally concave major side of the
post-applied hard shell is adjacent to and covers a portion of the
generally convex major side of the foam liner not covered by the
in-mold hard shell.Iaddend..
2. The helmet of claim 1, wherein the in-mold shell is located at
an occipital area of the helmet.
3. The helmet of claim 1, wherein the in-mold shell .[.comprises.].
.Iadd.is .Iaddend.polycarbonate.
4. The helmet of claim 1, wherein the post-applied shell is located
at a frontal, temporal, or coronal area of the helmet.
5. The helmet of claim 1, wherein the post-applied shell
.[.comprises.]. .Iadd.is
.Iaddend.poly(acrylonitrile-butyl-styrene).
6. The helmet of claim 1, comprising at least one conduit for air
flow, wherein the conduit is formed from the liner and the
post-applied shell.
7. The helmet of claim 1, comprising at least one through-bore in
the liner that is in communication with a conduit, wherein the
conduit is formed from the liner and the post-applied shell.
8. The helmet of claim 1, comprising at least one conduit for air
flow between the liner and the post-applied shell, wherein the
conduit has an entry point for air at the frontal area of the
helmet and has an exit point for air at the occipital area of the
helmet.
9. The helmet of claim 1, comprising an entry point for air at the
frontal area of the helmet, wherein the entry point can be closed
by a vent lid.
10. The helmet of claim 1, comprising at least one through-bore in
the liner that has a corresponding hole in the post-applied shell
at the coronal area of the helmet.
11. The helmet of claim 1, comprising at least one post at the
temporal area on both sides of the helmet for attachment to
eyewear.
12. The helmet of claim 1, comprising at least one of a chin strap,
ear muff, plastic trim piece or interior helmet padding.
13. The helmet of claim 1, wherein the liner comprises polystyrene
foam.
14. A helmet, comprising: a .Iadd.foam .Iaddend.liner having a
first generally concave major side and a second generally convex
major side; a first in-mold .Iadd.hard .Iaddend.shell having a
first generally concave major side and a second generally convex
major side, wherein the generally concave major side of the in-mold
shell is disposed on .Iadd.and bonded to .Iaddend.the surface at
the generally convex major side of the .Iadd.foam .Iaddend.liner
.Iadd.and partially covers the generally convex major side of the
foam liner .Iaddend.without providing spaces for air flow between
the liner and the first shell; and a second post-applied .Iadd.hard
.Iaddend.shell .Iadd.defined by a single layer of material, the
post-applied hard shell having a first generally concave major side
and a second generally convex major side, wherein the generally
concave major side of the post-applied hard shell is
.Iaddend.disposed on the generally convex major side of the
.Iadd.foam .Iaddend.liner .Iadd.and a portion of the generally
concave major side of the post-applied hard shell is adjacent to
and covers a portion of the generally convex major side of the foam
liner not covered by the in-mold hard shell .Iaddend.and
.[.providing.]. .Iadd.provides .Iaddend.spaces for air flow
.Iadd.formed .Iaddend.between the .Iadd.generally convex major side
of the foam .Iaddend.liner and the .Iadd.generally concave major
side of the .Iaddend.second .Iadd.hard .Iaddend.shell.
15. The helmet of claim 14, wherein the liner comprises
through-bores and channels from the front to the back of the
liner.
16. The helmet of claim 15, wherein the second post-applied shell
is applied over the channels in the liner to create passages for
air flow from the front of the helmet to the back of the
helmet.
17. The helmet of claim 15, wherein the second post-applied shell
includes a vent that corresponds with the through-bores in the
liner.
18. The helmet of claim 14, wherein the first shell covers an
occipital area of the liner, and the second shell covers at least
one of the frontal, temporal, or coronal areas of the liner.
.Iadd.19. A helmet, comprising: a foam liner having a first
generally concave major side and a second generally convex major
side, wherein the foam liner defines occipital, coronal, temporal,
and frontal areas on the generally convex major side; an in-mold
hard shell having a first generally concave major side and a second
generally convex major side, wherein the generally concave major
side of the in-mold shell is disposed on and bonded to the
generally convex major side of the foam liner at one of the
occipital, coronal, or temporal areas and provides exposed foam at
the frontal area of the foam liner; and a post-applied hard shell
defined by a single layer of material, the post-applied hard shell
having a first generally concave major side and a second generally
convex major side, wherein the generally concave major side of the
post-applied hard shell is disposed on the generally convex major
side of the foam liner and a portion of the generally concave major
side of the post-applied hard shell is adjacent to and extends over
the exposed foam on the frontal area of the foam
liner..Iaddend.
.Iadd.20. A helmet, comprising: a foam liner having a first
generally concave major side and a second generally convex major
side; an in-mold hard shell having a first generally concave major
side and a second generally convex major side, wherein the
generally concave major side of the in-mold shell is disposed on
and bonded to the surface of the generally convex major side of the
foam liner and partially covers the generally convex major side of
the foam liner; and a post-applied hard shell defined by a single
layer of material, the post-applied hard shell having a first
generally concave major side and a second generally convex major
side, wherein the generally concave major side of the post-applied
hard shell is disposed on the generally convex major side of the
liner and a portion of the generally concave major side of the
post-applied hard shell is adjacent to and covers a portion of the
foam liner not covered by the in-mold hard shell, wherein the
post-applied hard shell includes a plurality of downwardly
projecting vent fins at an occipital area of the hard
shell..Iaddend.
.Iadd.21. The helmet of claim 1, wherein the post-applied hard
shell is a poly(acrylonitrile-butyl-styrene) monolithic
material..Iaddend.
.Iadd.22. The helmet of claim 14, wherein the post-applied hard
shell is a poly(acrylonitrile-butyl-styrene) monolithic
material..Iaddend.
.Iadd.23. The helmet of claim 19, wherein the post-applied hard
shell is a poly(acrylonitrile-butyl-styrene) monolithic
material..Iaddend.
.Iadd.24. The helmet of claim 20, wherein the post-applied hard
shell is a poly(acrylonitrile-butyl-styrene) monolithic
material..Iaddend.
.Iadd.25. The helmet of claim 1, wherein the post-applied hard
shell comprises more than one portion, each portion being a single
layer thick, and each portion is separate and attached to a
distinct area of the liner..Iaddend.
.Iadd.26. The helmet of claim 14, wherein the post-applied hard
shell comprises more than one portion, each portion being a single
layer thick, and each portion is separate and attached to a
distinct area of the liner..Iaddend.
.Iadd.27. The helmet of claim 19, wherein the post-applied hard
shell comprises more than one portion, each portion being a single
layer thick, and each portion is separate and attached to a
distinct area of the liner..Iaddend.
.Iadd.28. The helmet of claim 20, wherein the post-applied hard
shell comprises more than one portion, each portion being a single
layer thick, and each portion is separate and attached to a
distinct area of the liner..Iaddend.
Description
FIELD OF THE INVENTION
The invention is related to a helmet having an outer shell, wherein
the shell is constructed from an in-mold shell portion and a
post-applied shell portion, and to the method of making the
helmet.
BACKGROUND OF THE INVENTION
Conventional helmets typically include a hard exterior shell and a
foam liner interior to the shell. There are two widely-used methods
of making a helmet with a liner and shell. In one method, the hard
outer shell and the foam liner are both made independently of each
other. Thereafter, the shell is applied to the liner with glue,
rivets, screws or is otherwise attached by physical means. As used
throughout this application, "post-applied shell" refers to a shell
or shell portion attached to the foam liner, after the foam liner
has been pulled from the mold, and such technique is referred to as
the "post-applied method." In a second method, the helmet's hard
outer shell is bonded to the helmet's inner foam liner
simultaneously with the formation of the liner. The liner is cast
with the shell in the mold. The liner material, typically
polystyrene, is injected into the mold containing the hard outer
shell. As used throughout this application, "in-mold shell" refers
to a shell or shell portion that is bonded to the foam liner at the
time of formation of the foam liner, and such technique is referred
to as the "in-mold method." The advantage with the latter method is
that the in-mold method results in a sturdier attachment between
the shell and the liner that can prevent separation of the shell
from the liner under a severe impact. The former method, however,
is not without advantages.
While the in-mold method has a distinct advantage in strength, the
post-applied method also has an advantage that cannot be fully
realized in a helmet with an in-mold shell. For example,
independently forming the liner and the shell, and thereafter,
attaching the shell to the liner, after formation of the liner,
permits the creation of channels on the exterior surface of the
liner (i.e., the surface facing the shell). Thus, when the shell
and liner are brought together, the channels on the liner are
converted into conduits between the shell and liner that are useful
for providing ventilation. Air flow between the shell and the liner
is not possible with a helmet having an in-mold shell, since all
the interior surfaces of an in-mold shell are covered with the foam
liner as a result of the method used.
Accordingly, there is a need to provide a sturdy in-mold shell
helmet with the ventilation advantages of a post-applied shell
helmet. Alternatively, there is a need for a sturdy shell to liner
attachment in a post-applied shell helmet. The present invention
fulfills these needs and has further related advantages.
SUMMARY OF THE INVENTION
The present invention is related to a helmet having an interior
foam liner and at least two shell portions exterior to the liner.
The helmet includes an exterior in-mold shell portion covering a
portion of the liner. The helmet also includes an exterior
post-applied shell portion covering a portion of the liner that is
not covered by the in-mold shell portion. In one embodiment, the
in-mold shell portion comprises polycarbonate and the post-applied
shell portion comprises poly(acrylonitrile-butyl-styrene). The
helmet includes conduits located between the liner and the exterior
post-applied shell portion for ventilation and air flow for
removing the heat generated by a user. The liner is made with
channels and through-bores that form the various air entry and exit
points and the conduits of the helmet. The exterior post-applied
shell portion includes holes and vent fins to assist in the entry,
exit, and direction of the air flow through the conduits.
A method of making a helmet having a liner and a shell includes
placing a first shell portion in a mold and making a casting of a
foam liner to provide a liner with an in-mold shell portion bonded
to the liner and partially covering a portion of the liner that is
desired to have a sturdy attachment between the in-mold shell and
the liner. After removing the liner from the mold, the method
includes attaching a second shell portion to the liner portions
that are not covered by the in-mold shell portion. Because the
liner has been provided with channels and through-bores, the
application of the post-applied shell portion results in conduits
and entry and exit points for the air that are created from the
post-applied shell portion and the liner.
The helmet made in accordance with the invention provides numerous
advantages, including the ability to provide ventilation between
the shell and the liner where ventilation is important, but also
provides a structurally stout attachment between the shell and the
liner where the integrity of the shell and liner attachment is
important or alternatively, where ventilation is unimportant.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this
invention will become more readily appreciated as the same become
better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
FIG. 1 is an illustration of a helmet according to the present
invention;
FIG. 2 is an illustration of a foam liner casting partially covered
by an in-mold shell portion bonded to the liner;
FIG. 3 is an illustration of a shell portion for post applying to
the liner;
FIG. 4 is an illustration showing the joining of a foam liner with
an in-mold shell portion to a post-applied shell portion; and
FIG. 5 is an illustration of the venting capabilities of a helmet
having an in-mold shell portion and a post-applied shell
portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally, helmets include an interior shock absorbent liner made
from a material capable of being foamed, such as polystyrene,
polyurethane, or other similar materials, and an exterior hard
shell made from materials, such as polycarbonate and
poly(acrylonitrile butadiene-styrene) (ABS).
A first conventional method of producing a liner with a shell
includes casting the foam liner with the entire shell in the mold.
After curing, the foam liner is pulled from the mold with the
in-mold shell integrally bonded to the foam liner. Additionally,
other helmet components besides the entire shell can be cast with
the foam liner to integrally embed the helmet components in the
liner. In the in-mold method, all interior surfaces of the shell
are exposed to the foam and are, therefore, bonded to the foam
liner. The in-mold method leaves no spaces between the interior
surface of the shell and the foam liner, thereby providing a very
sturdy attachment that can withstand a severe impact. However, the
advantage of the in-mold method also results in a helmet that
cannot be provided with venting between the shell and the liner for
the very reason that all interior surfaces of the shell are fully
covered by the foam. Venting between the shell and the liner is
desirable in some instances for increasing the rate of heat removal
from the body.
A second conventional method of producing a liner with a shell
includes manufacturing the liner and the entire shell independently
of one another and then bonding or otherwise attaching the entire
shell to the liner with an adhesive or through the use of rivets,
screws or other hardware. The liner is typically made by injecting
or pouring polystyrene granules inside of a mold and allowing the
polystyrene to expand to the shape of the mold. A mold release can
be applied to the mold surface, prior to casting the liner for
separating the liner from the mold. The positive mold can be
provided with any number of ridges and protrusions, which result in
channels and through-bores in the negative foam liner casting that
is removed from the mold. Once the foam liner is removed from the
mold, the shell can be bonded to the foam liner.
In the post-applied method, it is not necessary that the shell have
the exact contours of the foam liner. If venting is desired between
the shell and liner, it is advantageous that the shell does not
have the exact contours so that conduits can be formed between the
shell and the liner out of the channels in the liner to allow for
airflow therein. In direct contrast to the post-applied method for
making a helmet, the in-mold method of making a helmet is not
suitable for creating spaces for air flow between the shell and the
liner. This is because the in-mold method exposes all the interior
surfaces of the shell to the foam liner. While it is possible to
put apertures that extend through both the shell and the liner in
an in-mold helmet, it is not possible to provide channels for
airflow between the shell and the liner. In some instances,
apertures that extend through both the shell and the liner are
insufficient to remove the heat generated by a user.
According to the present invention, a helmet with a liner is
provided that has at least one in-mold shell portion and at least
one post-applied shell portion. The advantages of each shell type
can be exploited by locating the post-applied shell portion or
portions where ventilation between the shell and liner is desired,
for example, at the coronal or frontal areas of the helmet. The
coronal area is desirable because heat rises, and the frontal area
is desirable because air impacts the front of the helmet. The
in-mold shell portion or portions can be applied to the remainder
of the liner not covered by the post-applied shell or where
ventilation is of relatively minor importance. Alternatively, the
in-mold shell portion or portions can be applied to the areas where
a sturdy attachment between shell and liner is desired to protect
the most sensitive areas of the head. In one embodiment of the
invention, for example, an in-mold shell portion can be applied at
the occipital area of the helmet because air does not impact the
helmet in the occipital area as compared with the frontal or
coronal area. It is also possible to have overlapping portions at
the boundaries of the in-mold and post-applied shell portions. One
or more in-mold shell portion or portions and one or more
post-applied shell portion or portions can be applied to the
helmet. In other embodiments, it is possible that the in-mold shell
portion can be applied at other locations besides the occipital
area. For example, the in-mold shell portion can be applied to the
temporal, frontal or coronal areas of the helmet. Besides a
monolithic in-mold shell portion, more than one in-mold shell
portion can be applied to any one or more portions of the liner.
Similarly, the post-applied shell portion can be a monolithic shell
portion, or alternatively, post-applied shell portions can be
applied at distinct areas of the liner. Generally, terms such as
occipital (back), coronal (top), temporal (side) and frontal
(front) denote areas of the skull, as used herein however, the
terms are used to denote areas on the liner, shell or helmet that
are in proximity to these corresponding areas of the skull. It is
to be appreciated when referring to locations that designations
such as occipital, temporal, coronal, and frontal give only
approximate locations. Also, directions, such as upper, lower,
bottom or side, are to be taken in the context of the application
figures and are not limiting.
Referring now to FIG. 1, a helmet 100 according to the present
invention, is illustrated, wherein the helmet 100 may include an
in-mold shell portion 102 at the occipital area of the helmet 100,
and a post-applied shell portion 104 at the coronal area of the
helmet. The post-applied shell portion 104 may also extend to the
frontal and temporal areas of the helmet 100. In-mold shell portion
102 may extend into the temporal areas as well. Protective eyewear
106 is shown with the helmet 100 and the eyewear 106 is attached by
band 108 to a post 110 on the side of the helmet 100 at the
temporal area. Goggles, suitable as eyewear 106 is described in
U.S. patent application Ser. No. 11/003,929, filed on Dec. 3, 2004,
titled "Banded Goggles for a Winter Sports Helmet." This
application is expressly incorporated herein by reference. While
the eyewear 106 and helmet 100 can be made to be used as a set, it
is not necessary that the helmet 100 be made specifically for use
with eyewear 106. The helmet 100 can be made with or without the
post 110. The helmet 100 may include accessory helmet components,
such as ear muffs 192, plastic trim 190, interior padding 191, such
as textile covered foam and textile mesh, front and rear vents 193,
195, chin strap 197, and chin strap buckle 199.
Referring now to FIG. 2, an illustration of the in-mold shell
portion 102 and liner 112 as viewed looking down on the exterior
coronal area of the liner 112, is provided. It is to be appreciated
that liner 112 is contoured in a shape suitable to be worn on the
head. The in-mold shell portion 102 is shown bonded to the liner
112 at the top of the illustration. The in-mold shell portion 102
may be applied generally in the occipital and lower temporal areas,
however, other areas of liner 112 may be covered by the in-mold
shell portion 102. The in-mold portion 102 has been applied in a
modification of the conventional in-mold method that only uses a
partial shell.
The areas of the liner 112 not covered by the in-mold shell portion
102 are exposed foam and may be provided with a variety of
features, including channels and through-bores. The in-mold method
results in the absence of voids between the inner, major surface of
the in-mold shell portion 102 and the outer, major surface of the
liner 112. Accordingly, where ventilation between the shell and
liner is desired, no in-mold shell portion has been provided. As
seen in FIG. 2, the liner 112 includes channels 114, 116, 118, 120,
122, 124, 126, and 128 which may extend parallel to the major
surface of the liner 112 from the frontal area to the upper
occipital area. These channels may later form conduits for air when
the post-applied shell portion is bonded to the liner 112 at a
subsequent step. The liner 112 also includes through-bores that
completely penetrate through the liner 112 thickness perpendicular
to the major surface of the liner 112. Through-bores 130 and 132
are representative of the through-bores on both the right and left
halves of the helmet 100. Through-bores are provided within the
channels for a reason which is described below. Through-bores may
also be provided outside the channels. The post-applied shell 104
of FIG. 1 can selectively cover some or all of the through-bores to
provide ventilation through the post-applied shell 104 and liner
112 and also between the post-applied shell 104 and liner 112.
Generally, through-bores not within a channel are provided for
ventilation exclusively through the shell and liner, while
through-bores in the channels are provided for ventilation through
and between the shell and liner. The liner 112 may further includes
ridges 134, 136, 138, 140, 142, and 144 between the channels. It is
apparent that by applying the post-applied shell 104 that has a
smooth interior major surface, conduits may be created from the
channels in the liner 112 and the shell 104 that may extend from
the frontal area to the occipital area of the helmet 100. It can be
appreciated that some or all of the through-bores within the
channels may be covered with the shell, thereby providing a
mechanism for the transfer of heat from the head to the channels,
so that the removal of heat can be effectuated by air flow within
the channels. A center ridge 145 may be provided with elongated
through-bores 146, 148. Through-bores 146, 148 do not lie in
channels and therefore may be provided for ventilation through the
thickness of the helmet 100. Liner 112 also may include recessed
areas 150, 152, at the frontal area of the liner 112. The recessed
area 150 leads into recessed channels 114, 116, 118, and 120; and
the recessed area 152 leads into recessed channels 122, 124, 126,
and 128. Recessed areas 150 and 152 provide a space to install
opening and closing vent lids, of which vent lid 193 shown in FIG.
1, is representative. Channels may also terminate at the occipital
area as recesses or depressions, so that vent fins can fit within
the channels.
Referring now to FIG. 3, an illustration of the interior, major
surface of the post-applied shell 104 that may be attached to the
liner 112, is provided. It can be seen by comparison with FIG. 2
that the post-applied shell 104 does not have the exact contours
that are provided in the liner 112. The post-applied shell 104 may
be smooth in the areas, such as coronal areas 154, 156, where the
shell 104 provides cover for the channels shown in FIG. 2.
Post-applied shell 104 may also includes holes, such as holes 158,
160, at the frontal area of the shell 104, and pluralities of
holes, such as holes 162, 164, at the coronal area of the shell
104. Frontal holes 158 and 160 are provided for fresh air entry,
while holes, which are represented by holes 162, 164 are for heat
exit. Pluralities of vent fins, such as vent fins 166, 168, are
interposed between the holes at the coronal area, and are at an
angle. The post-applied shell 104 includes pluralities of vent fins
at the occipital area, of which vent fins 172, 174, are
representative. Vent fins 172, 174, may project downward to lie in
between the channels in the liner 112 shown in FIG. 2. Vent fins
172 are shown included in vents 195 in FIG. 1.
The post-applied shell 104 may define the entry points and exit
points for air when the shell 104 is applied to the liner 112.
Holes 158, 160 may be provided for air entry due to their placement
at the frontal area where air impact is at its greatest, while vent
fins 172 and 174 may lie at the air flow exit at the occipital
area, when combined with liner 112 and in-mold shell portion 102.
The post-applied shell 104 may provide cover for the areas that are
not covered by the in-mold shell portion 102, excepting some
overlap at the boundary region between the in-mold shell portion
102 and the post-applied shell portion 104 that creates an overhang
170 at the occipital area of the helmet 100 as seen in FIG. 1.
Referring now to FIG. 4, an illustration showing the post-applied
shell portion 104 being applied to the liner 112 with the in-mold
shell portion 102, is provided. As seen in the illustration, the
post-applied shell portion 104 may be constructed so that when
applied to the liner 112, various features of the post-applied
shell portion 104 cooperate with the features of the liner 112 to
produce conduits for ventilation. For example, the smooth interior
surfaces 154, 156 may come to rest adjacent and parallel to the
raised ridges, of which 140, 142, and 144, are representative.
Channels 122, 124, 126, and 128 are therefore covered by the smooth
surface 156 to provide conduits for air flow between the liner 112
and post-applied shell 104. As can be seen in the illustration,
through-bores, such as through-bore 130, may contribute to
ventilation by allowing the passage of air and heat from the head
into channels, such as channel 128. The air flow in the conduit
formed from channel 128, for example, exits at the occipital area
between the vent fins 172. Similar construction may be found on the
opposite half of the helmet. Vent lids 176, 178 are shown adjacent
to hole 158 and hole 160 that is covered by the vent lid 176 and
therefore hole 160 is not shown. The vent lids 176 and 178 may fit
within recesses 150 and 152 formed in the liner 112. Vent fins 172
and 174 located at the occipital area of the post-applied shell 104
are shown extending perpendicular to the interior, major surface of
the post-applied shell 104. Vent fins 172, for example, are
designed to fit within the channels 122, 124, 126, and 128, as
shown in FIG. 2. Through-bores 146 and 148 at the coronal area of
the liner 112 may be partially covered by the vent fins 166 and 168
located at the coronal area of the post-applied shell 104. It can
be appreciated that heat and air rising through the through-bores
146 and 148 may escape from between the vent fins 166 and 168. It
can also be appreciated that heat rising from the through-bore 130
may be carried away by the air entering from the hole 158, which
then passes into the recess 152 and therefrom is distributed to the
various channels, of which channel 128 is representative, and may
exit at the occipital area of the helmet between the vent fins
172.
Referring now to FIG. 5, an illustration diagramming various
possible air flow paths through the post-applied shell portion 104
and the liner 112, is provided. Air and heat is diagrammed being
carried away from the coronal area of the helmet 100 through hole
162 between coronal vent fins, such as vent fin 166, shown in FIG.
4. Such air and heat may pass through through-bore 148 of liner 112
shown in FIG. 4. The heat may be carried away by the air flowing
over the exterior surface of the helmet 100. Outside air may enter
through frontal holes 160 and 158 of the post-applied shell 104,
shown in FIG. 3, in between the fins of vent lids 176 and 178
located at the frontal area of the helmet 100, shown in FIG. 4.
Vent lids 176 and 178 can be moved up or down to permit or close
off air flow. The air may then enter the recessed portions 150, 152
shown in the liner 112 in FIG. 4. The air may then enter one of the
plurality of conduits formed from the channels of the liner 112
shown in FIG. 2. It can be appreciated that heated air rising
through the through-bores at the channels, such as through-bore
130, can be carried away by the air flowing within the conduits
formed from the channels. Heat and air exits the channels between
the liner 112 and the post-applied shell 104 at the occipital area
of the helmet 100 through vents on each side of the helmet 100,
such as vent 195, as seen in FIG. 1. Accordingly, a helmet with an
in-mold shell portion and a post-applied shell portion may have the
advantage of a very stout shell to liner bond, with the added
advantage of ventilation between the shell and the liner.
Furthermore, in the method of making a helmet in accordance with
the invention, an in-mold shell portion is provided in a mold, from
which the liner is formed. The mold may be provided with any number
of features to create channels and through-bores in the liner.
After removal from the mold, the liner is glued to a post-applied
shell otherwise attached to create air passages for ventilation
between the liner and the post-applied shell. Furthermore, it can
be appreciated that any of the exterior shell may be provided with
detailing designed to provide an aerodynamic advantage and appeal
to users.
While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
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