Helmet shell for a protective helmet

Description

1. Technical field

[0001] The present invention relates to a helmet shell for a ballistic protective helmet. In particular, the invention relates to a helmet shell with a curvature and a method for manufacturing such a helmet shell, as well as to a corresponding protective helmet. 2. State of the art

[0002] Ballistic helmets, also known as impact-resistant helmets, are widely used by police and military forces. They protect the wearer from head injuries caused by indirect or direct fire from projectiles and / or shrapnel. They also protect against blunt head injuries from blows.

[0003] A helmet shell for a ballistic helmet is designed to provide optimal protection for the wearer. Crucially, for effective protection, the helmet shell must possess high strength and high toughness properties. This ensures high stability of the helmet shell while maintaining a high absorption capacity against projectiles, particularly their kinetic energy. Furthermore, it is essential for effective wearer protection that this level of protection is provided across the entire helmet surface.

[0004] Existing helmet shells do not meet such requirements. In fact, existing protective helmets, as known from the prior art, exhibit that the shells are weaker, less stable, and / or less robust in a peripheral area. The protective effect of such helmets is therefore limited by critical weaknesses. Consequently, such conventional helmet shells pose a danger to the wearer if, for example, a projectile impacts the helmet near an edge of the shell. Therefore, optimal protection cannot be achieved with conventional helmet shells.

[0005] WO 97 / 37553 A1 relates to a ballistic helmet with a ballistic resistant outer shell that is resistant to high and low speed impacts, a chin strap assembly for fastening the helmet to the head and means for fastening the chin strap assembly to the helmet, wherein: the outer shell is a continuous shell without openings; an inner liner is provided which fits snugly against the outer shell over at least 70% of the area of ​​the inner surface of the outer shell, the inner liner carrying the means for fastening the chin strap assembly to the helmet; and the inner liner is fastened to the outer shell by a mechanical locking mechanism at the lower edge of the inner liner and at the lower edge of the outer shell.

[0006] GB 2 136 676 A relates to a multi-layered, bulletproof and / or splinter-resistant, self-rigid protective element, preferably for the protection of the human body or parts thereof, in particular a helmet, comprising an inner shell made of plastic, at least one intermediate layer, preferably textile, and an outer shell made of plastic. The connection between the inner shell and the outer shell is made via a groove-shaped profiled edge element, which is firmly connected to the edge region of the inner shell. The edge profile has an outer flange that encloses an outwardly projecting or angled feature of the edge section of the outer shell, and a central flange that rests against the inside of the edge section of the outer shell.

[0007] US 2021 / 330019 A1 specifies a brow plate for a ballistic helmet designed to move with the visor when it is opened and closed. A ballistic portion of the brow plate must be made of a sufficiently resistant material, such as titanium or a fiber composite. The helmet shell may be made of metal, fiber-reinforced plastic, and / or a combination of both (hybrid helmet). Examples of metals used include titanium, and examples of fiber-reinforced plastics include aramid and / or polyethylene fibers.

[0008] US 10,414,921 B1 concerns a multilayer ballistic material. One example is a body panel with a multilayer structure. In this example, the body panel is flexible enough to allow a curvature of at least 55°. The multilayer structure may include a titanium layer sandwiched between two polyethylene layers.

[0009] One object of the present invention is therefore to overcome the disadvantages of the prior art. In particular, the present invention addresses the problem of improving the protective effect of a ballistic helmet. In this way, the safety of the wearer should be increased. This safety should be achievable over the entire surface of the helmet. 3. Summary of the invention

[0010] The above problems, as well as further problems arising from the following description, are solved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims, and the person skilled in the art will find references to other suitable embodiments of the present invention in the disclosure of the present application.

[0011] The aims and objectives of the present invention are achieved, inter alia, by a product, in particular a helmet shell according to claim 1 and a corresponding protective helmet according to claim 14, and by a method for manufacturing a helmet shell according to the invention according to claim 15. The technical characteristics, advantages, and improvements over the prior art of the product, as shown below, apply equally to the method for manufacturing the product.

[0012] One aspect of the invention relates to a helmet shell for a ballistic protective helmet, comprising: (a) at least one inner layer, and (b) at least one outer layer, wherein the inner layer and the outer layer form an at least partially circumferential end region of the helmet shell, wherein the inner layer is at least partially curved outwards in the end region in order to at least partially enclose the outer layer.

[0013] A helmet shell according to the invention improves the stiffening of the helmet shell, particularly in the terminal area, i.e., in the edge region of the helmet shell. This increases the strength in this area and allows for improved absorption of ballistic foreign objects. Consequently, the safety of a protective helmet featuring such a helmet shell according to the invention can be significantly enhanced. In this way, the wearer of the protective helmet is better protected than is usually the case.

[0014] A helmet shell can be understood, for example, as an essentially spherical shell, cap, or helmet. Thus, a helmet shell is held in place on the wearer's head by means of its essentially spherical shape.

[0015] A termination area can be understood as an area that pertains to one end of the helmet shell. For example, if a wearer uses the helmet shell in the usual manner, the lower end of the helmet shell could be considered the termination area. The lower end can essentially be considered the lower end along the direction of gravity during normal use or wearing of the helmet. The apex of the helmet shell, on the other hand, can be understood as the upper end of the helmet shell along the direction of gravity during normal use of the helmet. For illustration, the termination area could be understood as the area located furthest away from the apex of the helmet shell. The termination area is also at least partially circumferential. Preferably, the termination area is completely circumferential, e.g., over an angular range of 360°.However, there may also be individual areas in which further technical features are incorporated, for example near an ear area of ​​the wearer, which means that a normally completely circumferential sealing area is not present.

[0016] The helmet shell can also comprise more than one inner and one outer layer. Preferably, the inner layer has a higher flexural stiffness than the outer layer. The inner layer can, for example, be made of titanium. The outer layer is preferably made of polyethylene and can also be fiber-reinforced. The outer layer is usually in contact with the environment. The inner layer is usually positioned closer to the wearer's head.

[0017] The inner layer is at least partially curved outwards in the finishing area.

[0018] In this context, the term "at least partially" means that the inner layer in the helmet's crown area is noticeably curved outwards in certain sections. It is not necessary for the inner layer to be curved outwards across the entire crown area. Even a partial outward curvature is sufficient to achieve a beneficial effect. This effect includes, among other things, increased robustness, strength, and stability of the helmet's crown. Consequently, the wearer's safety is improved, for example, against the impact of foreign objects, particularly ballistic munitions.

[0019] The outward curvature can be understood as the inner layer being reshaped, bent, flanged, folded, or deflected outwards, i.e., in the direction of the outer layer. This could be illustrated, for example, as follows: The helmet shell can be viewed from the inside as having a substantially convex shape. Furthermore, according to the invention, the outward curvature results in at least a partially concave shape in the final region.

[0020] According to the invention, the inner layer at least partially encloses the outer layer. Enclosure can, for example, mean that the inner layer partially surrounds or partially incorporates the outer layer. In this way, the outer layer can be better supported. Here, too, it is not necessary for the inner layer to completely enclose the outer layer, i.e., in the entire sealing area. However, this is not excluded. In any case, at least partial enclosure is sufficient according to the invention.

[0021] According to the invention, an advantageous tilting or deformation of the inner and outer layers can be achieved in this way upon impact with a ballistic foreign object. This is particularly relevant when a ballistic foreign object impacts near the top of the helmet shell. According to the present invention, the inner and outer layers can deform in such a way as to form a pocket that prevents the ballistic foreign object from being deflected towards the wearer's body. The pocket can, for example, form around the ballistic foreign object. In this way, an overall increased effective protective area is generated without increasing the actual surface area of ​​the helmet shell. Thus, the wearer's perception via all senses, such as sight or hearing, remains largely unaffected, while the protective effect is significantly increased.Such an advantageous improvement of a helmet shell has not been recognized in the prior art to date, since at best a horizontal, and therefore straight, termination in the circumferential termination area of ​​a helmet shell has been provided.

[0022] In the context of this revelation, a "ballistic foreign body" can be understood as a projectile, a bullet, a fragmentation impact, or any pointed or blunt body that may be moving rapidly.

[0023] A ballistic helmet can, for example, be an impact-resistant helmet. The described advantages of the invention have a significant impact on ballistic helmets. In particular, ballistic helmets present different challenges than lighter helmets, such as bicycle helmets or helmets commonly worn on construction sites. Therefore, improved protection against ballistic projectiles is less important for lighter helmets than it is for ballistic or impact-resistant helmets. Concepts known from bicycle helmets or "construction site helmets" cannot therefore be readily transferred to ballistic or impact-resistant helmets.

[0024] According to a further embodiment of the helmet shell, the inner layer in the end area is curved outwards at an angle of at least 20°, preferably 40°, more preferably at least 60°, further preferably at least 80°, most preferably at an angle of at least 90°, and / or the inner layer in the end area is curved outwards at an angle of at most 110°, preferably at most 100°, most preferably at an angle of at most 90°.

[0025] The angle of curvature can be understood as the angle formed by a tangent to the outwardly curved portion of the inner layer and a tangent to the non-outwardly curved portion at the helmet's end. An angle of 0° would mean that the inner layer is not curved outwards. An increased angle of curvature can improve stiffness at the end; however, an excessively large angle can create a weak point in the inner layer's material at the curvature. To account for these opposing effects, the inventors determined an optimal balance of approximately 90°.

[0026] Preferably, the helmet shell is designed such that the inner layer at least partially encloses the outer layer in an L-shape.

[0027] An L-shape can be understood as an essentially right-angled curve. Such an L-shape provides optimal stiffening of the helmet shell in the final area. This significantly increases the wearer's safety.

[0028] Another embodiment relates to one of the foregoing embodiments of the helmet shell, wherein the outer layer has an at least partially circumferential end face in the termination area, wherein the inner layer covers the end face of the outer layer to at least 10%, preferably at least 30%, more preferably at least 50%, further preferably at least 80%, most preferably at least 100%, and / or wherein the inner layer has a projection of at most 40%, preferably at most 30%, further preferably at most 20%, further preferably at most 10%, most preferably no projection, in each case with respect to the end face of the outer layer.

[0029] The circumferential front surface of the outer layer in the finishing area can be understood as the one that, under normal use, points downwards or away from the apex of the helmet shell. In particular, such a "lower" front surface can be considered the lower end of the outer layer when viewed along the direction of gravity during normal use or wearing of the protective helmet.

[0030] Typically, such a frontal area is not covered in prior art designs, resulting in weak points in the helmet shell. With the above design, this frontal area is advantageously covered by the inner layer. Increased coverage can achieve improved protection. A coverage of 80% can mean that 80% of the frontal area is covered.

[0031] Furthermore, the inner layer can also have a projection. A projection of 40%, for example, means that the inner layer projects outwards by a length of 40% of the wall thickness of the outer layer. An projection according to the invention allows for improved formation of a catch pocket when impacted by a ballistic foreign object.

[0032] Preferably, the inner layer, which is curved outwards in the termination area, can contact and / or receive the end face of the outer layer.

[0033] Contact or absorption ensures that no dirt, rain, or similar substances penetrate between the inner and outer layers in the helmet's sealing area. If a gap exists between these layers in the sealing area, it can be closed by applying a sealant, such as putty. However, this becomes unnecessary because the two layers are in contact and / or absorb each other. Furthermore, this results in a more compact design. Additionally, this method allows for a more space-saving helmet design overall.

[0034] According to another embodiment, the inner layer in the termination area can also be curved in such a way that the outer layer in the termination area is at least partially enclosed in a U-shape.

[0035] A U-shape is defined as a form in which the inner layer partially surrounds the outer layer at the end. Consequently, at least in the end area, there is a near-complete enclosure. This contributes significantly to the improved formation of a pocket upon impact with a ballistic projectile. Furthermore, the partial visibility of the inner layer from the outside can have an effect beyond the improved protective function, in terms of the wearer's acceptance and sense of security.

[0036] Preferably, the outer leg of the U-shape can have a length of at least 10%, preferably at least 30%, more preferably at least 50%, further preferably at least 80%, most preferably at least 100% of the web connecting both legs of the U-shape, and / or the outer leg of the U-shape can have a length of at most 150%, preferably at most 130%, further preferably at most 120%, further preferably at most 110%, most preferably at most 100% of the web connecting both legs of the U-shape.

[0037] In this way, the length of the outer leg of the U can be advantageously determined. Preferably, this length corresponds approximately to the length of the outward-facing portion of the inner layer after the first bend (100%). If the outer leg of the U is too long, this could result in a weight disadvantage. An outer leg of the U that is too short could impair the advantageous formation of a trap pocket in the event of impact with a foreign object.

[0038] Preferably, the inner layer and the outer layer can be firmly connected, preferably glued and / or screwed together, at least in the finishing area.

[0039] The bond can be achieved, for example, by a full-surface adhesive, such as an adhesive film. Advantageously, the two layers are not only firmly bonded at the end but can also be bonded across the entire dome area. The two layers can also be bonded with a two-component adhesive. Alternatively, the two layers can be bonded using a combination of a full-surface adhesive film and a two-component adhesive. Furthermore, the bond can also be achieved using a strip-shaped arrangement of one or more adhesive films and / or one or more adhesives. For example, the two layers can be bonded using a cross-shaped adhesive structure.

[0040] According to the invention, the connection also enables improved resistance and durability to temperature fluctuations. Furthermore, this type of connection can accommodate the thermal expansion of the different materials of the helmet shell. In particular, the different materials of the helmet shell may have different coefficients of thermal expansion and thus move relative to each other at the same temperature. According to the present invention, an improved connection can nevertheless be achieved.

[0041] In another example, the solid bond between the inner and outer layers can include aramid inserts and / or carbon.

[0042] In some cases, it can be advantageous to connect the inner and outer layers with screws. This is because screw connections are easier to assemble. Furthermore, screw connections can be disassembled essentially without damage. This allows for flexible assembly and, if desired, flexible disassembly. For example, simplified disassembly could be helpful for quickly and efficiently replacing a layer and / or a cap.

[0043] However, it can also be advantageous to use a screwless connection. A screw could, under fire, become a secondary projectile and seriously injure the wearer's head. Similarly, a protruding or through-bolt could also injure the head under impact.

[0044] Preferably, the outward curvature of the inner layer in the termination area has a radius of curvature with a length that corresponds to at least 100%, preferably at least 140%, further preferably at least 160%, more preferably at least 180%, most preferably at least 200% of the wall thickness of the inner layer in the termination area, and / or the outward curvature of the inner layer in the termination area has a radius of curvature with a length that corresponds to at most 400%, preferably at most 340%, more preferably at most 280%, more preferably at most 240%, most preferably at most 200% of the wall thickness of the inner layer in the termination area.

[0045] The radius of curvature should not be too small to avoid excessively weakening the material in the area of ​​curvature. With a strong curvature, the material could become more brittle. However, the curvature is advantageous for the wearer's safety. Therefore, a balance must be struck to account for both effects. This balance can depend, among other things, on the wall thickness of the inner layer and / or the manufacturing process. With a wall thickness of approximately 1 mm in the inner layer at the end of the helmet shell, a 200% radius of curvature, as described above, is 2 mm.

[0046] The outward curvature of the inner layer in the finishing area can essentially correspond to a flange.

[0047] A flange can also be understood as a rim, edge, forming, bend, angle, or similar. A flange can be produced, in particular, by flanging, for example with a flanging machine.

[0048] In a further embodiment, in the helmet cap according to one of the preceding embodiments, the inner layer is curved outwards section by section in the circumferential direction of the end area, so that the helmet cap has at least a first section without curvature and at least a first section with outward curvature in the circumferential direction of the end area.

[0049] The sections of the helmet shell in the end area without curvature can, for example, have a horizontal and therefore straight edge. Advantageously, sections can thus be provided where curvature is particularly important. In this way, specific areas of the wearer's head can be protected more effectively. Other areas may, for example, include additional components, making curvature unnecessary or impossible due to the design. For instance, in manufacturing-challenging locations such as radii, edges, corners, or the like, there may be no outwardly curved inner layer, or it may be minimal. Thus, the production of a helmet shell according to the invention can be made more efficient and cost-effective.

[0050] In a further embodiment, in the helmet cap according to one of the preceding embodiments, the inner layer is curved outwards section by section in the circumferential direction of the end region, so that the helmet cap has at least a first and a second section with outward curvature in the circumferential direction of the end region, wherein the second section has a different radius of curvature and / or is curved outwards at a different angle and / or covers the end face of the outer layer with a different value or has a different overhang than the first section with outward curvature.

[0051] This arrangement allows for different sections with varying degrees of stiffening. In particular, it enables flexible and targeted local improvements and increased safety of the helmet shell. This results in enhanced protection for the wearer.

[0052] Furthermore, the inner layer comprises titanium. The inner layer can comprise polyethylene, and / or a polyethylene-carbon-aramid material, wherein the inner layer preferably comprises titanium, and / or wherein the outer layer comprises polyethylene.

[0053] These materials are lightweight and durable. Titanium has the advantage of being particularly light and durable. Titanium thus offers excellent protection while maintaining a low weight. Aramid is very strong in tensile strength and non-combustible, making it a particularly preferred material. For example, an aramid can have a tensile strength of approximately 3000 MPa. The materials can also include carbon fibers embedded in a polymer matrix. The polymer matrix can be a thermoplastic polymer, a polyamide, or a polyetheretherketone. The carbon fibers can be woven together. This has the advantage of further improving durability. In this way, a helmet shell for a ballistic helmet can be provided, with the helmet shell acting as a bullet-resistant material.

[0054] The inner layer is preferably made of titanium.

[0055] The invention further relates to a ballistic protective helmet comprising: (a) a helmet shell as described, and (b) optionally an internal and / or external system.

[0056] The protective helmet according to the invention combines all the advantages of the helmet shell described above with an optional inner and / or outer system. This provides overall improved protection for the wearer, while simultaneously utilizing the advantageous effects of both an inner and outer system. This also results in greater comfort for the wearer.

[0057] An external system can, for example, attach accessories to a protective helmet from the outside. Such accessories include, for example, a visor, a light, a night vision device, a camera, or additional protective shields against direct frontal fire.

[0058] An internal system can, for example, include padding elements that incorporate one or more ventilation channels. This has the advantage of improving ventilation and thus wearing comfort.

[0059] The invention further relates to a method for manufacturing a helmet shell for a ballistic protective helmet, comprising the following steps: (a) Providing at least one inner layer and at least one outer layer, wherein the inner layer and the outer layer form at least a partially circumferential end region of the helmet shell, and (b) forming, in particular bending or flanging, the inner layer at least partially outwards in the end region in order to at least partially enclose the outer layer.

[0060] It is understood that the technical properties shown or described for the helmet shell, the advantages and the improvements compared to the state of the art also apply to the process for manufacturing a helmet shell for a ballistic protective helmet.

[0061] The applicant has succeeded in optimizing the manufacturing process of helmet shells, which, for example, incorporate titanium, to such an extent that these exhibit significantly improved ballistic protection than known helmet shells. In particular, the process is efficient and cost-effective. 4. Brief description of the characters

[0062] Preferred embodiments are described below only as examples. Reference is made to the following accompanying figures: Fig. 1 shows a conventional helmet shell in a side view and a close-up of a conventional helmet shell in a side view; Fig. 2 shows a helmet shell according to the present invention in a side view and a close-up of a helmet shell of the present invention in a side view; Fig. 3 shows a close-up of a helmet shell in a first embodiment of the present invention in a side view; Fig. 4 shows a close-up of a helmet shell in a second embodiment of the present invention in a side view; Fig. 5 shows a close-up of a helmet shell in a third embodiment of the present invention in a side view; Fig. 6 shows a close-up of a helmet shell in a fourth embodiment of the present invention in a side view; Fig. 7 shows a close-up of a helmet shell in a fifth embodiment of the present invention in a side view; Fig.Fig. 8 shows a helmet shell in a further embodiment according to the present invention in a side view; Fig. 9 shows a ballistic protective helmet in a further embodiment according to the present invention in a perspective view; Fig. 10 shows a ballistic protective helmet in a further embodiment according to the present invention in a perspective view; Fig. 11 shows a ballistic protective helmet of the previous embodiment in a top view; Fig. 12 shows a helmet shell in an embodiment according to the present invention in a state after impact with a ballistic foreign body; and Fig. 13 shows a flowchart of a method for manufacturing a helmet shell according to the present invention. 5. Detailed description of the figures

[0063] Only a few possible embodiments of the invention are described in detail below. However, the present invention is not limited to these, and a multitude of other embodiments are applicable without deviating from the scope of the invention. The presented embodiments can be modified and combined with one another in numerous ways, provided they are compatible, and certain features can be omitted where they appear unnecessary. In particular, the disclosed embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0064] While the embodiments described below are mainly described with reference to a helmet shell for a ballistic protective helmet, the person skilled in the art will recognize that the method for manufacturing a corresponding helmet shell also benefits from the aforementioned features and advantages.

[0065] Throughout the figures and descriptions presented here, the same reference symbols refer to the same elements. The figures may not be to scale, and the relative size, proportions, and representation of elements in the figures may be exaggerated for clarity, illustration, and convenience.

[0066] Fig. 1Figure 1 shows a conventional helmet shell 10' in a side view, as well as a close-up of a conventional helmet shell 10' in a side view. An inner layer 20' and an outer layer 30' are shown. In the terminal area 40' of the conventional helmet shell 10', the front surface 31' of the outer layer has a horizontal and open transition to the surrounding area.

[0067] This is particularly detrimental with regard to the protective effect of the helmet shell 10' against the impact of ballistic foreign objects.

[0068] Fig. 2 shows a helmet cap 10 according to the present invention in a side view as well as a detailed view of a helmet cap 10 of the present invention in a side view.

[0069] The helmet shell 10 for a ballistic protective helmet comprises at least one inner layer 20 and at least one outer layer 30. The inner layer 20 and the outer layer 30 form an at least partially circumferential end section 40 of the helmet shell 10. In addition, the inner layer 20 is at least partially curved outwards in the end section 40 in order to at least partially enclose the outer layer 30.

[0070] Such a helmet shell 10 improves the stiffening of the helmet shell 10, particularly in the end region 40 of the helmet shell 10. Such an end region 40 typically represents a weak point with regard to the robustness and resistance of the helmet shell. With this embodiment, the strength in this area can be significantly increased due to the curvature. Thus, the impact of a ballistic foreign object can be absorbed in an improved manner. In particular, the inner 20 and outer 30 layers can deform in such a way that, upon impact with a foreign object, a pocket is formed that prevents the ballistic foreign object from being deflected towards the wearer's body. The pocket can, for example, form around the ballistic foreign object.

[0071] Although in Fig. 2 Although only two layers are shown, the helmet shell 40 can also comprise several layers.

[0072] The inner layer 20 contains titanium. Titanium provides excellent protection while remaining lightweight. Alternatively, fiber-reinforced polyethylene can be used. This alternative is particularly suitable when further weight reduction is desired.

[0073] The wall thickness 23 of the inner layer 20 can be approximately 1.0 mm or more, for example 1.5 mm. The radius of curvature of the outwardly curved inner layer 20 is then, for example, 2 mm or more, for example 3 mm. The radius of curvature should not be too small in order to avoid weakening the material too much in the area of ​​curvature.

[0074] Fig. 3Figure 1 shows a detailed side view of a helmet shell 10 in a first embodiment of the present invention. In this exemplary embodiment, the inner layer 20 is curved outwards at an angle of 90° in the end region 40. In particular, the inner layer 20 encloses the outer layer 30 in an L-shape.

[0075] Furthermore, the outer layer 30 has an end face 31 that is at least partially circumferential in the termination region 40. In addition, the inner layer 20, which is curved outwards in the termination region 40, contacts the end face 31 of the outer layer 30. Moreover, the inner layer 20 covers approximately 100% of the end face 31 of the outer layer 30. However, other configurations and combinations are conceivable in light of the invention, and the invention is by no means limited to this embodiment.

[0076] Fig. 4Figure 1 shows a detailed side view of a helmet shell 10 in a second embodiment of the present invention. In this exemplary embodiment, the inner layer 20 is curved outwards at an angle of approximately 20° to 30° in the end region 40.

[0077] In this example, the inner layer 20, which curves outwards in the termination area 40, does not contact the end face 31 of the outer layer 30. The corresponding distance between the inner layer 20 and the outer layer 30 can be reduced by applying a sealant, for example, a sealant, especially putty. This prevents the ingress of dirt, rain, or similar substances. Furthermore, no sharp edges are formed.

[0078] Fig. 5Figure 1 shows a detailed side view of a helmet shell 10 in a third embodiment of the present invention. In this example, the inner layer 20 is curved in the end region 40 such that the outer layer 30 is at least partially enclosed in a U-shape in the end region 40.

[0079] Thus, the inner layer 20 partially surrounds the outer layer 30 in the termination area 40, also from the outside. In this way, at least in part, a nearly complete enclosure is achieved in the termination area 40. This contributes to the improved formation of a ballistic pocket 45 in the event of impact with a ballistic foreign object. The wearer's safety is therefore increased. The formation of a ballistic pocket is in Fig. 12 shown schematically.

[0080] The outer leg 22 of the U-shape has a length approximately 100% of the length of the connecting web 22 of the U-shape. However, other lengths are also conceivable and applicable in light of the invention.

[0081] Fig. 6 Figure 1 shows a detailed side view of a helmet shell 10 in a fourth embodiment of the present invention. In this exemplary embodiment, the outward curvature of the inner layer 20 in the end region 40 of the helmet shell 10 has a similar angle to that shown in Figure 2. Fig. 3 on.

[0082] The coverage of the end face 31 of the outer layer 30 can be adjusted in various ways. Each degree of coverage represents a beneficial increase in the safety of the carrier. In this example, the inner layer 20 covers approximately 60% to 70% of the end face 31 of the outer layer.

[0083] Fig. 7Figure 1 shows a detailed side view of a helmet shell 10 in a fifth embodiment of the present invention. In this exemplary embodiment, the outward curvature of the inner layer 20 in the end region 40 of the helmet shell 10 also has a similar angle as shown in Figure 1. Fig. 3 on.

[0084] In this example, the inner layer 20 has a protrusion of approximately 20% to 30% with respect to the end face 31 of the outer layer.

[0085] Fig. 8 Figure 1 shows a helmet shell 10 in a further embodiment according to the present invention in a side view. The helmet shell 10 has essentially similar or the same properties as the previously described embodiments of a helmet shell 10 according to the invention, unless otherwise described below.

[0086] The inner layer 20 of the helmet shell 10 according to this embodiment is curved outwards in sections in the direction of rotation of the end region 40. Thus, the helmet shell 10 has at least a first section without curvature 50 and at least a first section with outward curvature 51 in the direction of rotation of the end region 40.

[0087] Similarly, it shows Fig. 8 Further sections 52 and 53 may be present, either as an alternative or in addition to sections 50 and 51. Sections 50, 51, 52, and 53 may also be present in any combination. Likewise, several such sections may be present.

[0088] For example, the inner layer 20 is sectionarily curved outwards in the direction of rotation of the end region 40 such that the helmet shell 10 has at least a first 51 and a second 53 section with outward curvature in the direction of rotation of the end region. A section without curvature 52 may be located between the two sections. The second section 53 may have a different radius of curvature and / or be curved outwards at a different angle and / or the front surface 31 (not shown in Fig. 8The outer layer 30 may have a different value or a different overhang than the first section 51 with outward curvature. The different design of the outward curvature allows for different sections with varying degrees of stiffening. This can be advantageously used to further increase the safety of the helmet shell 10, and thus the safety of the wearer, locally at critical points.

[0089] Furthermore, it shows Fig. 8 Sections 50 and 52 are without curvature. Sections 50 and 52 are located at points on the end region 40 in the direction of rotation that form an edge. This can be understood to mean that sections 50 and 52 are located at points where the helmet cap 10 undergoes a change in height in the vertical direction.

[0090] The order according to Fig. 8This offers the advantage that sections of the helmet shell 10, in particular the end section 40 of the helmet shell 10, can be specifically designed and adapted to the local requirements in the direction of rotation of the end section 40. For example, further components on the protective helmet 100 can be provided in the direction of rotation, thus eliminating the need for curvature. Furthermore, at positions that are difficult to manufacture (radii, edges, corners, or the like), there can be no outwardly curved inner layer 20, or it can be only minimally curved. In this way, the manufacturing process becomes more efficient and cost-effective.

[0091] Fig. 9 Figure 1 shows a ballistic protective helmet 100 in a further embodiment according to the present invention in a perspective view. The embodiment of the Fig. 9 corresponds to that in Fig. 8The perspective view clearly shows the essentially convex shape of the helmet shell. Furthermore, the helmet shell is essentially a spherical cap, or spherical cap, which allows it to be fitted to the wearer's head.

[0092] Fig. 10 Figure 1 shows a ballistic protective helmet 100 in a further embodiment according to the present invention in a perspective view. In this embodiment, the inner layer 20 is curved in the end region 40 such that the outer layer 30 is enclosed in a U-shape in the end region 40. It can be seen that the U-shape has an outer leg 22 that is larger than 100% of the length of the connecting web 21 of the U-shape. In this figure, the outer leg 22 can even be more than 3 times as large or long as the connecting web 21 of the U-shape.

[0093] Fig. 11Figure 1 shows the ballistic helmet 100 of the previous embodiment in a top view. From this top view, an overhang of the inner layer 20 is visible. This is due to the fact that the inner layer 20 is curved in the end region 40 such that the outer layer 30 is at least partially enclosed in a U-shape in the end region 40. Thus, the protective effect of the helmet 100 is improved.

[0094] Fig. 12 Figure 1 shows a helmet shell in an embodiment according to the present invention in a state after impact by a ballistic foreign object. In particular, a detailed view of a helmet shell is shown, representing a termination area 40. The formation of a catch pocket 45 is schematically indicated.

[0095] The inner layer 20 and the outer layer 30 can deform upon impact with a foreign object in such a way that a ballistic pocket 45 is formed. This ballistic pocket 45 advantageously prevents the ballistic foreign object from being deflected towards the wearer's body. The ballistic pocket 45 forms around the ballistic foreign object. This can be attributed, among other things, to the U-shape of the inner layer 20. The outer leg of the U is advantageously designed so that a sufficiently large ballistic pocket 45 can form upon impact with a foreign object.

[0096] This significantly increases the wearer's safety. Furthermore, this method allows for an overall increase in the effective protective area of ​​the helmet shell 10 without increasing its actual surface area.

[0097] Fig. 13shows a flowchart of a process 1000 for manufacturing a helmet shell 10 according to the present invention.

[0098] The process 1000 for manufacturing a helmet shell 10 for a ballistic protective helmet 100 comprises the following steps: Providing 1100 at least one inner layer and at least one outer layer, wherein the inner layer and the outer layer form an at least partially circumferential end region of the helmet shell, and forming 1200, in particular bending or flanging, the inner layer in the end region at least partially outwards in order to at least partially enclose the outer layer.

[0099] In one example, forming 1200 could involve pressing the inner layer outwards in the finishing area. This pressing can be performed in a press die. Forming 1200 could also be divided into two separate steps to minimize material waste. For example, the inner layer in the finishing area could first be bent outwards at a first angle. Then, the inner layer in the finishing area could be bent outwards at a second angle. This second bend could follow the first bend. Thus, forming 1200 could be divided into two separate steps. The first angle could be 45°. The second angle could also be 45°, relative to the already bent inner layer. Therefore, after forming 1200, the inner layer would be bent outwards at 90°.In this pressing process, it can be advantageous if the inner and / or outer layer is guided by a press die during pressing. It would also be advantageous if the inner and / or outer layer were correctly positioned within the press die.

[0100] In another example, the forming process 1200 could include rolling the inner layer outwards in the finishing area. It would be conceivable to perform the rolling process similarly to a beading machine.

[0101] A beading machine can be understood as a device suitable or useful for forming straight or curved cavities or bulges on a flat material or on pipes. It can consist of two rollers, one with the positive shape and the other with the negative shape of the cavities or bulges. These rollers can be interchangeable. Material is placed between the rollers. One or both rollers can be set in motion manually or by a motor, drawing the material through. While the material is being drawn through, the upper roller, for example, can be gradually adjusted, resulting in a greater degree of deformation (e.g., bead depth). This process can be considered the origin of the term "bead," meaning a groove-shaped depression.

[0102] However, forming 1200 is preferably carried out by pressing. Rolling could be disadvantageous in that the arrangement leads to instability, which could result in reduced forming quality 1200.

[0103] Method 100 could also include a step of cutting or trimming the curved inner layer. For example, this cutting or trimming could be performed circumferentially at equal intervals. The cutting or trimming could also be carried out using a water jet, preferably a laser beam.

[0104] The scope of protection is determined by the patent claims and is not limited by the exemplary embodiments. 6. List of reference symbols

[0105] 10 Helmet shell 20 Inner layer 21 Web 22 Outer U-legs 23 Wall thickness 30 Outer layer 31 End face 40 End area 45 Catching bag 50 First section without curvature 51 First section with curvature 52 Second section without curvature 53 Second section with curvature 100 Protective helmet 1000Process 1100Process section: Provision 1200Process section: Transformation

Claims

1. A helmet cup (10) for a ballistic protective helmet (100), comprising: (a) at least one inner layer (20), wherein the inner layer (20) comprises titanium, and (b) at least one outer layer (30), wherein the inner layer (20) and the outer layer (30) form an at least partially circumferential termination region (40) of the helmet cup (10), wherein the inner layer (20) is at least partially curved outwardly in the termination region (40) in order to at least partially enclose the outer layer (30).

2. The helmet cup (10) according to the preceding claim, wherein the inner layer (20) is curved outwardly in the termination region (40) at an angle of at least 20°, preferably 40°, further preferably at least 60°, further preferably at least 80°, most preferably at an angle of at least 90°, and / or wherein the inner layer (20) is curved outwardly in the termination region (40) at an angle of at most 110°, preferably at most 100°, most preferably at an angle of at most 90°.

3. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) at least partially encloses the outer layer (30) in an L-shape.

4. The helmet cup (10) according to one of the preceding claims, wherein the outer layer (30) has an at least partially circumferential end face (31) in the termination region (40), wherein the inner layer (20) covers the end face (31) of the outer layer (30) by at least 10%, preferably at least 30%, further preferably at least 50%, further preferably at least 80%, most preferably by at least 100%, and / or wherein the inner layer (20) has a protrusion of at most 40%, preferably at most 30%, further preferably at most 20%, further preferably at most 10%, most preferably no protrusion with respect to the end face (31) of the outer layer (30).

5. The helmet cup (10) according to the preceding claim, wherein the inner layer (20) curved outwardly in the termination region (40) contacts and / or receives the end face (31) of the outer layer (30).

6. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) is further curved in the termination region (40) such that the outer layer (30) is at least partially enclosed in a U-shape in the termination region (40).

7. The helmet cup (10) according to the preceding claim, wherein the outer U-leg (22) of the U-shape has a length of at least 10%, preferably at least 30%, further preferably at least 50%, further preferably at least 80%, most preferably at least 100% of the web (21) of the U-shape connecting the two U-legs, and / or wherein the outer U-leg (22) of the U-shape has a length of at most 150%, preferably at most 130%, further preferably at most 120%, further preferably at most 110%, most preferably at most 100% of the web (21) of the U-shape connecting the two U-legs.

8. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) and the outer layer (30) are fixedly connected, preferably adhesively bonded and / or screwed, at least in the termination region (40).

9. The helmet cup (10) according to one of the preceding claims, wherein the outwardly directed curvature of the inner layer (20) in the termination region (40) has a radius of curvature with a length which corresponds to at least 100%, preferably at least 140%, further preferably at least 160%, further preferably at least 180%, most preferably at least 200% of a wall thickness (23) of the inner layer (20) in the termination region (40) of the inner layer (20), and / or wherein the outwardly directed curvature of the inner layer (20) in the termination region (40) has a radius of curvature with a length which corresponds to at most 400%, preferably at most 340%, further preferably at most 280%, further preferably at most 240%, most preferably at most 200% of a wall thickness (23) of the inner layer (20) in the termination region (40).

10. The helmet cup (10) according to one of the preceding claims, wherein the outwardly directed curvature of the inner layer (20) in the termination region (40) substantially corresponds to a flange.

11. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) is curved outwardly in sections in the circumferential direction of the termination region (40) such that the helmet cup (10) has at least one first section (50) without curvature and at least one first section (51) with outwardly directed curvature in the circumferential direction of the termination region (40).

12. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) is curved outwardly in sections in the circumferential direction of the termination region (40) such that the helmet cup (10) has at least one first (51) and one second section (53) with outwardly directed curvature in the circumferential direction of the termination region (40), wherein the second section (53) is curved outwardly at a different radius of curvature and / or at a different angle and / or covers the end face (31) of the outer layer (30) with a different value or has a different protrusion than the first section (51) with outwardly directed curvature.

13. The helmet cup (10) according to one of the preceding claims, wherein the inner layer (20) comprises polyethylene, and / or a polyethylene-carbon-aramide material, and / or wherein the outer layer (30) comprises polyethylene.

14. A ballistic protective helmet (100), comprising: (a) a helmet cup (10) according to one of the preceding claims, and (b) optionally an interior and / or exterior system.

15. A method (1000) for producing a helmet cup (10) for a ballistic protective helmet (100), comprising the following steps: (a) providing (1100) at least one inner layer (20) and at least one outer layer (30), wherein the inner layer (20) and the outer layer (30) form an at least partially circumferential termination region (40) of the helmet cup (10), and wherein the inner layer (20) comprises titanium, and (b) shaping (1200), in particular curving or flanging, the inner layer (20) in the termination region (40) at least partially outwardly in order to at least partially enclose the outer layer (30).