Helmets, sports equipment and methods incorporating oblique impact protection technology

Abstract

The present invention provides an oblique impact protection technology member (20), which includes a closed-cell foam layer (50), the closed-cell foam layer including a first surface (52), a second surface (54) and a plurality of wells (56) on the first surface (52). The first surface (52) includes a plurality of first surface holes (58), and the first surface holes (58) have a square shape. The second surface (54) is opposite to the first surface (52) and optionally includes a plurality of second surface holes (62). Each well (56) corresponds to a first surface hole (58), and the second surface (54) is substantially parallel or parallel to the first surface (52). A helmet (10) and / or a sports equipment (12) can include this technology, and the present invention provides a method for manufacturing this technology.

Description

Technical Field

[0001] The present invention relates to technology for protecting against oblique impacts, helmets incorporating such technology, and methods of manufacture. Background Art

[0002] Helmets are generally used to protect the user's head from impact and potential injury caused by accidents. Helmets may be used in specific situations such as sports helmets, which are known to provide maximum protection to the head from impacts in, for example, skiing, cycling, water sports, motorcycles and scooters, racing, horseback riding, motocross / BMX, American football, snowboarding, boxing, skateboard rugby, etc. Other helmets may be worn for protection in potentially dangerous situations such as construction sites, accident and natural disaster sites, combat, firefighting, police operations, riot control (riot helmets), etc. In other cases, such as when an infant is born with a flat spot or other head shape deformity (such as positional plagiocephaly), and / or cranial protrusions caused by improper fusion of the skull plates, a helmet may be worn to help shape the infant's head correctly as he / she grows (cranial orthoses).

[0003] The manufacturing process of helmets is well known and generally involves the use of a hollow mold into which an expandable material such as a foam and / or foam precursor is added. The mold is generally heated prior to or during the process, and a vacuum is often applied to help expand the foam and / or foam precursor. Various processes are known to manufacture foam articles, foam helmets, and the like, such as in-mold molding (also known as injection molding and co-injection molding), steam chamber molding, steam press molding, and the like. For example, in-mold molding is well known in the field of helmet manufacturing and is used to combine a hard outer shell with an internal polystyrene shape. Methods of adding an outer shell are known; or adding a painted outer shell to a foam, polystyrene foam, or other foam helmet. Some processes apply different materials to the mold simultaneously during the in-mold molding process (e.g., see US 2015 / 01137709 A1 to Cheng, published on April 30, 2015, the entire contents of which are incorporated herein by reference), while other conventional processes first form them separately and then adhere them together.

[0004] Additionally, there are various helmet standards around the world for bicycle helmets, motorcycle helmets, etc. For example, European Uniform Protective Helmet Standard ECE 22.05 (also known as "Regulation No. 22") (see: http: / / www.unece.org / trans / main / wp29 / wp29regs21-40.html), European CSN Engineering Standard EN 1077 for Helmets for Alpine Skiers and Snowboarders (see: https: / / www.en-standard.eu / csn-en-1077-helmets-for-alpine-skiers-and-snowboarders / ), European CSN Engineering Standard EN 1078 for Helmets for Pedal Cyclists, Skateboarders, and Roller Skates (see: https: / / www.en-standard.eu / csn-en-1078-a1-helmets-for-pedal-cyclists-and-for-users-of-skateboards-and-roller-skates / ), European CNS European Engineering Standard EN 1384 for Helmets for Equestrian Activities (see: https: / / www.en-standard.eu / csn-en-1384-helmets-for-equestrian-activities / ), etc. In addition, the U.S. Department of Transportation (DOT) has separate standards, such as Federal Motor Vehicle Safety Standard No. 218 related to Motorcycle Helmets (also known as "49CFR 571.218", "FMVSS 218", etc.) (see: https: / / www.nhtsa.gov / document / tp-218-07pdf).Japanese standards include, for example, JSA JIS 8133-2007 for Protective Helmets for Drivers and Passengers (see: http: / / www.freestd.us / soft / 136571.htm). In addition, other national standards are known in the art, such as Australian and Chinese helmet standards. Finally, the Snell Memorial Foundation has also published its own standards, such as M2010 for motorcycle helmets.

[0005] In such tests, the helmet to be tested is usually dropped at a given speed onto various anvils that are used to simulate the impact of the helmet on different surfaces. For example, a flat anvil simulates the helmet impacting a flat sidewalk, while a hemispherical anvil or an inclined anvil simulates the helmet impacting a road curb. Their anvil type, impact speed / force, duration, etc. are all described in the specific test above.

[0006] Suitable equipment for testing helmets according to ECE, EN and / or JIS tests includes, for example, the 1002MAU 1006 / CF / ALU - Monorail Shock Test Equipment available from AD Engineering srl of Bergamo, Italy. See, for example: http: / / www.adengin.it / en / products / 2_1002_MAU_1006_CF_ALU___Monorail_shock_ab.

[0007] However, it is increasingly being recognized that the types of impacts described above in flat anvils and hemispherical anvils are not sufficient to adequately account for real-world conditions. As a result, there is growing attention to protecting people from oblique impacts. The rationale is that current test methods and requirements for flat anvils and hemispherical anvils only represent impacts that occur when a helmet strikes the pavement at a 90° angle and when a helmet strikes a curb. However, there is growing recognition that the majority of impacts occur when a helmet strikes the pavement at an oblique angle. Furthermore, there is growing recognition that the torque transmitted in such oblique impacts can result in significant injury to soft tissue and the spine, and that oblique impacts are therefore a greater threat than previously recognized.

[0008] As a result, various new helmet technologies have been developed to address the dangers of angled impacts (see, for example, https: / / www.singletracks.com / blog / mtb-gear / most-of-the-new-helmet-technologies-are-more-alike-than-different / ). Most recently, MIPS (Multi-Directional Impact Protection System, see https: / / mipsprotection.com ) helmets have a low friction and slightly movable frame / layer between the inner surface of the helmet and the user's (i.e., wearer's) head. By allowing the helmet to slide slightly relative to the user's head during an impact, the MIPS system is said to provide better protection against oblique impacts because the forces transmitted to the user are reduced. While MIPS is currently the gold standard for oblique impact protection, it is specifically designed for oblique impact protection and does not, by itself, significantly protect against direct vertical impacts.

[0009] Bontrager’s WaveCel (https: / / wavecel.trekbikes.com / us / en_US / ) is a technology formed by a foldable open-cell structure that is claimed to outperform MIPS due to its foldability. However, these claims are currently being questioned by MIP and other industry players.

[0010] Koroyd uses a straw-like dual-core material to create an impact buffer in the helmet to protect against a variety of impacts. This technology can be used in conjunction with MIPS, for example.

[0011] Other technologies that achieve similar effects include the SPIN (Shearing Pad INside) rotational protection system, which attaches silicone pads between the inner surface of the helmet and the user's head. These gel pads are said to allow the helmet to shear in any direction during an oblique impact, again reducing the impact force transmitted to the user's head. In contrast, Fox's Fluid system attempts to mimic the properties of cerebrospinal fluid in the brain through the Fluid Pod in the helmet to reduce damage caused by oblique impacts.

[0012] Kali and Leatt use Armourgel, a shock-absorbing, nimble material that absorbs impact and flexes to reduce the transfer of force in oblique impacts. Kali uses Amourgel to form its LDL (low-density layer), which is shaped into a strip containing small cups that stiffen during impact. Leatt's 360° Turbine technology uses small, blue Amourgel foam discs located in strategic head locations, which are said to provide both cushioning for direct impacts and glide to reduce the force transferred to the user in oblique impacts.

[0013] 6D Helmets' ODS (Omnidirectional Suspension, see for example: https: / / www.6dhelmets.com / innovation / ) essentially forms 2 concentric helmets with a suspension layer between them. The ODS system allegedly provides the user with both linear and oblique impact protection. However, such a system introduces significant manufacturing complexity and essentially manufactures two separate helmets with close tolerances. As a result, such helmets can be expensive, difficult to manufacture, thick, and bulky.

[0014] The Shred uses strategically placed discs that are claimed to reduce the rotational impact forces transmitted to the user during oblique impacts.

[0015] However, current systems suffer from various disadvantages, such as increased cost, increased raw materials, increased manufacturing complexity, increased weight, complexity, reduced ventilation, reduced flexibility and / or discomfort. Therefore, there remains a need for improved helmets and improved helmet forming processes to address the problem of oblique impacts. Summary of the invention

[0016] Embodiments of the present invention relate to an oblique impact protection technology, which includes a closed-cell foam layer, the closed-cell foam layer including a first surface, a second surface, and a plurality of wells on the first surface. The first surface includes a plurality of first surface wells, and the first surface wells have a square shape. The second surface is opposite to the first surface and optionally includes a plurality of second surface wells. Each well corresponds to a first surface well, and the second surface is substantially parallel or parallel to the second surface.

[0017] Embodiments of the present invention are directed to a helmet incorporating angled impact protection technology. Embodiments of the present invention are directed to a sports equipment incorporating angled impact protection technology.

[0018] Embodiments of the present invention relate to a method for manufacturing a helmet by providing a female mold portion, providing a male mold portion, providing an inclined impact protection technology component including the inclined impact protection technology of the present invention, and providing an impact dissipation material. The male mold portion is complementary to the female mold portion, and thus the female mold portion and the male mold portion can be assembled together to form a hollow mold between them. The inclined impact protection technology component is applied to the male mold portion before the male mold portion and the female mold portion are assembled together, or after the male mold portion and the female mold portion are assembled together. During the manufacturing process, the impact dissipation material is in the form of a liquid or a plurality of beads; or as a plurality of beads. The inclined impact protection technology component and the impact dissipation material are subjected to an in-mold forming process in the hollow mold. In the process of the present invention, the impact dissipation material forms an impact dissipation component having an inner side of the impact dissipation component and an outer side of the impact dissipation component opposite to the inner side of the impact dissipation component. The in-mold process permanently bonds the inclined impact protection technology component (usually the outer side of the inclined impact protection technology component) to the inner side of the impact dissipation component.

[0019] Without being limited by theory, it is believed that the invention herein can reduce potential damage to the head, spine, bones and / or soft tissue by reducing the amount of force and / or torque transmitted to the user's body or head in an oblique impact event. Specifically, it is believed that the texture of the first surface comprising a plurality of wells allows the closed-cell foam layer to provide both a comfortable fit and lateral and transverse deflection of the layer. This in turn allows the layer to reduce the rotation and / or torque of the helmet before the helmet transmits the generated force and / or torque to the user's head. It is also believed that the present invention can provide significant protection from oblique impacts and traditional (i.e., 90°) impacts. In addition, it is believed that the present invention provides important or improved protection while reducing raw materials, reducing manufacturing complexity, reducing costs, reducing waste, reducing the manufacturing time of each helmet, improving breathability and / or ventilation for users, etc. In addition, it is believed that the oblique impact protection technology of the present invention can be very flexible, because those skilled in the art can be widely applied to various helmets, sports equipment, etc. with little or no additional improvements. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 shows a side cross-sectional view of an embodiment of a helmet 10 according to the present invention;

[0021] Figure 2 A partial top perspective close-up view of an embodiment of an oblique impact protection technology component is shown;

[0022] Figure 3 A partial bottom perspective close-up view of an embodiment of an oblique impact protection technology component is shown;

[0023] Figure 4 Shows Figure 1 A partial top view of an embodiment of an oblique impact protection technical component;

[0024] Figure 5 Shows Figure 1 and Figure 4 A partial side view of an embodiment of an oblique impact protection technical component;

[0025] Figure 6 A partial side view showing an embodiment of an oblique impact protection technology component; and

[0026] Figure 7 Schematic diagram of the 45° anvil and related helmet testing.

[0027] The drawings herein are for illustrative purposes only and are not necessarily drawn to scale. DETAILED DESCRIPTION

[0028] Unless otherwise specifically stated, all tests herein were conducted under standard conditions, including test temperatures of room temperature and 25°C, sea level (1 atmosphere) pressure, and pH 7 (if relevant), and all measurements were made in metric units. In addition, unless otherwise specifically stated, all percentages, ratios, etc. herein are by weight. It should be understood that, unless otherwise specifically stated, the materials, components, compounds, chemicals, etc. described herein are generally commercial and / or industry standard items available from multiple suppliers around the world.

[0029] Unless otherwise expressly indicated, the terms "inside" and "inboard" as used herein with respect to a helmet refer to a relative position toward the portion of the helmet that is or will be closer to the wearer's head. Unless otherwise expressly indicated, the terms "outside" and "exterior" as used herein refer to a relative position toward the portion of the helmet that is or will be closer to the outside of the helmet that is or will be farther from the wearer's head.

[0030] Embodiments of the present invention relate to an oblique impact protection technology, which includes a closed-cell foam layer, the closed-cell foam layer comprising a first surface, a second surface, and a plurality of wells on the first surface. The first surface comprises a plurality of first surface wells, and the first surface wells have a square shape. The second surface is opposite to the first surface and optionally comprises a plurality of second surface wells. Each well corresponds to a first surface well, and the second surface is substantially parallel or parallel to the second surface.

[0031] Without being limited by theory, it is believed that the invention herein can reduce potential damage to the head, spine, bones and / or soft tissue by reducing the amount of force and / or torque transmitted to the user's body or head during an oblique impact event or a traditional (i.e., 90°) impact. Specifically, it is believed that the texture of the first surface comprising a plurality of wells allows the closed-cell foam layer to provide both a comfortable fit and lateral and transverse flexing of the layer. This in turn allows the layer to reduce rotation and / or torque of the helmet before the helmet transmits the generated force and / or torque to the user's head.

[0032] Furthermore, it is understood that during use, the first surface often comes into contact with the user's body or head. It has been found that if the first surface has a larger surface area, the layer may not significantly reduce the force and / or torque transmitted to the user's body. Therefore, it is believed that the design of the present invention is optimized so that the first surface gently grips the user's head while the well wall can compress and / or bend to absorb a portion of the total force from the tilt impact. It is believed that this can reduce the total amount of force and / or torque transmitted to the user's body or head in the event of an accident.

[0033] The closed-cell foam that can be used herein is generally a foamed foam containing a plurality of closed cells. The closed-cell foam generally comprises a closed-cell foam material selected from the following group: foam rubber, polyurethane foam, polyethylene foam, ethylene vinyl acetate foam, latex foam, polyvinyl chloride foam, vinyl nitrile foam, and combinations thereof; or acrylic polyethylene foam, polyurethane foam, ethylene vinyl acetate foam; polyvinyl chloride foam, vinyl nitrile foam, and combinations thereof; or polyurethane foam, latex foam, rubber foam, polyvinyl chloride foam, vinyl nitrile foam, and combinations thereof; or vinyl nitrile foam.

[0034] The melting point of the closed-cell foam material is generally about 60°C to about 250°C, or about 80°C to about 180°C; or about 90°C to about 160°C. In one embodiment herein, the density of the closed-cell foam material is about 0.1 g / cm 3 To about 0.5g / cm 3 ; or about 0.15g / cm 3 To about 0.4g / cm 3 ; or about 0.175g / cm 3 To about 0.35g / cm 3 In embodiments herein, the layer has a hardness of about 20 to about 85; or about 25 to about 75; or about 30 to about 70.

[0035] Without being limited by theory, it is believed that the temperature range of such closed cell foam materials balances desirable properties, such as toughness, ability to permanently bond with other helmet components, comfort, etc. Such materials are well known in the art for use in helmet manufacturing, insulation, etc., and are available in varying grades and qualities from multiple suppliers around the world.

[0036] In one embodiment herein, the surface area of ​​the first surface apertures is greater than or equal to 25% of the surface area of ​​the corresponding first surface; or about 25% to about 95% of the surface area of ​​the corresponding first surface; or about 35% to about 90% of the surface area of ​​the corresponding first surface; or about 45% to about 85% of the surface area of ​​the corresponding first surface; or about 50% to about 80% of the surface area of ​​the corresponding first surface. As used herein, the surface area of ​​the corresponding first surface and / or the corresponding second surface is calculated as the total surface area including the surface area of ​​the apertures.

[0037] In one embodiment herein, the first surface is substantially parallel or parallel to the second surface. Typically, the thickness of the layer measured from the first surface to the second surface is from about 0.5 mm to about 2 cm; or from about 1 mm to about 1.5 cm, or from about 2 mm to about 1.2 cm; or from about 0.3 to about 1 cm.

[0038] The first surface herein refers to the surface of a layer or a plane formed by the topmost surface of the layer. In one embodiment herein, the first layer is intended to contact the user's body or head, and / or be the surface of the angled impact protection technology closest to the user's body or head.

[0039] The first surface hole herein has a square shape because it is believed that this shape provides improved benefits compared to other shapes. Various shapes, such as hexagonal, circular, etc., have been tested. In general, when various factors (such as performance, force / torque absorption, comfort, etc.) are taken into account, the square is proved to be the most acceptable. Without being bound by theory, it is believed that during the tilt impact, the layer bends and rotates around the user's body or head to reduce the force / torque transmitted thereto. Generally, it is believed that the shape with angles allows forces to accumulate / concentrate at these positions during the tilt impact. On the contrary, although the shape of the circular first surface hole will theoretically avoid concentrated impact forces, it is found that the use of a circular shape provides too much surface area in the middle of the first surface hole, which makes the layer uncomfortable and less effective. In addition, it is believed that polygons such as hexagonal holes contain too many angles (force / torque will be concentrated here). Therefore, it is believed that when the first hole includes a square shape, this provides the best balance between the following conditions: force / torque, comfort, breathability, etc. It is also believed that sharp corners may also unnecessarily concentrate forces, so in the embodiments of this article, the square includes rounded corners or four rounded corners.

[0040] The second surface is generally parallel to the first surface and may include a second surface hole or a plurality of second surface holes. In one embodiment herein, the second surface hole has a shape; or is selected from a square, a circle, an ellipse and a combination thereof; or a circle or an ellipse; or a circle.

[0041] The layer also includes a plurality of wells in the first surface, and each well corresponds to a first surface hole. In essence, each first surface hole forms the mouth of a well. It is believed that the wells are very important because a larger proportion of the well volume in the layer will in turn result in thinner walls, which will make the walls more able to flex and deform, thereby reducing the force / torque transmitted to the user's body or head. Therefore, those skilled in the art must consider balancing larger well volumes (which result in reduced force / torque transmission) with factors such as comfort, the sense of security of the helmet (or other equipment), and not sliding too much during regular use.

[0042] In one embodiment herein, the oblique impact protection technology reduces oblique impact force / torque transmission by at least 10%; or about 10% to about 50%; or about 12% to about 45%; or about 13% to about 40% compared to a similar helmet without the oblique impact protection technology, as measured by a modified Regulation No. 22 test using a 45° anvil instead of the normal flat and hemispherical anvils.

[0043] In one embodiment of the present invention, in addition to reducing oblique impact force / torque transmission, the oblique impact protection technology also reduces impact force transmission by at least 2%; or from about 2% to about 50%; or from about 3% to about 45%; or from about 4% to about 40% as measured by a modified Regulation No. 22 test with a flat anvil (i.e., traditional 90° impact) and / or a hemispherical anvil, as compared to a similar helmet that does not employ the oblique impact protection technology.

[0044] A well in this context may partially penetrate a layer, in which case it is characterized as a closed well, or may penetrate all the way through a layer, in which case it is characterized as an open well. A closed well typically has a well depth greater than or equal to 25% of the layer thickness; or from about 25% to about 99% of the layer thickness; or from about 35% to about 95% of the layer thickness; or from about 45% to about 90% of the layer thickness. The well depth is measured from the first surface; if a well bottom exists (i.e., a closed well), from the first surface plane to the well bottom. Typically, the well bottom is the point of the well farthest from the first surface; or the first surface plane measured perpendicularly from the first surface; or the first surface plane. In the absence of a wellbore, since the well completely penetrates the layer (e.g., the well is an open well), the well depth is defined as 100% and is equal to the layer thickness.

[0045] Therefore, in one embodiment of the present invention, a well in the plurality of wells is a closed well. Or at least 25% of the wells in the plurality of wells are closed wells; or at least 50% of the wells in the plurality of wells are closed wells; or substantially all of the wells in the plurality of wells are closed wells; or all of the wells in the plurality of wells are closed wells.

[0046] In the case of an open well, one skilled in the art will appreciate that the well depth is 100% of the thickness of the layer because the well forms a channel that passes completely through the layer. Thus, in embodiments comprising an open well, a first surface hole corresponds to a well, and the first surface hole and / or the well also corresponds to a second surface hole; in other words, the open well forms a channel connecting the first surface hole with the corresponding second surface hole. In one embodiment herein, a well in a plurality of wells is an open well, and the well corresponds to a second surface well; at least 25% of the wells in a plurality of wells correspond to second surface holes; at least 50% of the wells in a plurality of wells correspond to second surface holes; or substantially all of the plurality of wells correspond to second surface holes; or all of the plurality of wells correspond to second surface holes.

[0047] In one embodiment herein, a well in the plurality of wells is an open well, and the well corresponds to a second surface hole, thereby forming a channel from the first surface to the second surface; or at least 25% of the wells in the plurality of wells correspond to second surface holes, thereby forming multiple channels from the first surface to the second surface; or wherein at least 50% of the wells in the plurality of wells correspond to second surface holes, thereby forming multiple channels from the first surface to the second surface; or wherein substantially all of the plurality of wells correspond to second surface holes, thereby forming multiple channels from the first surface to the second surface; or all of the plurality of wells correspond to second surface holes, thereby forming multiple channels from the first surface to the second surface. In one embodiment herein, substantially all of the wells are open wells.

[0048] In one embodiment of the present invention, the oblique impact protection technology of the present invention is included in a piece of sports equipment selected from footwear, tights, masks, helmets, rackets, clubs, and combinations thereof; or footwear, tights, helmets, and combinations thereof. In one embodiment of the present invention, footwear useful in the present invention may include, for example, shoes, sandals, etc.; or basketball shoes, running shoes, ski boots, etc. In one embodiment of the present invention, tights useful in the present invention may include, for example, protective pads, clothing, wetsuits, etc.; or shoulder pads, knee pads, leg pads, protective armor, etc. In one embodiment of the present invention, the oblique impact protection technology of the present invention is included in a helmet (such as a sports helmet).

[0049] Helmets useful herein typically include an impact dissipating member and an angled impact protection technology attached directly or indirectly to the inner surface of the impact dissipating member. The impact dissipating member has an inner side of the impact dissipating member and an outer side of the impact dissipating member opposite the inner side of the impact dissipating member. The impact dissipating material useful in the present invention is typically selected from polystyrene, polypropylene, and mixtures thereof; or extruded polystyrene, expanded polystyrene; expanded polypropylene, and mixtures thereof; or expanded polystyrene, and mixtures thereof.

[0050] One embodiment herein includes a shell external to, and typically permanently bonded to, the outside of an impact dissipating member. The shell typically covers most, if not all, of the outside of the impact dissipating member and has a variety of purposes, such as aesthetics, additional impact dissipation, reduced friction, and the like. In one embodiment herein, the shell includes a shell material selected from polycarbonate, polystyrene, polyacrylate, and mixtures thereof; or extruded polystyrene, expanded polystyrene, and mixtures thereof; or expanded polystyrene; and mixtures thereof. Although the shell is typically thin, it does include an inside of the shell and an outside of the shell opposite the inside of the shell. The inside of the shell is also typically permanently constrained to the outside of the dissipating member, for example, during a molding process. Alternatively, after the shell is formed, the shell may be bonded to the outside of the impact dissipating member by an adhesive or other method known in the art.

[0051] The angled impact protection technology can be secured to the impact dissipation member and / or another helmet portion by, for example, a technique selected from bonding, in-mold forming, heat fusion, ultrasonic fusion, and combinations thereof; or in-mold forming. See, for example, the general description of the helmet and process-related information found in US 2015 / 01137709 A1 to Cheng, published on April 30, 2015.

[0052] Manufacturing process:

[0053] The process for making a helmet herein generally includes: providing a female mold portion; providing a male mold portion; providing an oblique impact protection technology component containing the oblique impact protection technology herein; and providing an impact dissipation material. The male mold portion is complementary to the female mold portion, and thus the female mold portion and the male mold portion can be assembled together to form a hollow mold between them. Before the male mold portion and the female mold portion are assembled together, or after the male mold portion and the female mold portion are assembled together, the oblique impact protection technology component is applied to the male mold portion.

[0054] The impact dissipation material can be applied to the hollow mold in the form of a liquid or a plurality of beads or as a plurality of beads. The inclined impact protection technology component and the impact dissipation material are subjected to an in-mold forming process in the hollow mold. In the process of this article, the impact dissipation material forms an impact dissipation component having an inner side of the impact dissipation component and an outer side of the impact dissipation component opposite to the inner side of the impact dissipation component. The in-mold forming process permanently bonds the inclined impact protection technology component (usually the outer side of the inclined impact protection technology component) to the inner side of the impact dissipation component. At this time, additional other components such as shells, attachment areas, frames, reflectors, etc. can also be formed in, on or near various helmet components. In one embodiment of this article, before the in-mold forming process, usually before or during the in-mold forming process, a shell material is provided and the shell material is applied to the female mold part. In this embodiment, the shell material forms a shell, and the in-mold forming process permanently bonds the shell or the inner side of the shell to the outer side of the impact dissipation component.

[0055] The in-mold forming process and machinery will typically perform the in-mold forming process at a temperature of about 65° C. to about 250° C., or about 80° C. to about 180° C., or about 90° C. to about 160° C. Such processes and related machinery are well known in the art and are available from various manufacturers worldwide.

[0056] The oblique impact protection technology component may be formed from a closed cell foam, a closed cell foam material, and / or one or more closed cell foam precursors by methods known in the art (eg, vacuum forming, vacuum blowing, etc.).

[0057] Attached photos :

[0058] Turning to the attached figure, Figure 1 1 is a side cross-sectional view of an embodiment of a helmet 10 according to the present invention. The helmet 10 will typically further include a complementary or mirrored left side view, but for simplicity, it is not shown here. The helmet 10 is an example of a sports equipment 12 and has an angled impact protection technology member 20, which has an angled impact protection technology member inner side 22 and an angled impact protection technology member outer side 24. The angled impact protection technology member outer side 24 is opposite to (i.e., on the opposite side of) the angled impact protection technology member inner side 22.

[0059] The helmet 10 also includes an impact dissipation member 26 formed of an impact dissipation material. The helmet 10 includes holes 28 that allow air to flow through the helmet 10 when the helmet is worn, thereby increasing the comfort and ventilation of the user. The helmet 10 will typically include a plurality of holes 28, which also reduces the weight of the helmet and reduces the amount of raw materials used and the production cost. A plurality of ribs 30 extend between and engage the holes 28, and these ribs are made of impact dissipation material. Thus, the ribs 30 form the structural basis of the impact dissipation member 26 of the helmet 10. The interior of the helmet 10 has a plurality of inclined impact protection technology members 20, each of which is permanently attached or permanently bonded to; or permanently molded to the impact dissipation member 26, typically at the ribs 30 between the holes 28. Specifically, the inclined impact protection technology member outer side 24 is typically molded to the impact dissipation member 26 at the ribs 30. The impact dissipation member 26 includes an impact dissipation member outer side 34.

[0060] The helmet 30 also includes a shell 32 that is located external to the impact dissipating member 26 and covers most of the impact dissipating member 26. The shell 32 has a shell inner side 36 that is permanently bonded to the impact dissipating member outer side 34. The shell outer side 38 is open to the air and is located at the portion of the helmet farthest from the user's head (not shown).

[0061] The helmet 10 has an additional feature 40 that is also molded to the impact dissipating member 26. In this case, the additional feature is a buckle for attaching, for example, a chin rest (not shown). The helmet 10 also includes another additional feature 40', in this case, a threaded hole for a screw that can be used to attach, for example, an insert for a wearer with a smaller head size, etc.

[0062] Figure 2 A partial top perspective close-up view of an embodiment of an oblique impact protection technology member 20 that can be used herein is shown. The oblique impact protection technology member 20 is formed of a closed cell foam layer 50 and includes a first surface 52 and a second surface 54. Those skilled in the art will appreciate that in Figure 2 Only a small portion of layer 50 is shown. The first surface 52 contains a plurality of wells 56. Figure 1 , each well 56 corresponds to a first surface hole 58, each first surface hole 58 having a square shape with four rounded corners 60. When the layer 50 is attached to, for example, a piece of sports equipment (see Figure 1 12) or helmet (see Figure 1 10), the second surface 54 is usually attached to the piece of sports equipment (see Figure 1 12) or helmet (see Figure 110). In this embodiment, it can be seen that all of the wells 56 are of the same shape and size, all of the first surface holes 58 are of the same shape and size, and all of the second surface holes 62 are of the same shape and size.

[0063] exist Figure 2 , each second surface hole 62 corresponds to a first surface hole 58, and each corresponds to a well 56, in which case the open well 64 forms a channel 66 between the first surface 52 and the second surface 54. It can be seen that between the well 56' and the well 56" is a well wall 68, which provides structural integrity to the layer 50 and bends and / or deforms under tilt impact to reduce the force / torque transmitted to the user. It can also be seen that in this embodiment, the transition between the first surface hole 58 and the well 56 includes a rounded edge 70, which makes the manufacture of the layer 50 easier and can also provide greater comfort to the user.

[0064] Figure 3 A partial bottom perspective close-up view of an embodiment of an oblique impact protection technology member 20 that can be used herein is shown. The figure clearly shows the second surface 54, which contains a plurality of second surface holes 62 and a plurality of wells 56, 56', 56". The first surface 52 is opposite to the second surface 54. Figure 3 It is also clearly shown that a well wall 68 is formed between the well 56' and the well 56".

[0065] Figure 4 Shows Figure 1 A partial top view of an embodiment of an angled impact protection technology member 20. The view looks toward the first surface 52 and clearly shows the first surface hole 58. The surface area of ​​the square first surface hole 58 can be calculated by measuring the width AW of the first surface hole and the length AL of the first surface hole, multiplying the width AW by the length AL and subtracting the surface area between the corresponding rounded corners 60. The surface area of ​​other non-square surface holes can be similarly calculated by geometric principles and / or formulas known in the art, or by a computer-aided design (CAD) program. Figure 4 , the width AW of the first surface hole is the farthest distance between any opposing edges, and the length of the first surface hole is measured as the farthest distance between any opposing edges in a direction perpendicular to the width of the first surface hole. Similarly, the surface area of ​​the corresponding first surface can be calculated by measuring the distance from the midpoint between each first surface hole 58 to find the width SA of the first surface and the length SL of the first surface, and then multiplying the width SA of the first surface by the length SL of the first surface.

[0066] Figure 5 Shows Figure 1 and Figure 468. A partial side view of an embodiment of an oblique impact protection technology member 20. The figure shows that the first surface 52 forms a first surface plane FSP; and the second surface 54 forms a second surface plane SSP parallel to the first surface plane FSP. It is clear that the width AW of the first surface hole 58 is measured from the (opposite) point where the first surface hole 58 breaks the first surface plane FSP, rather than from some point on the well wall 68. Likewise, for clarity, it is shown that the width AW of the first surface hole is measured at an angle perpendicular to the first surface plane FSP.

[0067] The layer thickness LT is the distance between the first surface plane FSP and the second surface plane SSP measured perpendicularly to the first surface plane FSP. Figure 5 , the layer thickness is substantially the same throughout the layer 50. In this figure, it can also be seen that the well depth WD is equal to 100% of the layer thickness LT, because the well 56 is an open well 64, which forms a channel 66 from the first surface (and the first surface plane FSP) to the second surface (and the second surface plane SSP). In this figure, a plurality of second surface holes 62 can also be seen.

[0068] Figure 6 A partial side view of an embodiment of an oblique impact protection technology member 20 is shown. The figure shows a layer 50 having a first surface 52 and a second surface 54 opposite the first surface. The first surface holes 58 on the first surface 52 correspond to wells 56 having well walls 68. The first surface 52 forms a first surface plane FSP and the second surface 54 forms a second surface plane SSP.

[0069] However, in this embodiment, each well 56 is a closed well 72 having a rounded edge 70 and a well bottom 74. A shallower second surface hole 62 is shown in this embodiment, although when a well bottom 74' is present, the second surface hole 62 does not connect to or form a channel with the first surface hole 52 (see Figure 4 66).

[0070] Figure 7 is a schematic diagram of a 45° anvil 76 and associated helmet testing. The helmet 20 is securely attached to a headform 78 and accelerated in a controlled manner toward the 45° anvil 76 in the direction indicated by arrow A. The 45° anvil 76 has an impact surface 80 that is angled 45° relative to the drooping direction of arrow A and also 45° relative to a normal flat anvil surface FA.

[0071] Upon impact, the helmet 20 rebounds from the impact surface 80 in the direction generally indicated by arrow B.

[0072] Test method:

[0073] The helmets herein are tested for oblique impact performance using an industry standard machine such as that described herein, e.g., Regulation No. 22, except that the anvil is a 45° anvil, which is an anvil having an impact surface that is angled 45 degrees from the ordinary flat anvil used in the normal Regulation No. 22 test (e.g., "Modified Regulation No. 22 with 45° anvil"), see e.g. Figure 7 The headform contains a sensor (e.g. accelerometer) or multiple sensors in which the velocity, acceleration etc. of the headform are measured in 3 dimensions. Additionally, a high-speed camera can be used to record the test.

[0074] Examples

[0075] Example 1:

[0076] The angled impact protection material was made of a closed cell foam material and adhered to a pre-formed helmet with an industry standard contact adhesive and was labeled "Helmet A". An identical helmet was manufactured, only lacking the angled impact protection material and was labeled "Comparison Helmet A1". A comparable helmet incorporating the MIPS system was manufactured and labeled "Comparison Helmet A2".

[0077] In the conventional Regulation No. 22 test using flat and hemispherical anvils and dropped from a height of 205 cm, the average peak G value of Helmet A was 4.7% less than that of Comparative Helmet A1 and 2.4% less than that of Comparative Helmet A2. Therefore, this data indicates that the present invention provides improved linear impact protection (i.e., less force transfer) compared to the comparative helmets.

[0078] Example 2:

[0079] The angled impact protection material was made of a closed cell foam material and adhered to a pre-formed helmet with an industry standard contact adhesive and was labeled "Helmet B". An identical helmet was manufactured, only lacking the angled impact protection material and was labeled "Comparison Helmet B1". A comparable helmet incorporating the MIPS system was manufactured and labeled "Comparison Helmet B2". A comparable helmet incorporating KALI's LDL system was manufactured and labeled "Comparison Helmet B3".

[0080] These helmets were tested using Modified Regulation No. 22 with a 45° anvil as described herein and dropped from a height of 210 cm. Data collected included front, X-axis rotation, Y-axis rotation, Z-axis rotation, occipital, and R-lateral measurements (in radians / second) from the headform. 2The average rotation of helmet B is 14.1% less than that of comparative helmet B1, 3.3% less than that of comparative helmet B2, and 7.5% less than that of comparative helmet B3. Therefore, this data shows that the present invention provides improved rotational impact protection (i.e., less force / torque transmission) compared to the comparative helmets.

[0081] Example 3:

[0082] The angled impact protection material was made of a closed cell foam material and adhered to a pre-formed helmet with an industry standard contact adhesive and was labeled "Helmet C". An identical helmet was manufactured, only lacking the angled impact protection material and was labeled "Comparison Helmet C1". A comparable helmet incorporating the MIPS system was manufactured and labeled "Comparison Helmet C2".

[0083] The test was conducted using Modified Regulation No. 22 with a 45° anvil as described herein and dropped from a height of 210 cm. The data collected included front, back, left, right, and top measurements from the headform (in radians / second). 2 The average rotation of helmet C is 15.5% less than that of comparative helmet C1 and 15.7% less than that of comparative helmet C2. Therefore, this data shows that the present invention provides improved rotational impact protection (i.e., less force / torque transmission) compared to the comparative helmets.

[0084] It should be understood that the foregoing merely illustrates and describes examples in which the present invention may be implemented and that modifications and / or variations may be made thereto without departing from the spirit of the present invention.

[0085] It should also be understood that certain features of the invention described in the context of separate embodiments for clarity may also be provided in combination in a single embodiment. Conversely, various features of the invention described in the context of a single embodiment for brevity may also be provided individually or in any suitable sub-combination.

[0086] All references specifically cited herein are hereby incorporated by reference in their entirety. However, citation or incorporation of such a reference as prior art to / for the present invention is not necessarily an admission of its appropriateness, citableness, and / or availability.

Claims

1. A tilt impact protection technical component, include: A closed cell foam layer comprising: A) a first surface comprising a plurality of first surface apertures, wherein the first surface apertures comprise a square shape; B) a second surface opposite to the first surface, the second surface comprising a plurality of second surface holes; and C) a plurality of wells in the first surface, wherein each well corresponds to a first surface hole, and a well wall is formed between the wells, wherein the well wall can be compressed and / or bent to absorb the force from the tilt impact; wherein the second surface is parallel to the first surface, The surface area of ​​the first surface pores is 50% to 80% of the surface area of ​​the corresponding first surface, The square comprises rounded corners or four rounded corners.

2. The oblique impact protection technical component according to claim 1, in, Each second surface hole corresponds to a first surface hole.

3. The oblique impact protection technical component according to claim 1, in, One of the plurality of wells is a closed well; or wherein at least 25% of the plurality of wells are closed wells; or wherein at least 50% of the plurality of wells are closed wells; or wherein all of the plurality of wells are closed wells.

4. The oblique impact protection technical component according to claim 1, in, One of the plurality of wells corresponds to a second surface hole; or wherein at least 25% of the plurality of wells correspond to second surface holes; or wherein at least 50% of the plurality of wells correspond to second surface holes; or wherein all of the plurality of wells correspond to second surface holes.

5. The oblique impact protection technical component according to claim 1, in, One of the plurality of wells is an open well, and wherein the well corresponds to a second surface hole, thereby forming a channel from the first surface to the second surface; or wherein at least 25% of the plurality of wells correspond to second surface holes, thereby forming a plurality of channels from the first surface to the second surface; or wherein at least 50% of the plurality of wells correspond to second surface holes, thereby forming a plurality of channels from the first surface to the second surface; or wherein all of the plurality of wells correspond to second surface holes, thereby forming a plurality of channels from the first surface to the second surface.

6. The oblique impact protection technical component according to claim 1, in, The layer thickness measured from the first surface to the second surface is 0.5 mm to 2 cm; or 1 mm to 1.5 cm, or 2 mm to 1.2 cm; or 0.3 to 1 cm.

7. The oblique impact protection technical component according to claim 1, in, The closed-cell foam comprises a closed-cell foam material, and the closed-cell foam material is selected from foam rubber, polyurethane foam, polyethylene foam, ethylene vinyl acetate foam, latex foam, polyvinyl chloride foam, vinyl nitrile foam and combinations thereof; or acrylic polyethylene foam, polyurethane foam, ethylene vinyl acetate foam; polyvinyl chloride foam, vinyl nitrile foam and combinations thereof; or polyurethane foam, latex foam, rubber foam, polyvinyl chloride foam, vinyl nitrile foam and combinations thereof.

8. A helmet comprising the oblique impact protection technical component according to claim 1.

9. The helmet according to claim 8, in, The oblique impact protection technology component is attached to the helmet by a technology selected from the group consisting of: bonding, in-mold forming, heat fusion, ultrasonic fusion, and combinations thereof; or in-mold forming.

10. The helmet according to claim 8, in, The oblique impact protection technology component reduces oblique impact force / torque transmission by at least 10%; or by 10% to 50%; or by 12% to 45%; or by 13% to 40% compared to a helmet without the oblique impact protection technology component.

11. A method of manufacturing a helmet, wherein The following steps are involved: A. Provide the female mold part; B. providing a male mold portion complementary to the female mold portion, wherein the female mold portion and the male mold portion can be assembled together to form a hollow mold therebetween; C. Provide a tilt impact protection technical component comprising a closed-cell foam layer, wherein the closed-cell foam layer comprises: i) a first surface comprising a plurality of first surface apertures, wherein the first surface apertures comprise a square shape; ii) a second surface opposite to the first surface, the second surface comprising a plurality of second surface holes; and iii) a plurality of wells in the first surface, wherein each well corresponds to a first surface hole, and well walls are formed between the wells, wherein the well walls are capable of compressing and / or bending to absorb forces from tilt impact; wherein the second surface is parallel to the first surface, the surface area of ​​the first surface holes is 50% to 80% of the surface area of ​​the corresponding first surface, and the square includes a rounded corner or four rounded corners; D. applying the tilted impact protection technology component to the male mold portion; and E. providing a shock dissipating material and applying the shock dissipating material into the hollow mold, wherein the tilted impact protection technical component and the impact dissipation material undergo an in-mold forming process in the hollow mold, Wherein, the tilted impact protection technical component includes an inner side of the tilted impact protection technical component, The oblique impact protection technical component includes an outer side of the oblique impact protection technical component opposite to the inner side of the oblique impact protection technical component. wherein the shock dissipating material forms a shock dissipating member including an inner side of the shock dissipating member, wherein the shock dissipation member comprises an outer side of the shock dissipation member opposite to the inner side of the shock dissipation member, and Wherein, the in-mold forming process permanently bonds the outer side of the inclined impact protection technology component to the inner side of the impact dissipation component.

12. The method of manufacturing a helmet according to claim 11, in, The in-mold forming process is carried out at a temperature of 65°C to 250°C, or 80°C to 180°C, or from 90°C to 160°C.

13. A sports equipment comprising an oblique impact protection technology component, the oblique impact protection technology component comprising a closed cell foam layer, in, The closed-cell foam layer comprises: A) a first surface comprising a plurality of first surface apertures, wherein the first surface apertures comprise a square shape; B) a second surface opposite to the first surface, the second surface comprising a plurality of second surface holes; and C) a plurality of wells in the first surface, wherein each well corresponds to a first surface hole, and a well wall is formed between the wells, wherein the well wall can be compressed and / or bent to absorb the force from the tilt impact; The second surface is parallel to the first surface, the surface area of ​​the first surface holes is 50% to 80% of the surface area of ​​the corresponding first surface, and the square includes a rounded corner or four rounded corners.

14. The sports equipment according to claim 13, in, The sports equipment is selected from the group consisting of footwear, tights, masks, helmets, rackets, clubs, and combinations thereof; or footwear, tights, helmets, and combinations thereof.

15. The sports equipment according to claim 13, in, The oblique impact protection technology component is attached to the sports equipment by a process selected from bonding, in-mold forming, heat fusion, ultrasonic fusion and combinations thereof; or in-mold forming.

Images