Molds used to manufacture sports helmets and related processes for molding such helmets.

Abstract

This invention relates to a mold and related molding process for manufacturing sports helmets (A), particularly cycling helmets. The mold includes: a frame (1) having at least one molding recess (2); and a counter frame (3) capable of engaging with the frame (1) to hermetically close the respective molding recess (2) and allow for at least one molding cycle. The mold also includes at least one intermediate support element (4) for supporting and positioning one or more parts (B) of the sports helmet (A) to be manufactured within the respective molding recesses (2) of the frame (1). The intermediate support element (4) remains within the respective molding recesses throughout the molding cycle to hold the parts (B) of the sports helmet (A) to be manufactured in their designated positions.

Description

Technical Field

[0001] This invention relates to molds for manufacturing sports helmets, particularly cycling helmets.

[0002] The present invention also relates to a process for molding the aforementioned sports helmets, and particularly related cycling helmets.

[0003] This invention relates to the field of sports helmets, and particularly cycling helmets. Background Technology

[0004] As is well known, cycling helmets are manufactured using suitable molds, and each mold has a female half-mold and a male half-mold.

[0005] Each mold is equipped with a corresponding supply channel for the polystyrene to be injected to form the helmet, and also has multiple holes for supplying steam necessary for performing the molding cycle.

[0006] During the molding cycle, the polystyrene, in spherical form, undergoes a softening and expansion process inside the mold cavity, giving the polystyrene the shape of the product to be manufactured—the base body of the helmet designed to absorb impact.

[0007] Once the base body has been obtained, it is removed from the mold to allow the operator to assemble other parts of the helmet, such as the upper shell, lower ring or lower shell, and any other parts that need to be connected to the base body.

[0008] The base body, along with the attached helmet parts, is inserted back into the mold for a second molding cycle designed to attach the attached parts to the base body in a defined manner.

[0009] Once the second molding cycle is complete, the resulting helmet is removed from the mold again to undergo final finishing operations, padding application, and quality control.

[0010] In order to improve the aforementioned molding process by making the molding process faster and more precise and by significantly improving the quality of the resulting products, the applicant has designed and developed a support template that allows additional components of the sports helmet to be manufactured to be positioned inside the relevant mold according to predetermined positions that must be maintained during the molding cycle.

[0011] The use of the aforementioned support template allows for the elimination of one of the two molding steps in the traditional molding process, thereby ensuring a high percentage of repeatability in the precise positioning of the additional components within the mold.

[0012] Italian Patent No. 102018000007587 describes the support template and the related molding process using such a support template in detail.

[0013] Although the aforementioned support templates and related molding processes allow for significant improvements over conventional molding techniques used in sports helmets, the applicant found that they do not eliminate certain drawbacks and can be improved in several aspects, primarily concerning total production time and the elimination or minimization of defects in the resulting sports helmets.

[0014] In particular, the applicant has discovered that the molding process for the support template described in Italian Patent No. 102018000007587 includes operational steps that present some key problems, which are related to production time, defects in the resulting sports helmet, and the risk of mold damage.

[0015] The applicant was actually able to notice that after all the additional components were positioned on the support template according to the relevant predetermined positions, the support template was first inserted into the relevant female mold to position the additional supported components in the relevant molding positions, in which the components were locked by the corresponding locking mechanisms. The support template was then removed, thus allowing the mold to be closed and the relevant molding cycle to begin.

[0016] Besides extending the molding time of each molding cycle and having an undesirable impact on total production time, the step of removing the support template from the associated female mold can, in some cases, cause imperceptible displacement of one or more additional components from their corresponding preset positions. At best, this incident may result in minor defects in the resulting sports helmet. At worst, the displacement of additional components can also cause mold damage when the mold is closed to begin the molding cycle. Summary of the Invention

[0017] The main objective of this invention is to provide a mold for manufacturing sports helmets, particularly cycling helmets, and a related molding process that can solve the problems encountered in the prior art.

[0018] One object of the present invention is to further accelerate the molding process for sports helmets and cycling helmets, thereby further reducing the total production time of such helmets.

[0019] Another objective of this invention is to ensure the availability of high-quality sports helmets and cycling helmets.

[0020] Another object of the present invention is to ensure the structural integrity of the molds used to manufacture the above-mentioned sports helmets and cycling helmets.

[0021] The objectives and other objectives mentioned above are achieved substantially by means of molds for manufacturing sports helmets, particularly cycling helmets, as described and claimed in the appended claims, and by related processes for molding such sports helmets.

[0022] By way of example, according to the present invention, a preferred but non-exclusive embodiment of a mold for manufacturing sports helmets, particularly cycling helmets, and a related process for molding such sports helmets and cycling helmets is now disclosed. Attached Figure Description

[0023] This description will be made below with reference to the accompanying drawings, which are provided for illustrative purposes only and therefore not limiting, in which:

[0024] Figure 1 This is a perspective view of a frame for a mold for manufacturing a sports helmet, particularly a cycling helmet, according to the present invention. The frame is provided with two molding recesses: one of which is occupied by a corresponding intermediate support element of the mold for supporting and positioning one or more parts of the corresponding sports helmet to be manufactured; and an empty molding recess.

[0025] Figure 2 yes Figure 1 Rear view of the frame of the mold involved;

[0026] Figure 3 yes Figure 1 Front view of the intermediate support element involved;

[0027] Figure 4 yes Figure 1 and Figure 3 Rear perspective view of the intermediate support element involved;

[0028] Figure 5 It is illustrated by decomposition diagram. Figure 1 , Figure 3 and Figure 4 A front-view perspective view of the intermediate support element and some components of the sports helmet to be manufactured;

[0029] Figure 6 yes Figure 1 and Figures 3 to 5 The front perspective view of the intermediate support element involved in the figure depicts, in an exploded view, some parts and other components of the sports helmet to be manufactured being joined in corresponding predetermined positions on the intermediate support element.

[0030] Figure 7 It is Figure 1 and Figures 3 to 6 The intermediate support element involved is inserted into Figure 1 and Figure 2A schematic perspective view of the corresponding molding recess in the mold frame involved, wherein the intermediate support element is provided with some parts of the sports helmet to be manufactured;

[0031] Figure 8 yes Figure 1 and Figures 3 to 7 The diagram shows a front-view schematic perspective of an intermediate support element, which houses some components of the sports helmet to be manufactured and is connected to an opposing frame of the mold. This opposing frame is designed to... Figure 1 and Figure 2 The corresponding molding recesses of the mold frame involved are closed;

[0032] Figure 9 It is Figure 1 and Figures 3 to 8 The intermediate support elements involved in the process are from Figure 1 and Figure 2 A schematic perspective view of the mold frame involved, showing the removal of the corresponding molding recess, with the intermediate support element equipped with the corresponding sports helmet obtained from the corresponding molding cycle.

[0033] Figure 10 yes Figure 1 and Figures 3 to 9 A schematic diagram showing the separation of the intermediate support element from the sports helmet obtained from the corresponding molding cycle;

[0034] Figure 11 and Figure 12 yes Figure 1 and Figures 3 to 10 The intermediate support elements involved are respectively in the rest position and in the locked position, and these sections are realized by longitudinal development along the corresponding locking protrusion of the intermediate support element.

[0035] With reference to the accompanying drawings, three components of a mold for manufacturing sports helmets, particularly cycling helmets, according to the present invention are shown individually or in pairs. Detailed Implementation

[0036] like Figure 1 and Figure 2 As can be seen, the mold includes at least one frame 1, which defines a space for molding at least one corresponding sports helmet A. Figure 9 and Figure 10 At least one molded recess 2, preferably two or more molded recesses 2.

[0037] Advantageously, the presence of two or more molding recesses 2 in each mold allows for the simultaneous manufacture of two or more sports helmets A, and significantly increases the number of sports helmets A produced.

[0038] Reference Figure 8The mold also includes opposing frames 3 for each molding recess 2, which can be engaged with the frame 1 to hermetically seal the corresponding molding recess 2 and allow at least one molding cycle for manufacturing the corresponding sports helmet A to be performed.

[0039] Reference Figure 1 and Figures 3 to 10 For each molded recess 2 provided in the frame 1, the mold also includes at least one intermediate support element 4 for supporting and positioning one or more parts B of the sports helmet A to be manufactured inside the corresponding molded recess 2 of the frame 1, the parts B being made of, for example, polycarbonate or other similar materials.

[0040] In detail, each intermediate support element 4 has: a first portion 5 arranged to receive one or more parts B of the sports helmet A to be manufactured in an engaged manner according to a corresponding predetermined position; and a second portion 6 opposite to the first portion 5, the second portion 6 having at least one grip handle 7, preferably two opposite grip handles 7, for manually positioning the intermediate support element 4 in a corresponding molding recess 2 of the frame 1 and subsequently positioning the parts B of the sports helmet A to be manufactured inside the molding recess 2.

[0041] like Figure 1 As can be observed, in order to allow optimal closure of each molding recess 2 of the mold frame 1 with the corresponding opposing frame 3, corresponding to the second part 6, each intermediate support element 4 is advantageously arranged to perfectly connect with the corresponding opposing frame 3. In this way, when each opposing frame 3 hermetically closes the corresponding molding recess 2 of the mold frame 1, the opposing frame 3 also abuts against the corresponding intermediate support element 4 present inside the molding recess 2 to hold the component B of the sports helmet A to be manufactured in a predetermined position during the relevant molding cycle.

[0042] like Figure 1 , Figures 3 to 6 and Figure 10 As can be observed, each intermediate support element 4 includes a generally annular structure 8, which has inside at least one support portion 9 and / or relief portion 10 of at least one component B of the sports helmet A to be manufactured.

[0043] Refer again Figure 1 , Figures 3 to 6 and Figure 10 The figures show that the support base 9 and / or relief portion 10 can be approached from the first part 5 of each intermediate support element 4, so that the positioning of the aforementioned component B of the sports helmet A is performed by keeping the first part 5 of each intermediate support element 4 facing upward or toward the figure of the operator performing the action of positioning these components B of the sports helmet A to be manufactured.

[0044] Preferably, the positioning of component B of the sports helmet A to be manufactured is performed by placing the second part 6 of each intermediate support element 4 on a working plane or similar support plane, such that the first part 5 of the intermediate support element 4 can be easily reached by the hand of the operator who must position component B of the sports helmet A to be manufactured.

[0045] Refer again Figure 1 , Figures 4 to 7 , Figure 9 and Figure 10 The aforementioned grip handle 7 is defined by the annular structure 8 of the corresponding intermediate support element 4.

[0046] Specifically, each grip handle 7 includes a grip portion 7a, which is designed to be manually gripped by an operator. The grip portion 7a of each grip handle 7 is defined by a block-shaped portion that engages, for example, with the annular structure 8 of the corresponding intermediate support element 4 by means of a corresponding threaded engagement element 7b.

[0047] Each grip handle 7 also includes at least one grip opening 7c, which is defined between the annular structure 8 of the corresponding intermediate support element 4 and the corresponding grip portion 7a, to allow the operator's fingers to be inserted when the operator must grip the grip handle 7.

[0048] Advantageously, the mold includes at least one engaging member 11 for stably connecting each intermediate support element 4 to the frame 1 within the respective molding recess 2.

[0049] Specifically, the connecting member 11 is operatively inserted between each intermediate support member 4 and the corresponding molded recess 2 of the frame 1.

[0050] More specifically, the engaging member 11 includes at least one locking seat portion 11a realized outside the annular structure 8 of each intermediate support element 4. Figures 3 to 12 Preferably, there are two opposite locking seats 11a.

[0051] For each molded recess 2 of the frame 1, the engaging member 11 further includes at least one locking protrusion 11b. Figure 1 , Figure 11 and Figure 12 Preferably, there are two opposite locking protrusions 11b. Each pair of locking protrusions 11b of each molded recess 2 can be in a resting position within the corresponding molded recess 2 of the frame 1. Figure 1 and Figure 11 ) and locked position ( Figure 12The frame 1 moves between the two parts. In the resting position, the corresponding intermediate support element 4 can be inserted into or removed from the corresponding molding recess 2. In the locked position, the locking protrusion 11b engages the corresponding locking seat 11a of the corresponding intermediate support element 4, thereby holding the corresponding locking seat 11a inside the corresponding molding recess 2 of the frame 1.

[0052] exist Figure 1 , Figure 11 and Figure 12 As can be observed, the locking protrusions 11b of each molded recess 2 are operatively positioned corresponding to the peripheral region of the corresponding molded recess 2, such that the movement of these locking protrusions 11b from the rest position to the locked position causes the locking protrusions 11b to shift toward the central portion of the corresponding molded recess 2, i.e., toward each other. Conversely, when the locking protrusions 11b of each molded recess 2 move from the locked position to the unlocked position, these locking protrusions 11b move away from the central portion of the corresponding molded recess 2, thereby moving away from each other.

[0053] Advantageously, the locking protrusion 11b of each molding recess 2 can be controlled by means of an actuation device located outside the mold (not visible in the drawings). Preferably, the actuation device for the locking protrusion 11b of each molding recess 2 includes at least one drive pedal. More preferably, the actuation device may include two or more drive pedals for independently controlling each pair of locking protrusions 11b of each molding recess 2 or collectively controlling all the locking protrusions 11b of the molding recesses 2 of the mold frame 1.

[0054] exist Figure 11 and Figure 12 It can be observed that the actuation device of the locking protrusion 11b of each molding recess 2 of the mold frame 1 is by means of a corresponding hydrodynamic actuator 11c operably positioned on the mold frame 1. Figure 2 , Figure 11 and Figure 12 To activate these locking protrusions 11b.

[0055] Advantageously, the mold includes at least one engagement constraint 12 ( Figure 1 and Figures 3 to 12 The coupling constraint 12 is used to stably connect each intermediate support member 4 to the corresponding opposing frame 3. Each coupling constraint 12 is operatively inserted between the corresponding intermediate support member 4 and the opposing frame 3.

[0056] In detail, each engagement constraint 12 includes: at least one engagement lug 12a, preferably two opposite engagement lugs 12a; and at least one engagement seat 12b, preferably two opposite engagement seats 12b, which are operatively inserted between the corresponding intermediate support element 4 and the corresponding opposing frame 3.

[0057] Preferably, each connecting lug 12a of each engagement constraint 12 protrudes outward from the annular structure 8 of the corresponding intermediate support element 4, and each connecting seat 12b of each engagement constraint 12 is implemented on the corresponding opposing frame 3.

[0058] Preferably, each connecting lug 12a and corresponding connecting seat 12b of each engagement constraint 12 are at least partially countershaped to ensure a stable connection between the corresponding intermediate support element 4 and the corresponding opposing frame 3.

[0059] According to a preferred aspect of the invention, each locking seat portion 11a of the engagement member 11 is externally implemented on the corresponding connecting lug 12a of the corresponding engagement constraint member 12.

[0060] Advantageously, for each molding recess 2 of the frame 1, the mold also includes at least one auxiliary support element identical to the corresponding intermediate support element 4. During the corresponding molding cycle of the mold, when the corresponding intermediate support element 4 engages in the corresponding molding recess 2, each auxiliary support element can be used to prepare one or more components B of the sports helmet A that still need to be manufactured.

[0061] In other words, although each intermediate support element 4 occupies the corresponding molding recess 2 during the relevant molding cycle of the corresponding sports helmet A, each auxiliary support element is set and prepared for the corresponding part B of the sports helmet to be manufactured subsequently, and the auxiliary support element is inserted into the corresponding molding recess 2 as soon as the molding recess 2 is disengaged from the corresponding intermediate support element 4.

[0062] The present invention also relates to a process for molding sports helmets A, particularly cycling helmets, which will be described below.

[0063] The molding process includes: providing the frame 1 of the mold, the frame 1 having a corresponding molding recess 2 for molding the corresponding sports helmet A; and preparing a corresponding opposing frame 3 of the same mold, the opposing frame 3 being designed to hermetically seal the corresponding molding recess 2 and allow the execution of the corresponding molding cycle.

[0064] The process also includes the following steps: preparing the corresponding intermediate support element 4 of the mold to support and position the component B of the sports helmet A to be manufactured inside the corresponding molding recess 2 of the mold frame 1.

[0065] After providing the frame 1, the corresponding opposing frame 3, and the corresponding intermediate support element 4, the molding process includes the following steps: placing one or more parts B of the sports helmet A to be manufactured in the first part 5 of each intermediate support element 4 according to the corresponding predetermined positions. Figure 5 and Figure 6 ).

[0066] In detail, the placement step is performed by approaching a series of seat portions 9 and / or relief portions 10 located inside the annular structure 8 of each intermediate support element 4 through the corresponding first portion 5 of each intermediate support element 4.

[0067] In order to facilitate easy access to the first part 5 of each intermediate support element 4 and to fix the component B of the corresponding sports helmet A to be manufactured in correspondence with the corresponding support part 9 and / or relief part 10, the first part 5 should be kept facing upward or toward the figure of the operator performing the action of placing the component B.

[0068] More specifically, the placement of component B of the sports helmet A to be manufactured is performed by placing the second part 6 of each intermediate support element 4 on a working plane or similar support plane, such that the first part 5 of the intermediate support element 4 can be easily accessed by the hand of an operator who must position component B of the sports helmet A to be manufactured in the corresponding support seat 9 and / or the corresponding support relief 10 of these intermediate support elements 4.

[0069] Once the step of placing component B of the sports helmet A to be manufactured in the corresponding support seat 9 and / or the corresponding support relief 10 of the corresponding intermediate support element 4 is completed, the molding process includes the step of positioning each intermediate support element 4 inside the corresponding molding recess 2 of the mold frame 1. Figure 7 The step is performed as follows: first, the first part 5 of each intermediate support element 4 is oriented toward the corresponding molding recess 2, and then the intermediate support element 4 is inserted into the corresponding molding recess 2 so that the component B of the corresponding sports helmet A to be manufactured is placed inside the corresponding molding recess 2 according to the corresponding predetermined position.

[0070] The step of positioning each intermediate support element 4 in the corresponding molded recess 2 using the corresponding component B of the corresponding sports helmet A to be manufactured is performed manually by the operator, preferably by grasping the grip portion 7a of each grip handle 7 defined corresponding to the second portion 6 of each intermediate support element 4.

[0071] Preferably, the step of positioning each intermediate support element 4 in the corresponding molding recess 2 is achieved by placing the intermediate support element 4 along the main lying plane X ( ) relative to the frame 1 of the mold. Figure 1 and Figure 2 Insert it into the corresponding molded recess 2 in a roughly orthogonal direction to perform the operation.

[0072] When each intermediate support element 4 is positioned inside the corresponding molding recess 2, each intermediate support element 4 is locked in the corresponding molding recess 2 to avoid undesirable displacement and to fix the predetermined position used by the component B of the corresponding sports helmet A to be manufactured.

[0073] exist Figure 12 It can be observed that the step of locking each intermediate support element 4 in the corresponding molded recess 2 of the mold frame 1 is performed by the interaction between the movable locking protrusion 11b located inside the corresponding recess 2 and the corresponding locking seat 11a realized on the outside of the corresponding intermediate support element 4.

[0074] By moving the corresponding locking protrusion 11b from the resting position ( Figure 1 and Figure 11 Start to locked position ( Figure 12 The step of locking each intermediate support element 4 in the corresponding molding recess 2 of the mold frame 1 is performed. In the rest position, the corresponding intermediate support element 4 can be inserted into or removed from the corresponding molding recess 2. In the locked position, the corresponding locking protrusion 11b engages the corresponding locking seat 11a of the corresponding intermediate support element 4, thereby holding the locking seat 11a inside the corresponding molding recess 2 of the mold frame 1.

[0075] The locking step is advantageously performed by operating the locking protrusion 11b by operating a control device located outside the mold, preferably at least one control pedal.

[0076] The locking of each intermediate support element 4 in the corresponding molding recess 2 can be initiated independently by operating the corresponding dedicated control pedal or simultaneously on all molding recesses 2 of the mold frame 1 by means of a suitable universal control pedal.

[0077] Once locking is complete, the molding process provides the following subsequent steps: engaging each opposing frame 3 of the mold to the frame 1 of the mold so as to hermetically seal the corresponding molding recess 2 at the second portion 6 of the corresponding intermediate support element 4 facing outward from the corresponding molding recess 2.

[0078] The step of engaging each opposing frame 3 of the mold to the frame 1 of the mold is also performed by engaging the aforementioned connecting lug 12a protruding outward from each intermediate support element 4 into the corresponding connecting seat 12b realized on the opposing frame 3 of the mold.

[0079] Once each molding recess 2 of the mold frame 1 has been closed, the corresponding known molding cycle is started by injecting the corresponding molding material—preferably polystyrene.

[0080] When the molding cycle has ended, the molding process includes the following follow-up steps: disconnecting each opposing frame 3 of the mold from the frame 1 of the mold in order to access the corresponding molding recess 2 and the corresponding intermediate support element 4 contained in the molding recess 2.

[0081] The step of disconnecting each opposing frame 3 of the mold from the frame 1 of the mold is also performed by disconnecting the corresponding connecting lug 12a protruding outward from the corresponding intermediate support element 4 from the corresponding connecting seat 12b realized on the corresponding opposing frame 3 of the mold.

[0082] Then, each intermediate support element 4 is released from the corresponding molding recess 2 through the interaction between the corresponding locking protrusion 11b, which is movable inside the corresponding molding recess 2, and the corresponding locking seat 11a implemented externally on each intermediate support element 4.

[0083] Specifically, by manipulating the corresponding locking protrusion 11b of each molding recess 2 from the locked position ( Figure 12 ) to the resting position ( Figure 1 and Figure 11 The movement of the ) performs the unlocking step. In this way, each intermediate support element 4 is released, so that the intermediate support element 4 can be removed from the corresponding molding recess 2.

[0084] Similar to the locking step, the unlocking step is also performed by operating at least one control device—preferably at least one drive and control pedal operatively connected to the corresponding locking protrusion 11b.

[0085] Once each support element 4 has been released, the support element 4, together with the corresponding formed sports helmet A, can be removed from the corresponding molding recess 2 of the mold frame 1. Figure 9 ).

[0086] The removal step is also performed manually by the operator who grips the gripping portion 7a of the corresponding gripping handle 7, which is located at the second part 6 of the intermediate support element 4.

[0087] The step of removing each intermediate support element 4 together with the corresponding sports helmet manufactured by the corresponding molding recess 2 is performed by taking the intermediate support element 4 out in a direction that is approximately orthogonal to the main lying plane X of the mold frame 1.

[0088] Subsequently, the molding process provides a step for separating each intermediate support element 4 from the corresponding manufactured sports helmet A. Figure 10 This allows the entire molding process to be repeated.

[0089] Advantageously, the above molding process may also include using the same auxiliary support element (not shown in the figures) as the intermediate support element 4 for each molding recess 2 of the mold frame 1.

[0090] When the corresponding intermediate support element 4 is located in the corresponding molding recess 2 during the corresponding molding cycle, the internal auxiliary support element advantageously sets the component B of the sports helmet A to be manufactured.

[0091] When the intermediate support element 4 is removed from the corresponding molding recess 2 at the end of the molding cycle, the corresponding auxiliary support element is immediately inserted into the corresponding molding recess 2 to start the subsequent molding cycle, thus minimizing the interruption in the production cycle of the sports helmet A.

[0092] Since the auxiliary support element is identical to the intermediate support element 4, the process steps performed on the intermediate support element 4 are also performed on the auxiliary support element in a similar manner. When the intermediate support element 4 is arranged inside the corresponding molding recess 2 of the mold frame 1 during the corresponding molding cycle, the operator prepares the auxiliary support element with the corresponding part B of the sports helmet to be manufactured. Conversely, when the auxiliary support element 4 is arranged inside the corresponding molding recess 2 of the mold frame 1 during the corresponding molding cycle, the operator prepares the auxiliary support element with the corresponding part B of the sports helmet to be manufactured.

[0093] The alternation of intermediate support element 4 and auxiliary support element ensures the continuity of the molding cycle of the sports helmet being manufactured, thus significantly increasing the number of helmets produced per unit time.

[0094] The aforementioned mold and related molding process solve the problems encountered in the prior art and allow for significant advantages.

[0095] In detail, the step of removing the traditional support template from the corresponding molding recess before the start of the molding cycle has been eliminated, which on the one hand speeds up the molding process and significantly reduces the total production time of sports helmets, and on the other hand ensures that the position of the parts of the sports helmet to be manufactured is maintained before the mold is hermetically sealed and during the execution of each molding cycle.

[0096] Therefore, it should be noted that holding the intermediate support element in the corresponding molding recess of the mold frame allows for an overall reduction in the process used to mold each sports helmet being manufactured.

[0097] In addition, holding the intermediate support element in the corresponding molding recess of the mold frame ensures that the position of each part of the sports helmet being manufactured remains unchanged before the mold is closed and throughout the molding cycle, resulting in a sports helmet of excellent quality and a structurally sound mold.

Claims

1. A mold for manufacturing a sports helmet (A), the mold comprising: At least one frame (1) defines at least one molding recess (2) for molding at least one corresponding sports helmet (A). At least one opposing frame (3) is capable of engaging with the frame (1) to hermetically seal the corresponding molding recess (2) and allow at least one molding cycle to be performed; The mold is characterized in that it includes at least one intermediate support element (4) for supporting and positioning one or more parts (B) of the sports helmet (A) to be manufactured inside the corresponding molding recess (2) of the frame (1), the intermediate support element (4) having: The first part (5) is arranged to receive one or more components (B) of the sports helmet (A) to be manufactured in an engaging manner according to corresponding predetermined positions. The second part (6) is opposite to the first part (5) and has at least one grip handle (7) for manually positioning the intermediate support element (4) in the corresponding molding recess (2) of the frame (1) and subsequently positioning the component (B) of the sports helmet (A) to be manufactured inside the molding recess (2), the second part (6) of the intermediate support element (4) being arranged to be coupled to the corresponding opposing frame (3). At least one joining member (11) is provided for stably connecting the intermediate support element (4) to the frame (1) inside the corresponding molding recess (2), the joining member (11) being operatively inserted between the intermediate support element (4) and the corresponding molding recess (2) of the frame (1). At least one engagement constraint (12) is provided for stably connecting the intermediate support element (4) to the opposing frame (3), the engagement constraint (12) being operatively inserted between the intermediate support element (4) and the opposing frame (3).

2. The mold of claim 1, wherein, The mold is configured for manufacturing cycling helmets.

3. The mold of claim 1, wherein, The frame defines two or more molded recesses (2).

4. The mold of claim 1, wherein, The second part (6) has two opposite grip handles (7).

5. The mold of any one of claims 1 to 4, wherein, The intermediate support element (4) includes an annular structure (8) having at least one support seat (9) and / or one relief portion (10) inside for supporting at least one component (B) of the sports helmet (A) to be manufactured, the support seat (9) and / or the relief portion (10) being accessible from the first portion (5).

6. The mold of claim 5, wherein, The joining member (11) includes: At least one locking seat (11a) is implemented outside the annular structure (8) of the intermediate support element (4); At least one locking protrusion (11b) is movable within a corresponding molding recess (2) of the frame (1) between a rest position and a locked position, in which the intermediate support element (4) is insertable into or removed from the molding recess (2), and in the locked position, the locking protrusion (11b) engages a corresponding locking seat (11a) of the intermediate support element (4) to retain the locking seat (11a) inside the corresponding molding recess (2) of the frame (1).

7. The mold of claim 6, wherein, The engagement member (11) includes two opposite locking seats (11a).

8. The mold of claim 6, wherein, The engagement member (11) includes two opposite locking protrusions (11b).

9. The mold of any one of claims 6-8, wherein, The locking protrusion (11b) can be controlled by means of an actuation device located outside the mold.

10. The mold of claim 9, wherein, The actuation device includes at least one drive pedal.

11. The mold of claim 9, wherein, The engagement constraint (12) includes at least one engagement lug (12a) and at least one engagement seat (12b), the engagement seat (12b) being operatively inserted between the intermediate support element (4) and the opposing frame (3).

12. The mold of claim 11, wherein, The engagement constraint (12) includes: At least one connecting lug (12a) protrudes outward from the annular structure (8) of the intermediate support element (4); At least one connecting seat (12b) is implemented on the opposing frame (3), and the connecting lug (12a) and the corresponding connecting seat (12b) are at least partially opposed to each other to ensure a stable connection between the intermediate support element (4) and the corresponding opposing frame (3).

13. The mold of claim 12, wherein, The engagement constraint (12) includes two opposite engagement lugs (12a).

14. The mold of claim 12, wherein, The engagement constraint (12) includes two opposite connecting seats (12b).

15. The mold according to any one of claims 12 to 14, wherein, The locking seat (11a) of the engagement member (11) is externally implemented on the corresponding connecting lug (12a) of the engagement constraint member (12).

16. The mold of claim 5, wherein, The grip handle (7) is defined by the annular structure (8) of the intermediate support element (4).

17. The mold of claim 16, wherein, The grip handle (7) includes: The gripping portion (7a) is defined by a block-shaped portion that engages with the annular structure (8) of the intermediate support element (4), and the gripping portion (7a) is designed to be manually gripped by the operator. A gripping opening (7b) is defined between the annular structure (8) of the intermediate support element (4) and the gripping portion (7a) of the gripping handle (7) to allow the operator's hand to be inserted when the operator must grip the gripping handle (7).

18. The mold of any one of claims 1-4, 6-8, 10-14, 16, 17, wherein, The mold includes at least one auxiliary support element that is the same as the intermediate support element (4). During the relevant molding cycle, when the intermediate support element (4) engages in the corresponding molding recess (2) of the frame (1) of the mold, the auxiliary support element can be used to prepare one or more parts (B) of the sports helmet (A) to be molded.

19. A process for molding a sports helmet (A), the process comprising the following steps: Provide at least one frame (1) of the mold, the frame (1) defining at least one molding recess (2) for molding at least one corresponding sports helmet (A). Prepare at least one opposing frame (3) for the mold, the opposing frame (3) being able to engage with the frame (1) to airtightly seal the corresponding molding recess (2) and allow at least one molding cycle to be performed; Prepare at least one intermediate support element (4) for supporting and positioning one or more parts (B) of the sports helmet (A) to be manufactured inside the corresponding molding recess (2) of the frame (1) of the mold. One or more components (B) of the sports helmet (A) to be manufactured are placed in the first part (5) of the intermediate support element (4) according to the corresponding predetermined positions; The intermediate support element (4) is positioned inside the corresponding molding recess (2) of the frame (1) of the mold, wherein the first part (5) faces the molding recess (2) to position the component (B) of the sports helmet (A) to be manufactured in the corresponding molding recess (2) according to the corresponding predetermined position. The intermediate support element (4) is sealed inside the corresponding molded recess (2) according to a predetermined position; The opposing frame (3) of the mold is joined to the frame (1) of the mold, thereby hermetically sealing the corresponding molding recess (2) in a manner corresponding to the second part (6) of the intermediate support element (4), the second part (6) being opposite to the first part (5). The molding cycle begins by injecting the corresponding molding material; When the molding cycle is completed, the opposing frame (3) of the mold is disconnected from the frame (1) of the mold to approach the corresponding molding recess (2) and the corresponding intermediate support element (4). Release the intermediate support element (4) from the corresponding molding recess (2); Remove the intermediate support element (4) together with the corresponding sports helmet (A) manufactured from the corresponding molding recess (2) of the frame (1) of the mold; Separate the intermediate support element (4) from the corresponding sports helmet (A) manufactured; Repeat the process again.

20. The process of claim 19, wherein, The process is used to mold cycling helmets.

21. The process of claim 19, wherein, The frame (1) defines two or more molded recesses (2).

22. The process of claim 19, wherein, The molding material is polystyrene.

23. The process of any one of claims 19-22, wherein, The steps of positioning the intermediate support element (4) in the corresponding molded recess (2) and removing the intermediate support element (4) together with the corresponding sports helmet (A) manufactured by the corresponding molded recess (2) are performed manually.

24. The process of claim 23, wherein, The steps of positioning the intermediate support element (4) in the corresponding molded recess (2) and removing the intermediate support element (4) together with the corresponding sports helmet (A) manufactured by the corresponding molded recess (2) are performed by gripping at least one grip handle (7) defined corresponding to the second part (6) of the intermediate support element (4).

25. The process according to claim 23, wherein: The step of positioning the intermediate support element (4) in the corresponding molding recess (2) is performed by inserting the intermediate support element (4) in a direction approximately orthogonal to the main lying plane (X) of the frame (1) of the mold. The step of removing the intermediate support element (4) together with the corresponding sports helmet (A) manufactured by the corresponding molding recess (2) is performed by removing the intermediate support element (4) in a direction that is substantially orthogonal to the main lying plane (X) of the frame (1) of the mold.

26. The process of any one of claims 19-22, 24, 25, wherein, The steps of locking the intermediate support element (4) inside the corresponding molded recess (2) of the mold frame (1) and unlocking the intermediate support element (4) from the corresponding molded recess (2) are performed by the interaction between at least one movable locking protrusion (11b) arranged in the molded recess (2) and at least one locking seat (11a) externally implemented on the intermediate support element (4).

27. The process according to claim 26, wherein: The step of locking the intermediate support element (4) in the corresponding molding recess (2) of the frame (1) of the mold is performed by activating the locking protrusion (11b) from the rest position to the locking position. In the rest position, the intermediate support element (4) can be inserted into or removed from the molding recess (2). In the locking position, the locking protrusion (11b) engages the corresponding locking seat (11a) of the intermediate support element (4), thereby holding the locking seat (11a) inside the corresponding molding recess (2) of the frame (1) of the mold. The step of unlocking the intermediate support element (4) from the corresponding molded recess (2) is performed by moving the locking protrusion (11b) from the locked position to the resting position.

28. The process of claim 27, wherein, The locking and unlocking steps are performed by operating the movement of the locking protrusion (11b) by operating a control device located outside the mold.

29. The process of claim 28, wherein, The control device is a control pedal.

30. The process according to any one of claims 19 to 22, 24, 25, 27 to 29, wherein: The step of engaging the opposing frame (3) of the mold to the frame (1) of the mold is also performed by engaging at least one connecting lug (12a) protruding outward from the intermediate support element (4) into at least one connecting seat (12b) realized on the opposing frame (3) of the mold. The step of disconnecting the opposing frame (3) of the mold from the frame (1) of the mold is also performed by disconnecting the connecting lug (12a) protruding outward from the intermediate support element (4) from the corresponding connecting seat (12b) implemented on the opposing frame (3) of the mold.

31. The process according to any one of claims 19 to 22, 24, 25, 27 to 29, further comprising the following step: Prepare at least one auxiliary support element that is identical to the intermediate support element; During the molding cycle in which the intermediate support element (4) is located in the corresponding molding recess (2) of the frame (1) of the mold, one or more parts (B) of the sports helmet (A) to be manufactured are positioned on the first part of the auxiliary support element according to the corresponding predetermined positions. After the intermediate support element (4) is removed from the molding recess (2) of the frame (1) of the mold, the auxiliary support element is positioned in the corresponding molding recess (2) of the frame (1) of the mold, wherein the first portion faces the molding recess (2) to position the component (B) of the sports helmet (A) to be manufactured in the corresponding molding recess (2) according to the corresponding predetermined position; The auxiliary support element is sealed inside the corresponding molded recess (2); The opposing frame (3) of the mold is joined to the frame (1) of the mold to hermetically seal the corresponding molding recess (2) at the second part of the auxiliary support element opposite to the first part. The molding cycle begins by injecting the corresponding molding material.

32. The process of claim 31, wherein, During the corresponding molding cycle, when the auxiliary support element is located within the corresponding molding recess (2), the following steps are performed: Separate the intermediate support element (4) from the corresponding manufactured sports helmet (A); and, One or more components (B) of the subsequent sports helmet (A) to be manufactured are positioned in the first part (5) of the intermediate support element (4) according to the corresponding predetermined positions to perform a new molding cycle.

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